Study of dynamic multi-dimensional temperature and concentration distributions in liquid-sprayed fluidized beds

A physically based model was developed for heat and mass transfer processes in liquid-sprayed fluidized beds. Such fluidized beds are used for granulation, coating and agglomeration. The complex correlations of a number of microprocesses, spraying, wetting, drop deposition, heat transfer, drying and mass transfer were studied, and transient three-dimensional distributions of air humidity, air temperature, particle wetting efficiency, liquid film temperature, particle temperature, local liquid loading and local evaporation rate were calculated. For the evaluation of the model, the stationary spatial air temperature distributions were measured at a fluidized bed pilot plant of the institute. The fluidized bed of monodisperse wood- or glass beads was sprayed with clear water. Conclusions are drawn on the relevance of particle dispersion, spraying and drying to simulating temperature and concentrations distributions.     

Fluidized bed spray granulation: Investigation of the coating process on a single sphere

The coating and granulation of solid particles in a fluidized bed is a process which converts pumpable and atomizable liquids (solutions, slurries, melts) into granular solids in one step by means of drying. The solution to be processed is sprayed onto a fluidized bed. Particle growth can take place either via surface layering or agglomeration. In the case of surface layering the atomized droplets deposit a thin layer of liquid onto the seed particles. The solvent is then evaporated by the hot fluidizing, leaving behind the dissolved material on the surface. Although fluidized bed spray granulation and film coating have been applied in industry for several years, there is still a lack of understanding of the physical fundamentals and the mechanisms by which spherical granules are formed. Hence a new method was developed which allows the direct observation of the subsequent particle-forming mechanisms such as droplet deposition, spreading, wetting and drying. The authors present a laboratory scale apparatus in which a single freely suspended particle can be coated under well defined and constant coating and drying conditions. With this device, particle-growth-rate and the development of particle morphology were measured and investigated under various experimental conditions.     

Numerical Spray Model of the Fluidized Bed Coating Process

In this study, a new model for the batch top-spray fluidized bed coating process is presented. The model is based on the one-dimensional (axial) discretization of the bed volume into different control volumes, in which the dynamic heat and mass balances for air, water vapor, droplets, core particles, and coating material were established. The coupling of the droplet phase's mass and heat transfer terms with the gas and solid phases was established by means of a droplet submodel in which droplet trajectories were individually simulated.

The model calculation method combines a Monte Carlo technique for the simulation of the particle exchange with the first-order Euler's method for solving the heat and mass balances, enabling the prediction of both the dynamic coating mass distribution and the one-dimensional (axial) thermodynamic behavior of the fluidized bed during batch operation. The simulation results were validated using experimental two-dimensional spatial air temperature and air humidity distributions, which were measured in a fluidized bed pilot reactor using a scanning probe.

Sensitivity analysis was carried out to study the effect of controllable process variables, such as fluidization air and atomization air properties, as well as the properties of the spraying liquid upon the simulated dynamic temperature and humidity distributions. Also, the effects of relevant process variables on growth rate uniformity and process yield were studied. Based on these sensitivity studies it was concluded that nozzle parameters, such as air pressure and positioning with respect to the bed, are as important as the fluidization air properties (humidity, temperature, and flow rate) for the coating growth rate uniformity and process yield.     

Numerical Spray Model of the Fluidized Bed Coating Process

In this study, a new model for the batch top-spray fluidized bed coating process is presented. The model is based on the one-dimensional (axial) discretization of the bed volume into different control volumes, in which the dynamic heat and mass balances for air, water vapor, droplets, core particles, and coating material were established. The coupling of the droplet phase's mass and heat transfer terms with the gas and solid phases was established by means of a droplet submodel in which droplet trajectories were individually simulated.

The model calculation method combines a Monte Carlo technique for the simulation of the particle exchange with the first-order Euler's method for solving the heat and mass balances, enabling the prediction of both the dynamic coating mass distribution and the one-dimensional (axial) thermodynamic behavior of the fluidized bed during batch operation. The simulation results were validated using experimental two-dimensional spatial air temperature and air humidity distributions, which were measured in a fluidized bed pilot reactor using a scanning probe.

Sensitivity analysis was carried out to study the effect of controllable process variables, such as fluidization air and atomization air properties, as well as the properties of the spraying liquid upon the simulated dynamic temperature and humidity distributions. Also, the effects of relevant process variables on growth rate uniformity and process yield were studied. Based on these sensitivity studies it was concluded that nozzle parameters, such as air pressure and positioning with respect to the bed, are as important as the fluidization air properties (humidity, temperature, and flow rate) for the coating growth rate uniformity and process yield.     

Monte Carlo modeling of binder‐Less spray agglomeration in fluidized beds

Fluidized bed spray agglomeration is used in the industry to increase the particle size and to improve several properties, for example, bulk density, flowability, and dissolution behavior of particulate products. Usually, a binder liquid is sprayed on a particle bed. If amorphous materials are used, spraying of pure water may cause agglomeration due to glass transition at wet spots on the particle surface. As no process models covering binder‐less spray agglomeration currently exist, a model based on a Monte Carlo method is presented. In this method, the process is described by events and processes on the single particle scale. Additionally, agglomeration experiments in a lab‐scale fluidized bed using three different maltodextrins are presented. For each experiment, a simulation was performed. The simulation results are compared with the obtained experimental data. © 2018 American Institute of Chemical Engineers AIChE J, 64: 3582–3594, 2018     

Influence of Polymeric Suspension Characteristics on the Particle Coating in a Spouted Bed

The influence of the coating suspensions and particle properties on the coating process in a conventional spouted bed is presented. Glass beads were coated at fixed operating conditions with different formulations of aqueous polymeric coating suspensions in a spouted bed of laboratory scale. The wettability of the solids by the liquid was quantified by the contact angle and surface tension of the coating suspensions. The coating efficiency and particle growth were correlated with the adhesion of the coating suspension to the solid particle, which is a function of the solids and liquid characteristics. The physical properties of the coated particles—particle mean diameter, sphericity, bulk, absolute and apparent densities, porosity and flow velocity—were determined and compared to the properties of uncoated particles.     

Influence of Polymeric Suspension Characteristics on the Particle Coating in a Spouted Bed

Abstract

The influence of the coating suspensions and particle properties on the coating process in a conventional spouted bed is presented. Glass beads were coated at fixed operating conditions with different formulations of aqueous polymeric coating suspensions in a spouted bed of laboratory scale. The wettability of the solids by the liquid was quantified by the contact angle and surface tension of the coating suspensions. The coating efficiency and particle growth were correlated with the adhesion of the coating suspension to the solid particle, which is a function of the solids and liquid characteristics. The physical properties of the coated particles—particle mean diameter, sphericity, bulk, absolute and apparent densities, porosity and flow velocity—were determined and compared to the properties of uncoated particles.     

Statistical modelling of the spouted bed coating process using positron emission particle tracking (PEPT) data

Coating of particles larger than about 1 mm can be achieved in a spouted bed, a particle mobilization device in which a strong particle circulation occurs, rapidly upwards in a lean central “spout” region and downwards in a slowly moving annular settled bed. In a spouted bed coater, a spray nozzle is placed at the base of the spout, spraying upwards into a distinct coating zone. The coating formation in a spouted bed is inter alia a function of (i) the particle motion, that is, how often and where particles enter and traverse the coating zone and (ii) the extent of droplet collection by individual particles passing through the coating zone. The coating model proposed here is based on the statistical history of individual particles, whose projected area governs the collection of spray droplets in the coating zone. Positron emission particle tracking (PEPT) has been used to determine the particle trajectories, the distribution of cycle times and the size and voidage of the spout. Whilst the model is not capable of delivering absolute values of coating mass a priori, it can predict deviations from a mean, which can itself be determined from an overall mass balance. To validate the model, a spouted bed coating process was studied in which coarse PVC spheres were coated with the hot‐melt coating material polyethylene glycol (PEG) 1500. Coating mass distributions, derived from the weight data of individual particles before and after manual coating removal, compared (for the studied conditions) very well with the predictions of the model.     

喷液流化床中传热特性

引言流化床反应器由于其特有的众多优点,尤其是传热效果好、床层温度均匀,而在工业上得到广泛的应用．然而随着工业的发展,生产能力的提高,对流化床的换热能力提出了更高的要求．于是出现了许多强化流化床传热的方法,例如乙烯氧氯化反应中的内置换热管法;乙炔制醋酸乙烯中的外加夹套法;催化裂化反应中的粒子循环法．在80年代初期出现了一种流化床带液操作的新方法,它在气相法聚乙烯生产中的应用（其操作工艺被简称为冷凝工艺）具有远大的前景．该工艺是在一般的气相法聚乙烯流化床反应工艺的基础上,在流程中添加易挥发的液体,使反…     

Identification of thermal zones and population balance modelling of fluidized bed spray granulation

Air temperature measurements in a fluidized bed of glass beads top sprayed with water showed that conditions for particles growth were fulfilled only in the cold wetting zone under the nozzle which size and shape depended on operating conditions (liquid spray rate, nozzle air pressure, air temperature, and particles load). Evolution of the particle size distribution during agglomeration was modelled using population balance and representing the fluidized bed as two perfectly mixed reactors exchanging particles with particle growth only in the one corresponding to the wetting zone. The model was applied to the agglomeration of non-soluble glass beads and soluble maltodextrin particles spraying respectively an acacia gum solution (binder) and water. Among the three adjustable parameters, identified from experimental particle size distributions evolution during glass beads agglomeration, only one describing the kinetics of the size distribution evolution depended on process variables. The model allowed satisfying simulation of the evolution of the particle size distribution during maltodextrin agglomeration.     

A new fluidized bed coating process via photo‐initiated cationic polymerization

An ultraviolet (UV) photo‐polymerization particle coating process was developed by coupling the photo‐initiated cationic polymerization with the fluidized bed coating techniques. Unlike the conventional air‐suspension coating in the fluidized bed, the new process employs a UV curable composition instead of a solvent/water‐borne system as a coating material, which has a rapid curing rate and virtually no inhibition to oxygen and moisture. A modified fluidized bed coater equipped with a quartz window allows UV light to penetrate and to initiate the curing of photo‐sensitive polymerizable chemicals coated on the particles. A UV‐curable liquid composed of cycloaliphatic epoxide, oxetane, and triarylsulfonium cationic photo‐initiator was specifically formulated for the fluidized bed particle coating process. A systematic experimental approach including photo‐Differential Scanning Calorimetry, Fourier Transform Infrared Spectroscopy, and tackiness measurements has been developed to characterize the curing mechanism of the cationic UV curable formulations and to optimize the chemical compositions. The effects of the UV curable chemicals, viscosity of coating liquid, and the fluidization operating conditions on the physical properties of coated particles have been thoroughly investigated. Under optimized conditions, this novel process is very efficient as follows: particles can be coated very rapidly with ultra‐thin films of the cured chemicals, with little, if any, formation of particulate agglomeration. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Encapsulation of irregularly shaped solid forms of proteins in a high-pressure fluidized bed

By combining the advantages of a high-pressure fluidized bed with the adjuvant properties of a supercritical fluid, namely RESS-process, solid proteins could be encapsulated by paraffin. Two different irregular shaped proteins, a model protein (bovine serum albumin, BSA) and a pharmaceutical protein (insulin) were investigated. Mixing the highly non-spherical protein particles with lactose allows its usage as bed material despite the unfavourable shape properties. The paraffin encapsulation of respective bed mixtures with BSA was successful with paraffin loadings up to 9.1 g/100 g_bed and yields up to nearly 100%, depending on process parameters. During the encapsulation process, breakage of the bed material occurred, resulting in mean sauter diameters of even less than 35 μm. Dissolution tests pointed out, that 100% dissolution after more than 180 min could be achieved. Thus, the particle breakage induced by the nozzle jet during the coating process seems to support the encapsulation of fines. A principle application of the process for insulin encapsulation for a selected set of process parameters has been demonstrated.     

Two-phase flow hydrodynamic study in micro-packed beds – Effect of bed geometry and particle size

Microscopic visualizations nearby the wall region of micro-fixed beds and hydrodynamic measurements during gas–liquid two-phase flows were carried out with an aim to investigate the effect of particle size and capillary tube shape on the bed pressure drop, flow regime transition, hysteresis and bed transient response to flow-rate step perturbations. Visualizations through inverted microscopy revealed that a decrease in particle size leads to early inception of a high interaction flow regime whereas changing capillary shape from circular to square had no effect on flow regime changeover. The effect of particle size on the wetting pattern hysteresis in square micro-packed beds was also investigated in both imbibition and drainage paths. It was found that wetting pattern hysteresis decreases with a decrease in particle size. Finally, the transient behavior of micro-fixed beds of circular and square geometries packed with particles of two different sizes were studied by monitoring the bed pressure drop variations upon step changes in liquid flow rate at iso-G conditions. Larger particle sizes and square geometry showed shorter transient times as compared to smaller particle sizes and circular geometry.     

3-D modelling of kerosene-fuelled HVOF thermal spray gun

Liquid-fuelled high-velocity oxy-fuel (HVOF) thermal spraying systems are capable of generating more momentum output to powder particles in comparison with gas-fuelled systems. The use of low-cost fuel such as kerosene makes this technology particular attractive. High-quality coating requires thermal spraying systems delivering consistent performance as a result of the combustion during HVOF spraying. The combustion of kerosene is very complicated due to the variation of fuel composition and subsequently makes it extremely challenging for process control. This paper describes a 3-D simulation using mathematical models available in a commercial finite volume CFD code. The combustion and discrete particle models within the numerical code are applied to solve the combustion of kerosene and couple the motion of fuel droplets with the gas flow dynamics in a Lagrangian fashion. The effects of liquid fuel droplets on the thermodynamics of the combusting gas flow are examined thoroughly.     

Utilizing the autocatalysis of Co to prepare low-cost WC-Co powder for high-performance atmospheric plasma spraying

A novel method of incorporating fluidized bed chemical vapor deposition (FBCVD) with electroless plating was developed to effectively prepare the core-shell structured WC-Co composite powders. The Co nanoparticles decorated on the surface of WC particles by FBCVD acted as active catalysts for the subsequent electroless plating process. The particle size and quantity of the decorated Co particles determined the electroless plating rate but the particle size played more important role. For the conditions tested, the maximum electroless plating rate of 2.34 mg/g/min was obtained by using an optimal FBCVD pretreatment at 750°C for 3 minutes. WC-12Co composite powders with a commercial composition widely used for atmospheric plasma spraying (APS) were efficiently prepared. The composite powders exhibited excellent suitability for APS by forming a homogenous Co-W-C ternary liquid stream. The APS coating is not only well-bonded with the substrate but also consisted of hard nonequilibrium Co₃W₃C and W₂C phases with a uniform distribution. Both remarkably improved the hardness and tribological properties of the APS coating.     

Reactive plasma spraying of supersaturated tungsten super-hard Ta-Hf-W-C solid solution coating

A supersaturated tungsten Ta-Hf-W-C solid solution coating is successfully prepared by a reactive plasma spraying. The reaction process and solution behavior of TaC-HfC-WC-C composite powder during induction plasma spheroidization (IPS) and vacuum plasma spraying (VPS) are described. Compared with the direct spraying, the coating made by IPS-VPS multi-stage plasma heating process has lower porosity and better composition uniformity. The highest hardness obtained by nanoindentation can reach up to 43.3 GPa due to solid solution strengthening. This work provides a new method and a potential material for thermal spraying super-hard coatings.     

CFD modeling of the Wurster bed coater

In the Wurster bed coater, the wetting, drying, and circulation of particles are combined to produce a high quality coating. The drying and wetting conditions in a laboratory scale Wurster bed coater are modeled and compared with experimental data. A model combining multiphase fluid dynamics with heat and mass transfer is developed to model the particle and gas motion and the transport of thermal energy and moisture. A wetting region is defined, where a specified moisture content is set in the particle phase, above the jet inlet, to describe the injection of coating liquid. The simulation shows the characteristic circulation of particles in the equipment, as well as the behavior of the moisture in the system and agrees well with measurements. The simulation indicates how different process conditions influence the drying regions. The results show that most of the drying, under typical operating conditions, takes place in the Wurster tube. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

用石蜡-CO_2超临界流体快速膨胀在流化床中进行细颗粒包覆

对超临界流体快速膨胀技术在流化床中进行细颗粒的表面包覆进行了研究 ,以实现细颗粒中关键成分的有效控制释放 .实验研究了含有包覆剂———石蜡的超临界二氧化碳流体通过微细喷嘴快速膨胀到装有细颗粒的流化床中 ,膨胀射流中所产生的微核在细颗粒表面均匀沉积 ,形成细颗粒表面薄层包覆 .结果分析表明 ,超临界流体快速膨胀前的温度是包覆过程的关键参数 ,通过控制操作过程参数可以获得良好的包覆结果     

细长钢管内壁涂塑工艺

采用流化床和热喷涂方法喷涂直径小于２０ｍｍ的长钢管内壁。叙述了工艺过程和涂层检测方法。