Layer inversion and mixing of binary solids in two- and three-phase fluidized beds

Water fluidization in a 210 mm diameter semi-cylindrical acrylic column of a binary solids mixture of 3.2 mm polymer beads (ρ_s=1280 kg/m³) and 0.385 mm glass beads (ρ_s=2500 kg/m³) at superficial liquid velocities from 18.1 to 43.1 mm/s is shown to generate layer inversion at a superficial liquid velocity, U_L, of 33.1 mm/s. Introduction of air with a superficial velocity, U_g, of 1.92 mm/s yielded a layer inversion velocity at U_L=30.4 mm/s. The latter is explainable if it is assumed that the determinant of layer inversion is the interstitial liquid velocity and that therefore the main function of the gas in this respect is to occupy space.Mixing of the binary solids, as quantified by a mixing index applied to measured particle compositions at different levels of the fluidized bed, is shown to be greatest at the layer inversion velocity for liquid fluidization and, in general, to increase as co-current gas flow increases at a fixed value of U_L.     

On the onset of incipient fluidization

The onset of incipient fluidization is investigated theoretically and simulated by a computational fluid dynamics (CFD) procedure. The onset of incipient instability in a particle bed is preceded by stable gas diffusion in the interstices and is caused by a critical momentum force that may overcome the inertia of the particles. The critical momentum force is provided by the critical superficial gas velocity U_c in the form of critical mass flux of diffusion. It is found that the first movement of particles may be predicted by a critical transient Rayleigh number determined by a critical superficial velocity equals to the minimum fluidization velocity, U_mf. The onset of incipient fluidization was found to occur at a critical transient Rayleigh number of 3.1, which is close to the lowest theoretical value for buoyancy convection in a porous medium bounded by free surfaces. Consequently the onset times of incipient fluidization may be predicted accurately. The finding has been found to be supported by the present CFD study, past experiments and simulations in the literature.     

Pressure and voidage fluctuations in slugging fluidized beds

In fully developed slugging fluidized beds, the maximum amplitude of absolute pressure fluctuations is reached with increasing superficial gas velocity when the slug length reaches a maximum, and the separation distance between successive slugs starts to decrease. U_c, the superficial gas velocity at which absolute pressure fluctuations reach a maximum, thus indicates the early stage of transition from slugging to core-annular flow. U_c, identified based on standard deviations of differential pressure fluctuations or local voidage fluctuations, can be predicted by slug flow models and does not signify a transition to turbulent fluidization.     

Dynamics of segregation and fluidization of binary mixtures in a cylindrical fluidized bed

Dynamics of segregation and fluidization of unary particles and binary mixtures in a cylindrical fluidized bed is investigated using temporally– and spatially–resolved measurements of solids volume fraction (α_s) performed using Electrical Capacitance Tomography (ECT). Through the comparison with high-speed imaging, we have shown that ECT can be used to measure the segregation behavior in cylindrical fluidized beds quantitatively. ECT measurements have been used further to quantify the effects of mixture composition, particle–diameter ratio, and superficial gas velocity on the bed segregation behavior. Dynamics of fluidization behavior is characterized using the time–evolution of local α_s fluctuations, corresponding frequency distribution, and bubble size distribution. Further, a relation between the measured variance of α_s fluctuations at different radial locations and corresponding flow structures under different fluidization conditions is established. The present work helps to understand dynamics of segregation and fluidization of binary mixtures and to provide a database for validation of Eulerian multifluid CFD models.     

Modified gas‐perturbed liquid model (GPLM) for minimum fluidization velocity in a two‐phase inverse fluidized bed reactor with Newtonian and non‐Newtonian systems

In the present investigation minimum fluidization velocity, U_mf, in a two‐phase inverse fluidized bed reactor is determined using low‐density polyethylene and polypropylene particles of different diameters (4,6 and 8 mm) by measuring pressure drop. In a glycerol system U_mf decreased gradually with increase in viscosity up to a value of 6.11 mPa s (60%) and on further increase there was a slight increase in U_mf. In the case of the glycerol system the U_mf was found to be higher when compared to water. In the non‐Newtonian system (carboxymethylcellulose), U_mf decreased with increase in concentration in the range of the present study. The U_mf was found to be lower when compared to water as liquid phase. The modified gas‐perturbed liquid model was used to predict the minimum fluidization liquid velocity (U_lmf) for Newtonian and non‐Newtonian systems. Copyright © 2006 Society of Chemical Industry     

Effets de differents parametres sur les vitesses de transition de la fluidisation en regime turbulent

Much controversy exists in the literature about the effects of different variables on the onset of the turbulent regime in gas-solid fluidization, U_c, and on the transport velocity, U_tr. In order to study the effect of four hydrodynamic factors upon these transition velocities, a basic 8-run Plackett-Burman design was used. The factors and their level were: (a) diameter of column (82 vs 200 mm), (b) particles (FCC vs Sand), (d) static bed height (300 vs 450 mm) and (g) size distribution of particles (narrow vs wide). In each run, U_c and U_tr were determined experimentally by means of differential pressure transducer and also with a capacitance probe. The experimental results and statistical analysis show that bed diameter has the most important impact (61% variability upon U_c and 51 % upon U_tr). The product of particle size and density (ρ_pd_p) seems to have a significant effect (35% variability upon U_c and 47% upon U_tr). Static bed height has a slight impact. There is essentially no effect of the particle size distribution. Results show that interactions effects are negligible between these factors. Finally, two correlations for U_c and U_tr, which are in agreement with literature data are proposed.     

Transition velocities and phase holdups at minimum fluidization in gas–liquid–solid systems

Hydrodynamic experiments were performed using a 127‐mm diameter column with 3.2‐mm porous alumina, 3.3‐mm polymer blend, 5.5‐mm polystyrene and 6.0‐mm glass spheres, with water, aqueous glycerol solution and silicone oil as liquids, and air as the gas. The voidage at minimum fluidization fell initially to a minimum, then rose gradually with increasing superficial gas velocity, and was lower for three‐phase systems than for corresponding two‐phase (liquid–solid) fluidized beds. The compaction appears to be due to agitation by gas bubbles near the minimum liquid fluidization condition. The gas holdups agree reasonably well with the correlation of Yang et al. (1993). Curves of minimum liquid fluidization velocity, U_lmf, vs. superficial gas velocity, U_g always show U_lmf decreasing as U_g increases, initially in a concave‐downward manner, but sometimes concave‐upward.     

The onset velocity of a liquid–solid circulating fluidized bed

The critical transition velocity, U_cr, previously defined by Liang et al. [W.-G. Liang, S.-L. Zhang, J.-X. Zhu, Y. Jin, Z.-Q. Yu and Z.-W. Wang, Flow characteristics of the liquid–solid circulating fluidized bed, Powder Technol., 90 (1997) 95–102.] to demarcate the liquid–solid conventional and circulating fluidization regimes, was found to vary with the total solids inventory and the solids feeding system. In this work, an onset velocity for circulating fluidization regime, U_cf, is proposed to give the lowest U_cr value and to provide a convenient demarcation velocity that is independent of system geometry. This liquid velocity is obtained by measuring the time required to empty all particles in a batch operated fluidized bed under different liquid velocities. This method can be used for a wide range of particles and involves less influence of the operating conditions such as the solids inventory and the solids feeding system. Compared to the critical transition velocity, this newly defined onset velocity is a more intrinsic parameter, only dependent on the liquid and particle properties. Based on the experimental results obtained in this work and other published results, the influence of particle properties and equipment setup on the onset velocity is also discussed.     

Elutriation and Species Segregation Characteristics of Polydisperse Mixtures of Group B Particles in a dilute CFB Riser

Experiments in a dilute, gas‐solids circulating fluidized bed have been conducted, with an emphasis on the impact of polydispersity on elutriation and species segregation. Two categories of polydispersity were studied: binary mixtures with various compositions and continuous particle size distributions (PSDs) with various widths. Qualitative differences between the two include (i) total elutriation flux of binary mixtures increases with the composition of fines (U_t < U_s) but not so for continuous PSDs and (ii) elutriation flux of coarse particles (U_t > U_s) depends non‐monotonically on fines composition for binary mixtures but monotonically for continuous PSDs. These differences are explained by the increasing size disparity of continuous PSDs as distribution width increases, while the size disparity remains constant in binary mixtures of varying compositions. A third qualitative difference is the monotonic decrease in mass % of coarse particles with riser height observed for continuous PSDs, and a nonmonotonic behavior for binary mixtures. © 2012 American Institute of Chemical Engineers AIChE J, 59: 84–95, 2013     

Dispersed phase characteristics in three phase (liquid-liquid-solid) fluidized beds

Two ideal droplet length (l,) distributions have been derived for two different droplet shapes. The dispersed phase holdup (?_d) increases with increasing dispersed phase velocity (U_d), but decreases with increasing continuous phase velocity, (U_c) in three-phase fluidized beds. In the droplet-coalescing flow regime, l_v and the droplet rising velocity (v_d) increase, but the spherical droplet fraction (k) decreases with increasing U_d and u_c. In the droplet-disintegrating flow regime, the effects of u_d and U_c on l_v and k are insignificant, but v_d increases with increasing U_c. Maximum values of l_v, occur in the bed containing 1.7 mm diameter particles and l_v has an uniform length of around 2.0 mm in beds with particle size larger than 3.0 mm.     

气泡驱动液固流化床内二元颗粒的流化行为

采用密度稍重于和稍轻于流体的两种颗粒,研究了气泡驱动液固流化床内二元颗粒的流化行为。通过测量压差和拍摄视频的方法确定了初始流化气速U_in,g、固含率和气含率。重颗粒的U_in,g通过流化床底部的压差变化确定,轻颗粒的U_in,g则通过观察得到。研究表明,在气泡驱动的液固流化床内,重颗粒和轻颗粒的初始流化气速都随藏量的增加而增加,但重颗粒增加幅度更大。完全流化后,重颗粒固含率在轴向上分布不均匀,而轻颗粒则分布较为均匀。在二元颗粒体系内,上部轻颗粒的流化受到下部重颗粒的影响而底部重颗粒的流化不受轻颗粒影响,导致重颗粒U_in,g和固含率分布主要受自身藏量影响,而轻颗粒U_in,g随二元颗粒的总藏量变化。     

Numerical modeling of particle fluidization behavior in a rotating fluidized bed

In this study, numerical modeling of particle fluidization behaviors in a rotating fluidized bed (RFB) was conducted. The proposed numerical model was based on a DEM (Discrete Element Method)-CFD (Computational Fluid Dynamics) coupling model. Fluid motion was calculated two-dimensionally by solving the local averaged basic equations. Particle motion was calculated two-dimensionally by the DEM. Calculation of fluid motion by the CFD and particle motion by the DEM were simultaneously conducted in the present model. Geldart group B particles (diameter and particle density were 0.5 mm and 918 kg/m³, respectively) were used for both calculation and experiment. First of all, visualization of particle fluidization behaviors in a RFB was conducted. The calculated particle fluidization behaviors by our proposed numerical model, such as the formation, growth and eruption of bubble and particle circulation, showed good agreement with the actual fluidization behaviors, which were observed by a high-speed video camera. The estimated results of the minimum fluidization velocity (U_mf) and the bed pressure drop at fluidization condition (ΔP_f) by our proposed model and other available analytical models in literatures were also compared with the experimental results. It was found that our proposed model based on the DEM-CFD coupling model could predict the U_mf and ΔP_f with a high accuracy because our model precisely considered the local downward gravitational effect, while the other analytical models overpredicted the ΔP_f due to ignoring the gravitational effect.     

Determination of minimum fluidization velocity by pressure fluctuation measurement

Using the standard deviation of pressure fluctuations to find the minimum fluidization velocity, U_mf, avoids the need to de-fluidize the bed so U_mf, can be found for operational bubbling fluidized beds without disrupting the process provided only that the superficial velocity may be altered and that the bed remains in the bubbling fluidized state. This investigation has concentrated on two distinct aspects of the pressure fluctuation method for U_mf determination: (1) the minimum number of pressure measurements required to obtain reliable estimates of standard deviation has been identified as about 10000 and (2) pressure fluctuation measurements in the plenum below the gas distributor are suitable for U_mf determination so the problems of pressure probe clogging and erosion by bed particles may be avoided.     

Fluidization of mixtures of two solids differing in density or size

The complex mechanism by which homogeneous mixtures of two solids achieve fluidization is subjected to theoretical analysis, to elaborate relationships capable to provide their “initial” and “final fluidization velocity” u_if and u_ff, i.e., the limits that encompass the suspension process. The article shows how the equation that describes the force equilibrium of fluidization can be rewritten in forms that account for the distribution of the components of density‐ or size segregating mixtures during the transition to the fluidized state. This approach leads to the theoretical expression of u_if and u_ff of either type of system, whose differences of behavior are correctly reproduced by accounting for the voidage reduction typical of beds of particles of different size. The comparison with experimental results at varying mixture composition demonstrates that the equations give a coherent interpretation of the dependence of the fluidization velocity interval of two‐solid mixtures on the principal variables of interest. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Effective particle diameters for simulating fluidization of non‐spherical particles: CFD‐DEM models vs. MRI measurements

Computational fluid dynamics—discrete element method (CFD‐DEM) simulations were conducted and compared with magnetic resonance imaging (MRI) measurements (Boyce, Rice, and Ozel et al., Phys Rev Fluids. 2016;1(7):074201) of gas and particle motion in a three‐dimensional cylindrical bubbling fluidized bed. Experimental particles had a kidney‐bean‐like shape, while particles were simulated as being spherical; to account for non‐sphericity, “effective” diameters were introduced to calculate drag and void fraction, such that the void fraction at minimum fluidization (ε_mf) and the minimum fluidization velocity (U_mf) in the simulations matched experimental values. With the use of effective diameters, similar bubbling patterns were seen in experiments and simulations, and the simulation predictions matched measurements of average gas and particle velocity in bubbling and emulsion regions low in the bed. Simulations which did not employ effective diameters were found to produce vastly different bubbling patterns when different drag laws were used. Both MRI results and CFD‐DEM simulations agreed with classic analytical theory for gas flow and bubble motion in bubbling fluidized beds. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2555–2568, 2017     

Linking micro‐scale predictions of capillary forces to macro‐scale fluidization experiments in humid environments

The effects of increasing relative humidity (RH) on fluidization/defluidization are investigated experimentally and understood via particle‐level predictions for the resulting capillary force. Experimentally, defluidization is found to be more sensitive to small changes in RH than fluidization. This sensitivity is captured by a new defluidization velocity U_df, which characterizes the curvature of the defluidization plot (pressure drop vs. velocity) observed between the fully‐fluidized (constant pressure drop) and packed‐bed (linear pressure drop dependence on velocity) states; this curvature is indicative of a partially‐fluidized state arising from humidity induced cohesion. Plots of U_df vs. RH reveal two key behaviors, namely U_df gradually increases with a relatively constant slope, followed by an abrupt increase at RH ～55%. Furthermore, the bed transitions from Group A to Group C behavior between RH of approximately 60–65%. From a physical standpoint, these macro‐scale trends are explained via a theory for capillary forces that, for the first time, incorporates measured values of particle surface roughness. Specifically, a model for the cohesive energy of rough surfaces in humid environments shows the same qualitative behavior as U_df vs. RH for RH <55%, unlike predictions of the cohesive force. Furthermore, the abrupt transition at RH ～60–65% is explained via the previously observed onset of liquid‐like water adsorption, rather than crystal/ice‐like adsorption, onto glass surfaces. © 2016 American Institute of Chemical Engineers AIChE J, 62: 3585–3597, 2016     

Bubble behavior in corrugated‐wall bubbling fluidized beds—Experiments and CFD simulations

A new concept to harness bubble dynamics in bubbling fluidization of Geldart D particles was proposed. Various geometrical declinations of a cold‐prototype corrugated‐wall bubbling fluidized bed were compared at different flow rates (U_g) to conventional flat‐wall fluidized bed using high‐speed digital image analysis. Hydrodynamic studies were carried out to appraise the effect of triangular‐shaped wall corrugation on incipient fluidization, bubble coalescence (size and frequency), bubble rise velocity, and pressure drop. Bubble size and rise velocity in corrugated‐wall beds were appreciably lower, at given U_g/U_mb, than in flat‐wall beds with equal flow cross‐sectional areas and initial bed heights. The decrease (increase) in size (frequency) of bubbles during their rise was sustained by their periodic breakups while protruding through the necks between corrugated plates. Euler‐Euler transient full three‐dimensional computational fluid dynamic simulations helped shape an understanding of the impact of corrugation geometry on lowering the minimum bubbling fluidization and improving gas distribution. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

An adhesive CFD‐DEM model for simulating nanoparticle agglomerate fluidization

Nanoparticles are fluidized as agglomerates with hierarchical fractal structures. In this study, we model nanoparticle fluidization by assuming the simple agglomerates as the discrete element in an adhesive (Computational Fluid Dynamics—Discrete Element Modelling) CFD‐DEM model. The simple agglomerates, which are the building blocks of the larger complex agglomerates, are represented by cohesive and plastic particles. It is shown that both the particle contact model and drag force interaction in the conventional CFD‐DEM model need modification for properly simulating a fluidized bed of nanoparticle agglomerates. The model is tested for different cases, including the normal impact, angle of repose (AOR), and fluidization of nanoparticle agglomerates, represented by the particles with the equivalent material properties. It shows that increasing the particle adhesion increases the critical stick velocity, angle of repose, and leads from uniform fluidization to defluidization. The particle adhesion, bulk properties, and fluidization can be linked to each other by the current adhesive CFD‐DEM model. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2259–2270, 2016     

Fluidization of Group B particles with a rotating distributor

A novel rotating distributor fluidized bed is presented. The distributor is a rotating perforated plate, with 1% open-area ratio. This work evaluates the performance of this new design, considering pressure drop, Δp, and quality of fluidization. Bed fluidization was easily achieved with the proposed device, improving the solid mixing and the quality of fluidization.In order to examine the effect of the rotational speed of the distributor plate on the hydrodynamic behavior of the bed, minimum fluidization velocity, U_mf, and pressure fluctuations were analyzed. Experiments were conducted in the bubbling free regime in a 0.19 m i.d. fluidized bed, operating with Group B particles according to Geldart's classification. The pressure drop across the bed and the standard deviation of pressure fluctuations, σ_p, were used to find the minimum fluidization velocity, U_mf. A decrease in U_mf is observed when the rotational speed increases and a rise in the measured pressure drop was also found. Frequency analysis of pressure fluctuations shows that fluidization can be controlled by the adjustable rotational speed, at several excess gas velocities.Measurements with several initial static bed heights were taken, in order to analyze the influence of the initial bed mass inventory, over the effect of the distributor rotation on the bed hydrodynamics.     

Magnetic resonance imaging of gas–solid fluidization with liquid bridging

Magnetic resonance imaging is used to generate snapshots of particle concentration and velocity fields in gas–solid fluidized beds into which small amounts of liquid are injected. Three regimes of bed behavior (stationary, channeling, and bubbling) are mapped based on superficial velocity and liquid loading. Images are analyzed to determine quantitatively the number of bubbles, the bubble diameter, bed height, and the distribution of particle speeds under different wetting conditions. The cohesion and dissipation provided by liquid bridges cause an increase in the minimum fluidization velocity and a decrease in the number of bubbles and fast particles in the bed. Changes in liquid loading alter hydrodynamics to a greater extent than changes in surface tension or viscosity. Keeping U/U_mf at a constant value of 1.5 produced fairly similar hydrodynamics across different wetting conditions. The detailed results presented provide an important dataset for assessment of the validity of assumptions in computational models. © 2017 American Institute of Chemical Engineers AIChE J, 64: 2958–2971, 2018