{"id":634,"date":"2017-05-01T16:24:20","date_gmt":"2017-05-01T23:24:20","guid":{"rendered":"http:\/\/rccostello.com\/wordpress\/?p=634"},"modified":"2026-05-08T03:45:25","modified_gmt":"2026-05-08T10:45:25","slug":"holl-reactor-process-intensification","status":"publish","type":"post","link":"https:\/\/www.rccostello.com\/wordpress\/process-intensification\/holl-reactor-process-intensification\/","title":{"rendered":"The HOLL-REACTOR\u00ae for Intensified Chemical Reaction Technology &#8211; Part 1"},"content":{"rendered":"<p>The&nbsp;<a href=\"http:\/\/rccostello.com\/spinning_tube.html\">HOLL-REACTOR<sup>\u00ae<\/sup><\/a>&nbsp;is one of the most important tools in a chemical engineers&nbsp;arsenal for creating smaller processes through process intensification.<\/p>\n<p><strong>Molecular Collisions<\/strong><\/p>\n<p>It&#8217;s obvious that when two liquid reagents are brought into contact with one another, for initiating a chemical reaction, the task of bringing astronomical numbers of reagent molecules into a one-on-one contact in a minimum amount of time is a gargantuan task.<\/p>\n<p>Consider this: 1 gram of H<sub>2<\/sub>O contains 3.34 x 10<sup>22<\/sup> molecules. While other liquid reagents contain similarly large numbers of molecules per gram.<\/p>\n<p><strong>Continuous Stirred Tank Reactors<\/strong><\/p>\n<p>Conventionally, the Continuous Stirred Tank Reactor (CSTR) has been trying to fulfill this task alongside battling an additional host of problems. One of the most important of which is the achieving, controlling and maintaining uniform temperature distribution of the reagents within a minimum amount of time. This can require seconds, minutes, hours and even days depending on how eager the reagents want to react and how efficiently and uniformly the mixing can be evoked and maintained as far down as into the sub-Kolmogoroff molecular universe (~25 \u03bcm) of the reagent mix, where molecular clusters need to be disentangled continuously (see <a href=\"http:\/\/www.sciencedirect.com\/science\/book\/9780122060700\">\u201cTurbulence Phenomena\u201d by J.T. Davies<\/a>, University of Birmingham, England).<\/p>\n<figure id=\"attachment_653\" aria-describedby=\"caption-attachment-653\" style=\"width: 486px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Stirred-tank-Reactor.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-653 size-full\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Stirred-tank-Reactor.jpg\" alt=\"Continuous Stirred Tank Reactor From the Pharmaceutical Industry\" width=\"486\" height=\"402\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Stirred-tank-Reactor.jpg 486w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Stirred-tank-Reactor-300x248.jpg 300w\" sizes=\"auto, (max-width: 486px) 100vw, 486px\" \/><\/a><figcaption id=\"caption-attachment-653\" class=\"wp-caption-text\">Continuous Stirred Tank Reactor<\/figcaption><\/figure>\n<p>The economics of chemical reacting demands minimizing time and effort used for uniformly mixing reagent molecules while maintaining optimum temperature and pressure control. In general, the latter two requirements are the easiest to achieve while obtaining uniform mixing of the reagents remains to this day, the number one problem of chemical reactor design.<br \/>\nThe above illustrations show the side view and cross-section of a typical, conventional tank reactor as most frequently used in the chemical and biochemical industries. To solve the above described problems of conventional chemical reactors, Richard Holl developed The <a href=\"http:\/\/rccostello.com\/spinning_tube.html\">Holl-Reactor<sup>\u00ae<\/sup><\/a> (US Patents) which no longer uses vigorous stirring of reagents as with the CSTR. Now, the reagents are quickly co-sheared inside a narrow annular gap established between the inner surface of a stationary tube and the outer surface of a fast spinning inner tube. The reagents are being pumped through this annular gap while their temperature is being regulated by an annular heat exchanger mantle, wrapped around the stator tube, as depicted in the following illustrations:<\/p>\n<figure id=\"attachment_652\" aria-describedby=\"caption-attachment-652\" style=\"width: 870px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Shear-Film.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-652 size-full\" title=\"Holl Shear Film Chemical Reaction Method\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Shear-Film.jpg\" alt=\"Ottino Type Macromixing Following by Sub-Kolmogoroff Mixing\" width=\"870\" height=\"669\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Shear-Film.jpg 870w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Shear-Film-300x231.jpg 300w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Shear-Film-768x591.jpg 768w\" sizes=\"auto, (max-width: 870px) 100vw, 870px\" \/><\/a><figcaption id=\"caption-attachment-652\" class=\"wp-caption-text\">Holl Shear Film Chemical Reaction Method<\/figcaption><\/figure>\n<p><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Molasses-and-milk.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-651\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Molasses-and-milk.jpg\" alt=\"Holl Shear Film Chemical Reaction Method\" width=\"217\" height=\"189\"><\/a><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Molasses-and-milk-2.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-650 size-full\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/05\/Molasses-and-milk-2.jpg\" alt=\"Holl Shear Film Chemical Reaction Method\" width=\"260\" height=\"194\"><\/a><\/p>\n<p>The main reason for the <a href=\"http:\/\/rccostello.com\/spinning_tube.html\">HOLL-REACTOR&#8217;s<sup>\u00ae<\/sup><\/a> superior performance is the replacement of agitator stirred mixing by high speed annular shear-mixing. CSTR&nbsp;mixing is typically characterized by high power consumption, amply described in the following pertinent publications:<\/p>\n<p>1) <a href=\"https:\/\/www.amazon.com\/Mixing-Principles-Applications-Shinji-Nagata\/dp\/0470628634\">&#8220;Mixing, Principles and Applications&#8221; by Dr. Shinjji Nagata<\/a>, John Wiley &amp; Sons<br \/>\n2) <a href=\"http:\/\/www.sciencedirect.com\/science\/book\/9780122060700\">&#8220;Turbulence Phenomena&#8221; by Dr. J. T. Davies<\/a>, Birmingham University, UK<br \/>\n3) <a href=\"http:\/\/history.aip.org\/history\/exhibits\/einstein\/essay-brownian.htm\">&#8220;Brownian Movement&#8221; by Dr. Albert Einstein<\/a><br \/>\n4) &#8220;<a href=\"https:\/\/books.google.com\/books\/about\/The_Kinematics_of_Mixing.html?id=8OLVcbRoNSgC\">The kinematics of mixing: stretching, chaos, and transport&#8221; by J.M Ottino<\/a><\/p>\n<p>Surprisingly, the power consumption of HOLL-REACTORS<sup>\u00ae<\/sup>&nbsp;are less than 20% that of CSTR&#8217;s. The explanation for this low power use is the HOLL-REACTOR&#8217;s<sup>\u00ae<\/sup> similarity with the principle of operation for lubricated journal bearings. The difference with the HOLL-REACTOR<sup>\u00ae<\/sup> being is the use of liquid reagents instead of oils for \u201clubrication&#8221;.<\/p>\n<p>One of the new HOLL-REACTOR&#8217;s<sup>\u00ae<\/sup> unexpected features is the fact that it has surpassed clients requirements for selectivity and yield in certain chemical reactions. This was tested in the R&amp;D labs of one of the world\u2019s largest manufacturers of chemicals.<\/p>\n<p>Next week in Part 2, we will talk about various applications of the Holl-Reactor\u00ae.<\/p>\n<p>Let <a href=\"http:\/\/rccostello.com\/index.html\">COSTELLO <\/a>and the <a href=\"http:\/\/rccostello.com\/spinning_tube.html\">HOLL-REACTOR<sup>\u00ae<\/sup><\/a> help you design a small intensified chemical process that saves CAPEX and OPEX!<\/p>\n<p><strong>Phone: 310-792-5870 Email: rcca@rccostello.com<\/strong><\/p>\n<p><strong>Website: <a href=\"http:\/\/rccostello.com\/\">rccostello.com<\/a><\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The&nbsp;HOLL-REACTOR\u00ae&nbsp;is one of the most important tools in a chemical engineers&nbsp;arsenal for creating smaller processes through process intensification. Molecular Collisions It&#8217;s obvious that when two liquid reagents are brought into contact with one another, for initiating a chemical reaction, the task of bringing astronomical numbers of reagent molecules into a one-on-one contact in a minimum [&hellip;]<\/p>\n","protected":false},"author":11,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[1,92],"tags":[],"class_list":["post-634","post","type-post","status-publish","format-standard","category-modular-plants","category-process-intensification","entry","has-post-thumbnail"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>HOLL Reactor Technology for Process Intensification Systems &#8211; 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