The rise of a buoyant sphere in a gas-fluidized bed

The rise velocity, V, of a single sphere, released in the bottom of a bed of sand fluidized by air, was measured: the sphere had a diameter of 9.0 or 13.2 mm; its density ranged from 900 to . These experiments with a single sphere used: (i) a bubbling bed, diameter 141 mm, with 1.05<U/U_mf<2.00, (ii) a slugging bed, diameter 24 mm, with 1.70<U/U_mf<3.20. Here U is the fluidizing velocity; U=U_mf at incipient fluidization. It was found that, for each sphere in a given bed, V=V_mf+C(U-U_mf): the constant C was up to 10 times larger for bubbling beds than slugging beds.The rise velocity at incipient fluidization, V_mf, is governed, for both types of bed, by the apparent viscosity of the incipiently fluidized bed. Therefore, Stokes's law was used to predict V_mf, but using an important modification: since each buoyant sphere appears to carry on its top a defluidized ‘hood’ of particles, Stokes's law was applied to the composite ‘particle’ consisting of the sphere plus its hood. Analysis of the measured V_mf then gave the volume of the hood, in agreement with direct measurements of it above a fixed cylinder in a two-dimensional bed. In addition, the analysis gave the apparent viscosity of the incipiently fluidized bed to be 0.66 Pa s, in excellent agreement with the estimate of Grace (Can. J. Chem. Eng. 48 (1970) 30) for similar sand.     

Fluidization with hot compressed water in micro-reactors

In this paper the concept of micro-fluidized beds is introduced. A cylindrical quartz reactor with an internal diameter of only 1 mm is used for process conditions up to and 244 bar. In this way, fast, safe, and inherently cheap experimentation is provided. The process that prompted the present work on miniaturization is gasification of biomass and waste streams in hot compressed water (SCWG). Therefore, water is used as fluidizing agent. Properties of the micro-fluid bed such as the minimum fluidization velocity (U_mf), the minimum bubbling velocity (U_mb), bed expansion, and identification of the fluidization regime are investigated by visual inspection. It is shown that the micro-fluid bed requires a minimum of twelve particles per reactor diameter in order to mimic homogeneous fluidization at large scale. It is not possible to create bubbling fluidization in the cylindrical micro-fluid beds used. Instead, slugging fluidization is observed for aggregative conditions. Conical shaped micro-reactors are proposed for improved simulation of the bubbling regime. Measured values of U_mf and U_mb are compared with predictions of dedicated 2D and 3D discrete particle models (DPM) and (semi)-empirical relations. The agreement between the measurements and the model predictions is good and the model supports the concept and development of micro-fluid beds.     

The effects of particle and gas properties on the fluidization of Geldart A particles

We report on 3D computer simulations based on the soft-sphere discrete particle model (DPM) of Geldart A particles in a 3D gas-fluidized bed. The effects of particle and gas properties on the fluidization behavior of Geldart A particles are studied, with focus on the predictions of U_mf and U_mb, which are compared with the classical empirical correlations due to Abrahamsen and Geldart [1980. Powder Technology 26, 35-46]. It is found that the predicted minimum fluidization velocities are consistent with the correlation given by Abrahamsen and Geldart for all cases that we studied. The overshoot of the pressure drop near the minimum fluidization point is shown to be influenced by both particle-wall friction and the interparticle van der Waals forces. A qualitative agreement between the correlation and the simulation data for U_mb has been found for different particle-wall friction coefficients, interparticle van der Waals forces, particle densities, particle sizes, and gas densities. For fine particles with a diameter , a deviation has been found between the U_mb from simulation and the correlation. This may be due to the fact that the interparticle van der Waals forces are not incorporated in the simulations, where it is expected that they play an important role in this size range. The simulation results obtained for different gas viscosities, however, display a different trend when compared with the correlation. We found that with an increasing gas shear viscosity the U_mb experiences a minimum point near , while in the correlation the minimum bubbling velocity decreases monotonously for increasing μ_g.     

Hydrodynamic similarity in circulating fluidized bed risers

Hydrodynamic similarity in the fully developed zone of co-current upward gas-solid two-phase flow systems under different operating conditions was investigated by measuring the axial profiles of pressure gradient, radial profiles of solid concentration and particle velocity in two circulating fluidized bed (CFB) risers of 15.1 and 10.5 m high, with FCC and sand particles, respectively. The experimental data obtained from this work and in the literature show that when the scaling parameter, G_s/(ρ_pU_g), is modified as , a detailed hydrodynamic similitude of the gas-solid flow in the fully developed zone of the risers under different operating conditions can be achieved. Furthermore, the experimental results from different gas-solid flow systems also show that as long as remains constant, there is the same solid concentration in the fully developed zone of different CFB risers with different particles. With the same , the local solid concentrations, the descending particle velocities, the cluster frequencies and the solid concentrations inside clusters in the fully developed zone of the risers all display the same axial and radial distribution, respectively. In other words, the empirical similarity parameter, , appears to have incorporated the effects of operating parameters (G_s and U_g), so that, the gas-solid flow in the fully developed zone of CFB risers under those different operating conditions but having the same shows similar micro- and macro-hydrodynamic characteristics. The study shows that the empirical similarity parameter, , is also independent of the upward gas-solid flow systems.     

Regeneration of coked catalysts—modelling and verification of coke burn-off in single particles and fixed bed reactors

The regeneration of a coked naphtha reforming catalyst (Pt/Re-Al₂O₃) was studied by kinetic investigations on the effective rate of coke burn-off. For temperatures of industrial relevance for the catalyst, i.e., below (deactivation), the coke burn-off within the cylindrical particles is determined by the interplay of chemical reaction and pore diffusion; limitation by external mass transfer can be excluded for . Based on the parameters of the intrinsic kinetics and of the structure of the catalyst (porosity, tortuosity), the regeneration process is modelled and discussed both on the level of a single particle and in a technical fixed bed reactor. The results of modelling are compared with data from lab-scale investigations (coke profiles within the particles) and the performance data of the regeneration in an industrial fixed bed reactor (moving reaction zone); the agreement of calculation and measurement is in both cases complete.     

Lateral mixing in trickle bed reactors

Knowledge of lateral mixing is essential to understand heat and momentum transfer parameters in both single-phase liquid and two-phase gas-liquid co-current down flow through packed bed columns. The reactors through which gas and liquid concurrently flow downwards through a bed of catalytic packing are called trickle bed reactors. Experimental data on lateral mixing coefficients from both the heat transfer and radial liquid distribution studies are obtained over a wide range of flow rates of gas and liquid using glass spheres (4.05 and 6.75 mm), ceramic spheres (2.59 mm), and ceramic raschig rings (4 and 6.75 mm) as packing materials covering trickle flow, pulse flow, and dispersed bubble flow regimes. In the present work, an expression for estimation of lateral mixing coefficient (αβ)_L is derived using the data on radial liquid distribution studies. The agreement between the values of (αβ)_L obtained from heat transfer studies and from radial liquid distribution studies using the experimental data shows that there exists an analogy between the heat transfer and radial liquid distribution in packed beds. Since (αβ)_L is an important variable for estimation of various heat and mass transfer parameters, a correlation for (αβ)_L based on present heat transfer study is proposed. The agreement between the (αβ)_L values estimated from the proposed correlation and experimental values is satisfactory with a standard deviation (s.d.) of 0.119.     

Effect of cohesive powders on the elutriation of particles from a fluid bed

The elutriation of fine particles (Group C or A particles in Geldart's classification) from a fluid bed of mixed fine and coarse particles is investigated in a steady state. Al(OH)₃ and alumina and TiO₂ powder of 0.5- were used as fines. FCC, alumina, Al(OH)₃, limestone, silica sand, SiC particles of 44- were used as coarse particles. The paper investigates the effect on the elutriation rate constant of both fine powders and coarse particles (i) of the weight fraction of Geldart C powders in the bed, (ii) of the superficial gas velocity, and (iii) of the size of C powder and size of coarse particles in the bed.The elutriation rate constant of group C or group A particles is not only affected by the properties of the elutriated powders or particles and gas velocity, but also by both the weight fraction and size of C powder in the bed. This finding differs from the elutriation result of A or B particles from a fluidized bed.     

Mass transfer around freely moving active particles in the dense phase of a gas fluidized bed of inert particles

The mass transfer coefficient around freely moving active particles under bubbling/slugging fluidized bed conditions was measured in a lab-scale reactor. The technique used for the measurements consisted in the oxidation reaction of carbon monoxide at over one or few Pt catalyst spheres immersed in an inert bed of sand. It was shown that this technique is simple and accurate, and allows to overcome most of the difficulties and uncertainties associated with other available techniques. The experimental campaign was carried out by varying the fluidization velocity (0.15-0.90 m/s), the active particle size (1.0-10.0 mm) and the inert particle size (0.1-1.4 mm). Results were analyzed in terms of the particle Sherwood number. Experimental data showed that Sh is not influenced by the fluidization velocity and by a change of regime from bubbling to slugging, whereas it increases with a square root dependence with the minimum fluidization velocity and with the active particle size. These results strongly suggest that the active particles only reside in the dense phase and never enter the bubble/slug phase. Data were excellently fitted by a Frössling-type correlation:

Sh=2.0·ε_mf+K·(Re_mf/ε_mf)^1/2·Sc^1/3     

Heat transfer in a pulsed bubbling fluidized bed

Surface-to-bed heat transfer and pressure measurements were carried out in a 0.17 m ID pulsed bubbling fluidized bed with glass bead and silica sand particles having mean diameters ranging from 37 μm to 700 μm to investigate the effects of flow pulsation on heat transfer and bed hydrodynamics. A solenoid valve was used to supply pulsed air to the bed at 1 to 10 Hz. The bed surface was found to oscillate with the frequency of pulsation, the oscillation's amplitude decreasing with frequency. The standard deviation of the bed pressure drop in the pulsed bed was found to be larger than that in the conventional bed due to the acceleration force imposed by pulsation. For both Geldart B and A particles, high frequency pulsation (7, 10 Hz) enhances the heat transfer compared to continuous flow, the enhancement diminishing with superficial gas velocity and particle size. For Geldart B particles, the effect of pulsation on heat transfer ceases around U_o/U_mf = 3.5, whereas 24% improvement in heat transfer coefficient was obtained for 60 μm glass bead particles (Group A) at superficial gas velocities as high as U_o/U_mf = 27. Furthermore, in the fixed bed (U_o/U_mf < 1) for Geldart B particles, 1 Hz pulsation was found to be very effective resulting in two- to three-fold increase in heat transfer coefficient compared to continuous flow at the same superficial gas velocity. The flow pulsation loses its effect on heat transfer with increasing static bed height, i.e., when H_bed/D > 0.85.     

DEM-LES simulation of coal combustion in a bubbling fluidized bed Part II: coal combustion at the particle level

The discrete element method-large eddy simulation (DEM-LES) is used to model coal combustion at the particle level in a bubbling fluidized bed. The gas phase is modelled as a continuum and the solid phase is modeled by DEM. Chemical reactions consist in the heterogeneous reactions of char with O₂, CO, CO₂, NO, and N₂O, and in the homogeneous reactions involving CO, O₂, NO, and N₂O. The colliding particle-particle heat transfer is based on the analysis of the elastic deformation of the spheres during their contact. The model predicts the effects of the particle heterogeneous flow structure on the thermal characteristics of coal particles when heating and burning, and the gaseous emissions from a fluidized sand-coal binary mixture. The heating rates are 1627 and for, respectively, 0.8 and diameter coal particles fed into the fluidized bed. The instantaneous contribution of the collision heat transfer is weak, less than 5.0% of the total power exchanges (coal combustion, radiation, convection and collision) during the heating and 1.5% during the combustion. The temperature of the coal particles exceeds the bed temperature, which is in qualitative agreement with experimental data from literature. The effects of the diameter of coal particles, of the bed temperature, and of the inlet gas velocity on the thermal characteristics are also studied.     

Study of transition velocities from bubbling to turbulent fluidization by statistic and wavelet multi-resolution analysis on absolute pressure fluctuations

Experiments were conducted in three circulating fluidized beds of high, high and high (with an expanded top section of 1.5 m high) at ambient condition. The spent fluid cracking catalyst (FCC), glass beads and sand particles were taken as bed materials. The transition velocities U_c and U_k were analyzed by means of traditional statistic analysis and multi-resolution analysis (MRA) of wavelet analysis on the absolute pressure fluctuation (APF) signals acquired at different axial positions in the beds. According to the standard deviation of APF, the effects of axial positions and static bed heights on U_c and U_k were systematically investigated. An appropriate measuring interval of relative axial position was recommended to identify U_k and two correlations calculated by regression of data in literatures and this work were proposed to predict U_c and U_k for absolute pressure measurement. By means of MRA of wavelet analysis, a redefined variable, homogeneous index HI, deduced from the energy of SF and LF subsignals, was successfully applied to determine the U_c and U_k and demarcated the dynamic behaviors of Geldart group A (spent FCC) and group B (sand particles and glass beads) particles in the circulating fluidized beds.     

Temperature variations in the oxygen carrier particles during their reduction and oxidation in a chemical-looping combustion system

A particle reaction model including mass and heat transfer has been developed to know the temperature variations produced inside the oxygen carrier particles during the cyclic reduction and oxidation reactions taking place in a chemical-looping combustion (CLC) system. The reactions of the different oxygen carriers based on Cu, Co, Fe, Mn, and Ni during the reduction with fuel gas (CH₄, CO, and H₂) and oxidation (O₂) have been considered. In these systems, the oxidation reaction is always exothermic with subsequent heat release; however, the reduction reaction can be exothermic or endothermic depending on the metal oxide and the fuel gas. The heat generated inside the oxygen carriers during the exothermic reactions increases the particle temperature, and could affect the particle structure if the temperature increase is near to the melting point of the active materials. Several variables that affect the reaction rate and the heat transport process have been analyzed to know their effect on the internal particle temperature. For a given oxygen carrier and reaction, the maximum temperature of the particles depended mainly on the particle size, the reaction rate, and the external heat transfer resistance, being lower than the effect of the oxygen carrier porosity, type of inert material, and metal oxide content. The highest temperature variations were reached for the oxidation reactions, with the maximum corresponding to the Ni and Co oxygen carriers with values of for particles. The highest temperature increase observed during the reduction reactions corresponded to the reaction of CuO with CO, with values of for particles. For the rest of the reactions and metals, the variations in the particle temperature were below for particle sizes below . Under the typical operating conditions that exist in a CLC system, with particle sizes lower than , % of metal oxide content, and overall conversion times lower than , the increases of temperature with respect to the bulk conditions were lower than for any reaction of any oxygen carrier. Moreover, the temperature profiles inside the particles were near flat in most of the practical conditions, and no local points with high temperatures were found. Thus, changes in the solid porous structure of the carrier due to sintering during oxidation in fluidized bed reactors are not expected working at typical temperatures of CLC systems (1000-).     

Heat transfer characterization of gas-liquid flows in a trickle-bed

Instantaneous local fluid-solid heat transfer coefficient (h_t) in a laboratory scale trickle-bed was measured using a constant-voltage anemometry technique. It was observed that convective heat transfer rate in the liquid-rich pulses was approximately 4 times that in gas-continuous bases for the air-water system. Time-averaged heat transfer rate was found to be positively influenced by both gas and liquid flow rates, with a stronger dependence on the latter. Heat removal efficiency, taking pressure drop penalty into account, suggested an optimum at intermediate liquid flow rate. Based on the measurements, a four-parameter heat transfer model featuring heat transfer coefficients in liquid-rich pulses (h_tp) and gas-continuous bases (h_tb), pulsing frequency and pulse fraction was developed to characterize transient h_t under various flow regimes. This model can be used in any trickle-bed reactor simulation that accounts for the dynamic interactions of catalytic reactions and heat transfer. It was found that while h_tp and h_tb correspond to liquid-solid and gas-solid heat transfer, respectively, and are determined mainly by the fluid properties, pulsing frequency and pulse fraction are the factors characterizing different flow regimes. Pulsing frequency, which can significantly impact reaction, may be tuned by selecting appropriate packing size, since smaller sizes generate higher frequency pulses. For example, a two-fold higher frequency was detected in packing as compared to that with packing. Flow regime evolution along the column axial location was identified visually, while the dispersed bubbling flow retreating to pulsing flow owing to gas bubble coalescence was evidenced by the heat transfer measurements.     

Combustion of liquid petroleum gas in a fluidized bed furnace with a jetting-mixing distributor

Liquid petroleum gas (LPG) fluidized beds have potential applications in metal heating or workpiece heat treatments. The combustion of LPG and the controls of the atmosphere inside the bed and the bed temperature are very concerned. The combustion of LPG has been investigated in a pilot-scale bubbling fluidized bed with a jetting-mixing nozzle distributor and hollow corundum sphere particles of 0.867-1.212 mm in diameter and 386-870 kg/m³ in bulk density at 800-1100°C. Experiments were carried out for fuel-rich mixtures to explore the possibility to obtain mild oxidizing, non-oxidizing or reducing atmosphere in the bed. Air factor (the ratio of the volume of air actually fed into the bed to that in a stoichiometric mixture) is in between 0.3 and 1.0 and U/U_mf 1.3-3.0. The distributor brings LPG and air into an intense contact sufficient to permit in-bed combustion without backfire problems. The experimental results show that the fluidized bed furnace offers excellent thermal uniformity and temperature control. The size of the combustion zone is usually larger than that of the temperature variation zone. Particle properties, initial bed height, air factor and U/U_mf all affect the bed temperature profile, whereas only the air factor and U/U_mf have significant effects on the combustion in the bed. The bed temperature can be adjusted by separate or combined adjusting of air factor and U/U_mf.     

The nature of the flow just above the perforated plate distributor of a gas-fluidised bed, as imaged using magnetic resonance

Flow patterns within a 3D bed of oil-containing seeds fluidised by nitrogen have been observed for the first time using magnetic resonance imaging (MRI). Attention was focused on the lower region of the bed, just above the multi-orifice distributor: the orifices were 1.0 or 1.5 mm in diameter with square or triangular layouts, of pitch 7-10 mm. Two sizes of seeds were used: 1.2 and 0.50 mm. Each MRI image was a time-average over and measured the local concentration of seeds. Values of U/U_mf were in the range 0.0-3.6, where U is the superficial gas velocity and U=U_mf at incipient fluidisation. The images revealed:

(1)

There was a substantial ‘jet’ above each orifice in the distributor, remarkably these ‘jets’ were found even when U?U_mf. The length of a ‘jet’ increased with U/U_mf. Because of the time-averaged nature of the measurements, a ‘jet’ could be: (a) a permanent void, (b) a stream of bubbles, or (c) a ‘jet’ followed by bubbles.

(2)

When U/U_mf<1.0, the particles surrounding each ‘jet’ were in motion. This was apparent, particularly as U/U_mf approached 1.0, even though the bed was not fully fluidised at all points.

(3)

When U/U_mf>1.0, the upper parts of the ‘jets’ merged with each other forming a central dilute core. For the first time, a time-averaged velocity map over a horizontal plane was obtained; it demonstrated that the central core was rising upwards and that the surrounding material was descending.

(4)

Between each pair of ‘jets’, there was a small region of motionless particles sitting on the upper surface of the distributor, forming a fixed dead zone. A criterion for the maximum pitch of the orifices, to minimise the volume of this dead zone between pairs of ‘jets’, has been derived.

Simple correlations between dimensionless groups summarise the measurements well, giving the length and half angle of a ‘jet’ in terms of the gas velocity and other variables. These correlations are consistent with published results and include a dependence on the pitch of the orifices, which was found to be important.     

Particle growth kinetics of calcium fluoride in a fluidized bed reactor

Crystallization process in a fluidized bed reactor to remove fluoride from industrial wastewaters has been studied as a suitable alternative to the chemical precipitation in order to decrease the sludge formation as well as to recover fluoride as synthetic calcium fluoride.In the modeling, design and control of a fluidized bed reactor for water treatment it is necessary to study the particle growth kinetics. Removal of fluoride by crystallization process in a fluidized bed reactor using granular calcite as seed material has been carried out in a laboratory-scale fluidized bed reactor in order to study the particle growth kinetics for modeling, design, control and operation purposes.The main variables have been studied, including superficial velocity (SV, ), particle size of the seed material (L₀, m) and supersaturation (S). It has been developed a growth model based on the aggregation and molecular growth mechanisms. The kinetic model and parameters given by the equation fits well the experimental data for the studied range of variables.     

Solids mixing in the riser of a circulating fluidized bed

Gas/solid and catalytic gas phase reactions in CFBs use different operating conditions, with a strict control of the solids residence time and limited back-mixing only essential in the latter applications. Since conversion proceeds with residence time, this residence time is an essential parameter in reactor modelling. To determine the residence time and its distribution (RTD), previous studies used either stimulus response or single tracer particle studies.The experiments of the present research were conducted at ambient conditions and combine both stimulus response and particle tracking measurements. Positron emission particle tracking (PEPT) continuously tracks individual radioactive tracer particles, thus yielding data on particle movement in “real time”, defining particle velocities and population density plots.Pulse tracer injection measurements of the RTD were performed in a 0.1 m I.D. riser. PEPT experiments were performed in a small ( I.D.) riser, using ¹⁸F-labelled sand and radish seed. The operating conditions varied from 1 to 10 m/s as superficial velocity, and 25- as solids circulation rate.Experimental results were compared with fittings from several models. Although the model evaluation shows that the residence time distribution (RTD) of the experiments shifts from near plug flow to perfect mixing (when the solids circulation rate decreases), none of the models fits the experimental results over the broad (U,G)-range.The particle slip velocity was found to be considerably below the theoretical value in core/annulus flow (due to cluster formation), but to be equal at high values of the solids circulation rate and superficial gas velocity.The transition from mixed to plug flow was further examined. At velocities near U_tr the CFB-regime is either not fully developed and/or mixing occurs even at high solids circulation rates. This indicates the necessity of working at U> approx. ( to have a stable solids circulation, irrespective of the need to operate in either mixed or plug flow mode. At velocities above this limit, plug flow is achieved when the solids circulation rate . Solids back-mixing occurs at lower G and the operating mode can be described by the core/annulus approach. The relative sizes of core and annulus, as well as the downward particle velocity in the annulus (∼U_t) are defined from PEPT measurements.Own and literature data were finally combined in a core/annulus vs. plug flow diagram. These limits of working conditions were developed from experiments at ambient conditions. Since commercial CFB reactors normally operate at a higher temperature and/or pressure, gas properties such as density and viscosity will be different and possibly influence the gas-solid flow and mixing. Further tests at higher temperatures and pressures are needed or scaling laws must be considered. At ambient conditions, reactors requiring pure plug flow must operate at and . If back-mixing is required, as in gas/solid reactors, operation at and is recommended.     

Influence of carbon dioxide partial pressure and fluidization velocity on activated carbons prepared from scrap car tyre in a fluidized bed

The effect of carbon dioxide partial pressure and fluidization velocity on activated carbons produced by carbon dioxide activation of scrap car tyre rubber in a fluidized bed has been studied. The method consisted of carbonization at under nitrogen followed by activation at . Three types of activated carbons were produced using activated gas concentrations of 20, 60 and 100% carbon dioxide by volume, the rest nitrogen, at a constant fluidization velocity (0.0393 m/s) to investigate the influence of carbon dioxide partial pressure. Within the experimental setup and activation time of 4 h, it was observed that BET surface area and total pore volume increased with carbon dioxide partial pressure reaching and , respectively, for 100% activation with carbon dioxide. Three other types of activated carbons were produced using 100% carbon dioxide at two (0.0393 m/s), three (0.0589 m/s) and four (0.0786 m/s) times the minimum fluidization velocity (U_mf). The BET surface area and total pore volume were observed to increase with fluidization velocity (which can be viewed as an indicator of the intensity of mixing in the bed), reaching and , respectively, at four times the minimum fluidization velocity.