Online measurement and control of solids moisture in fluidised bed dryers

Currently, two main methods are used to take online measurement of the solids moisture in fluidised bed dryers, namely microwave resonance and near infrared spectroscopy. In this paper, a new online approach to solids moisture measurement of batch fluidised bed dryers by electrical capacitance tomography (ECT) is presented for the first time. Based on online measurement of solids moisture, it is possible to implement feedback control and process optimisation of batch fluidised bed drying processes, aiming to increase the operation efficiency and to improve product quality. A twin-plane ECT sensor with eight electrodes in each plane is mounted in the bottom of a glass fluidisation chamber. From the adjacent electrode pairs, the water content of the solids is estimated based on the correlation between the moisture content and the permittivity value. To reduce measurement error, the effect of temperature on moisture measurement is compensated. The fluidisation velocity is estimated by a semi-empirical function based on the measured water content. The acquired information is sent to a controller to adjust the air flow rate of the fluidised bed dryer. To validate the moisture measurement by ECT, a mathematical model has been developed, based on the measured temperature and relative humidity of the outlet air. The Landweber iteration method is applied to reconstruct images. The averaged solids concentration along the radial direction at different fluidisation conditions is given and compared with results by the linear back-projection (LBP) method. Results from batch drying processes with online measurement and feedback control are given and compared with no feedback control. To compare the operation efficiency, the thermal efficiency is considered and the results show the possibility of online control and optimisation of the fluidised bed drying processes, based on online measurement of solids moisture by ECT. Some challenges and future work are discussed.     

Investigation of gas–solids flow characteristics in a conical fluidized bed dryer by pressure fluctuation and electrical capacitance tomography

It is important to investigate the gas–solids flow characteristics of fluidized bed drying processes to improve the operation efficiency and guarantee the product quality. This paper presents research into fluidized bed drying processes measured by high-frequency differential pressure fluctuation and electrical capacitance tomography (ECT). Power spectra analysis is combined with dynamic calibration for ECT to reveal the complex gas–solids flow behavior. Bubble characteristics are visualized by cross-sectional and quasi-3D ECT images. In addition, results by discrete wavelet transform analysis are given and compared with the analysis results of previous sections. It has been found that bubbles would coalesce in different ways under different operation conditions, and discrete wavelet transform sub-signals of ECT measurements are sensitive to particle moisture. This work reveals the complex hydrodynamic behavior in the fluidized bed dryer and provides valuable information for process control.     

Experimental study on gas-solids flows in a circulating fluidised bed using electrical capacitance tomography

It is difficult to measure the gas-solids flow in a circulating fluidised bed (CFB) because of the complicated and rapid transient process. Electrical capacitance tomography (ECT), a cross-sectional imaging technique, has been used to measure the dilute flow in a large square CFB. A sensor has been specifically designed for the measurement and a new algorithm has been developed for image reconstruction. Flow conditioning parts (internals) are designed and placed inside the CFB, aiming to enhance the contact between gas and particles in the dilute gas-solids flow. The dynamic characteristics and detailed information were obtained on two sections in the bed at different height. The performance of the internals is related to their size, combination, height in the bed and the superficial gas velocity. It has been confirmed that a particular combination of internals can increase the solids concentration in the central area of a cross-section, and can improve the probability density distribution (PDD) with a moderate gas velocity. Using a combination of a large internal at an upper location and a small one at a lower location can optimise the flow in the CFB.     

Modelling of batch fluidised bed drying of pharmaceutical granules

This paper presents a mathematical model based on a three-phase theory, which is used to describe the mass and heat transfer between the gas and solids phases in a batch fluidised bed dryer. In the model, it is assumed that the dilute phase (i.e., bubble) is plug flow while the interstitial gas and the solid particles are considered as being perfectly mixed. The thermal conductivity of wet particles is modelled using a serial and parallel circuit. The moisture diffusion in wet particles was simulated using a numerical finite volume method. Applying a simplified lumped model to a single solid particle, the heat and mass transfer between the interstitial gas and solid phase is taken into account during the whole drying process as three drying rate periods: warming-up, constant rate and falling-rate. The effects of the process parameters, such as particle size, gas velocity, inlet gas temperature and relative humidity, on the moisture content of solids in the bed have been studied by numerical computation using this model. The results are in good agreement with experimental data of heat and mass transfer in fluidised bed dryers. The model will be employed for online simulation of a fluidised bed dryer and for online control.     

In‐line near infrared spectroscopy monitoring of pharmaceutical powder moisture in a fluidised bed dryer: An efficient methodology for chemometric model development

This work proposes a novel chemometric methodology for in‐line near infrared spectroscopy (NIRS) monitoring of pharmaceutical powder moisture in a fluidised‐bed dryer. The collected spectra are analysed by multivariate chemometrics involving the preparation of numerous laboratory samples. A different methodology, using only plant samples, was tested in real‐time. A specially designed probe tip, allowing for robust in‐situ spectral acquisition, was designed. The results prove that NIRS can be as efficient as traditional quality analyses, e.g. loss‐on‐drying, in measuring powder moisture content in a fluidised bed dryer with a calibration model based only on plant samples. © 2011 Canadian Society for Chemical Engineering     

Using Electrical Capacitance Tomography to Investigate Gas Solid Contacting

An ECT system has been shown to be useful in observing differences in particle behaviour in a bubbling fluidised bed. An image analysis technique is further described that utilises the construction of solids concentration profiles at three key values, x = 0.2, x = 0.5 and x = 0.8, which have been identified as important solids concentrations in a new Bubble Structure Model. Significant differences in the bubble structure are shown to result when the concentration of fine particles is slightly increased in a bubbling fluidised bed. Changes of this type would seriously alter the gas solid contact efficiency in the fluidised bed, which would significantly influence selectivity of in‐bed catalytic reactions and gas residence time.     

ECT imaging of three-phase fluidized bed based on three-phase capacitance model

In this work, the electrical capacitance tomography (ECT) with neural network multi-criteria optimization image reconstruction technique (NN-MOIRT), early developed by the authors, is applied to imaging bubble column and three-phase fluidized bed systems in the real time manner. Air, norpar (paraffin) and glass-beads are used as the gas, liquid, and solid phases, respectively. A three-phase capacitance model coupled with a two-region model is proposed to attain the gas holdup and the solids fraction from the permittivity maps of the three-phase system. The two-region model assumes that the solids fraction in the emulsion phase in the no bubble region is the same as in the bubble region. The three-phase capacitance model combines series and parallel capacitance connections among gas, liquid and solid components to relate the three-phase permittivity to each phase holdup. A direct image calculation to obtain the gas holdup from the permittivity map of the three-phase system is also performed by determining the permittivity threshold for the gas bubbles. Comparisons of the gas holdup obtained by ECT with that obtained from liquid head measurement showed a good agreement, validating the applicability of the model and its associated image calculation.     

基于LSTM神经网络的流化床干燥器内生物质颗粒湿度预测

生物质作为一种储量丰富、环境友好且易于获取的可再生能源，日渐成为能源研究利用领域的热点。生物质湿度是影响生物质利用效率的关键因素，因此干燥是生物质利用之前的必要步骤。流化床由于其良好的传热传质特性，在干燥过程中得到了广泛的应用。为了实时监测生物质颗粒的干燥过程，利用弧形静电传感器阵列，结合用于时间序列建模的长短期记忆（LSTM）神经网络，实现了流化床干燥器内生物质颗粒湿度的预测。在实验室规模的流化床干燥器上进行了多工况实验获取训练和测试数据，通过模型参数优化确定了LSTM模型。通过与标准循环神经网络（RNN）模型的预测结果的对比表明，LSTM神经网络模型的平均相对误差较小，能够较为准确地预测流化床干燥器内生物质颗粒的湿度。     

一种新的电容层析成像电极组合激励测量模式

电容层析成像图像重建为非线性不适定反问题,其敏感场分布不均匀,可获得的测量数据有限,中心处物体的成像效果不佳。增加电极数目,可获得更多的电容测量数据,减小其不定性,同时改善敏感场分布。但同时导致电容测量值变小,测量精度下降。在保证电容测量精度的前提下,提出了24电极组合式电容层析成像传感器结构,研究了两种激励测量方案,并与传统12电极电容层析成像传感器进行了对比分析,包括电容测量值的大小及其动态测量范围、灵敏场分布的均匀性以及不同流型下的重建图像。仿真结果表明,与12电极电容层析成像传感器相比,采用24电极组合式电容层析成像传感器,其电容测量值大,可较好地保证测量精度,其灵敏度分布更加均匀,对中心处物体的成像质量明显提高。     

Application of electrical capacitance tomography to the fluidized bed drying of pharmaceutical granule

A novel calibration technique that accounts for the presence of moisture has allowed for the application of electrical capacitance tomography (ECT) to a fluidized bed dryer containing wet pharmaceutical granule. A statistical attractor comparison test denoted as the S-statistic has been used to analyze both the reconstructed and non-reconstructed ECT images to determine radial variations in hydrodynamic behavior at an axial location 10.5 cm above the distributor. This analysis has shown that variations in the bed dynamics associated with the loss of moisture during the drying process are most intense near the walls of the dryer, while the central region is characterized by a more consistent dynamic behavior. Investigation of the voidage distribution in the individual tomograms over this period in the drying process shows that the changes in the S-statistic correspond to a reduction in area of the region involved in bubbling behavior. Tomograms from early in the drying process indicate a central core of gas channeling through the very wet granule. This is due to the high cohesive forces present at high moisture. At moisture contents below 5-wt%, near the end of drying, significant divergence in dynamic behavior is identified in the S-statistic. This divergence is associated with the appearance of asymmetric bubbling behavior in the individual tomograms.     

Measurement Techniques to Monitor and Control Fluidization Quality in Fluidized Bed Dryers: A Review

Fluidized bed dryers (FBD) are commonly employed in many industries to dry particulate solids. FBDs provide good solids mixing, high rates of heat and mass transfer, and relative ease of material handling. For efficient operation, it is important to be able to monitor and control the fluidization regime, particle size distribution (PSD), moisture content, and bulk density as well as product chemical properties. This review provides an overview of the trends in the application of different experimental techniques to monitor and control the hydrodynamic conditions of FBDs which influence the particle physiochemical properties. This review covers a wide range of measurement techniques, including infrared moisture sensor (IR), near infrared (NIR) spectroscopy, analysis of pressure fluctuations, optical imaging techniques, acoustic emission (AE), electrical capacitance tomography (ECT), spatial filter velocimetry (SFV), Raman spectroscopy, focused beam reflectance measurement (FBRM), microwave resonance technology (MRT), triboelectric probes, positron emission particle tracking (PEPT), and some novel techniques for monitoring and control of FBDs. The present review summarizes the use of the diverse techniques and outlines their merits and limitations. Prospects for future research in this area are also identified. The measurement techniques can be used for research, development, and operation of fluidized bed equipment used in non-drying applications as well.     

A Cross-Flow Model for Continuous Plug Flow Fluidized-Bed Cross-Flow Dryers

Plug flow fluidized bed cross-flow dryers have been used in drying of particulate solids such as paddy and other grains for many years. However, simulation of the performance of any particular design of the dryer has always been problematic due to the inadequate overall empirical models used that are too inflexible and too specific to the particular design. In addition, previous theoretical models of the plug flow fluidized bed cross-flow dryer did not model the gas cross flow properly and had difficulty in modeling the moving solid bed. A new steady-state cross-flow model of the dryer that models the gas cross-flow is proposed. The profiles for the solids and air moisture contents and temperatures were found to be dependent on the gas-solid flow ratio, G/F, the specific heat demand, C_PY(T_I - T_A)/(Y_E - Y_I), the total number of a transfer units, N_T = Gε/KφaSL and the specific drying load, (X_I - X_P)/ (Y_E - Y_I). The model was validated by comparing the simulated data with experimental data that were obtained by drying paddy in a plug flow fluidized bed cross-flow dryer pilot plant. The model was found to estimate very well the solids moisture content and temperature, the gas moisture content and temperature profiles, and the driving force profile.     

电容层析成像在气固流化床测量中的应用

气固流化床广泛应用于化工、炼油、冶金、电力等工业生产领域。由于流化床中气固两相流动的复杂性,流化床测量方法的研究成为了一个重要的研究领域。电容层析成像（ECT）是20世纪80年代以来发展起来的一种非介入式多相流测量技术,已经在多相流测量领域发挥了重要作用。总结了国内外近年来应用ECT技术进行气固流化床测量的进展,特别是对气固流化床内固体相浓度、流化床流型识别、固体相速度等方面工作进行了总结,并简单介绍了ECT在流化床干燥中的应用,讨论了ECT和其他测量方法结合使用情况。最后对ECT在流化床测量中的局限性和发展方向进行了讨论。     

A STOCHASTIC APPROACH TO THE DRYING OF SOLIDS IN A MULTI-STAGE FLUIDIZED BED

The residence times of solids flowing through a fluidized bed dryer exhibit dispersion about the mean. In this paper, expressions for the probability density functions of solids moisture content in the various stages of a multi-stage dryer are derived. A simple recurrence relationship for the moments of the distribution is also presented. The analysis is applied to the drying of cereal grains, and it is shown that the degree of drying increases with the number of stages in the dryer. Probability density functions of the moisture content are presented.     

A STOCHASTIC APPROACH TO THE DRYING OF SOLIDS IN A MULTI-STAGE FLUIDIZED BED

The residence times of solids flowing through a fluidized bed dryer exhibit dispersion about the mean. In this paper, expressions for the probability density functions of solids moisture content in the various stages of a multi-stage dryer are derived. A simple recurrence relationship for the moments of the distribution is also presented. The analysis is applied to the drying of cereal grains, and it is shown that the degree of drying increases with the number of stages in the dryer. Probability density functions of the moisture content are presented.     

Integration of ECT measurements with hydrodynamic modelling of conventional gas-solid bubbling bed

The electrical capacitance tomography (ECT) provides fast images of the cross-sectional concentration distribution of solid-gas flow in a confined volume. This information can be integrated with numerical simulation to estimate some of the most important hydrodynamic quantities in solid-gas flow, such as the particles velocity, interstitial gas velocity and particle-particle contact forces.In this study, using the two-fluid approach, momentum and energy balance equations, along with the appropriate boundary conditions, have been solved by integrating the numerical procedure with the experimental data of the fluidised bed pressure drop and pixel distribution of particle concentration available from the ECT measurements. Preliminary results of time-dependent hydrodynamic features of the bed are presented. These results were analysed and assessed using the available experimental literature data on conventional bubbling fluidised bed. In general, it is demonstrated that the integration of ECT measurements with numerical modelling offers a unique and promising technique for comprehensive non-intrusive information on gas-solid flow systems.     

基于数据驱动的卷积神经网络电容层析成像图像重建

针对电容层析成像技术的图像重建问题，提出了基于数据驱动的卷积神经网络图像重建方法。根据气固两相流的流型特点，通过数值模拟的方法随机生成了60000组介质分布图像，并利用有限元法计算了与之对应的电容向量，从而建立了一个“电容向量-介质分布”数据集；然后根据电容层析成像图像重建特点建立了卷积神经网络模型，对数据集中的训练集进行学习和训练，并利用测试集对训练结果进行了验证与评价。在此基础上，对获得的ECT图像重建卷积神经网络模型进行了静态实验和流化床测试实验研究。模拟和实验结果表明：所建立的卷积神经网络能较好地实现ECT图像重建，可直接用于流化床内的颗粒浓度分布测量。     

Measurement of particle concentration in a Wurster fluidized bed by electrical capacitance tomography sensors

It is essential to measure and monitor the particle flow characteristics in a Wurster fluidized bed to understand and optimize the coating processes. In this article, two electrical capacitance tomography (ECT) sensors are used to measure the particle concentration in different regions in a Wurster fluidized bed for the “cold” particle flows. One ECT sensor has a 12‐4 internal‐external electrodes and another has eight electrodes. The 12‐4‐electrode ECT sensor is used to measure the particle concentration in the annular fluidization region (outside of the Wurster tube) and the eight‐electrode ECT sensor is used to measure the particle flow in the central region (inside the Wurster tube). The effect of particle type, particle moisture, fluidization velocity, and geometrical parameters on the Wurster fluidization process is studied based on the two ECT measurements. The radial particle concentration profiles in the annular fluidization and central flow regions with different operation parameters are given. Fast Fourier Transform analysis of the particle concentration in the Wurster tube is performed with different superficial air velocities. The optimum operating ranges of the Wurster fluidization process for different particles are given. In the end of the article, computational fluids dynamics simulation results are given and used to compare with the measurement results by ECT for a typical Wurster fluidized bed. © 2014 American Institute of Chemical Engineers AIChE J 60: 4051–4064, 2014     

An Evaluation of Factors Influencing the Energy-Efficient Operation of Well-Mixed Fluidized Bed Dryers

This article describes the results of calculations of specific energy consumption, E_s, performed on a well-mixed fluidized bed dryer simulator. Exhaust air temperature-humidity loci required to yield a specified outlet moisture content were also determined. Most of the calculations related to solids whose drying rate was gas-film controlled. Six model drying curves were employed to examine the effects of drying rate and hygroscopicity in addition to the normal operating parameters. The results indicated that E_s was highest for slow-drying hygroscopic solids and lowest for fast-drying, non-hygroscopic solids. Specific energy consumption increased with decreasing bed temperature and outlet moisture content and with increasing heat loss but was independent of solids loading and airflow rate. For both the aforementioned solids and a much slower drying material (wheat), there was close agreement between the zero heat loss data and a single theoretical curve approximating the performance of an ideal adiabatic dryer. Distinct differences between the behavior of well-mixed and plug flow fluidized bed dryers are reported.     

Real-time monitoring of milk powder moisture content during drying in a spouted bed dryer using a hybrid neural soft sensor

The direct measurement of the moisture content of dried products would be more interesting for process control purposes. However, the most common procedures for such measurement are either slow or expensive for industrial dryers. Alternatively, one might reduce the cost of an effective measurement procedure by using other sensors (which are less expensive and whose response is faster), which can provide information for a physical–mathematical model representing well the drying process. In this context, the objective of this work was the application of a previously developed soft sensor for the online measurement of milk powder produced in a spouted bed dryer. A hybrid neural model was used as part of a soft sensor and coupled to the data acquisition interface. The sensor was capable of estimating milk powder moisture content when the dryer was submitted to disturbances on air inlet temperature and paste inlet flow rate. On the other hand, the model failed to describe paste accumulation within the bed, which is the reason why the soft sensor tended to overestimate moisture content for longer operation times.