流化催化裂化沉降器内油气的流动规律

采用Reynolds应力输运模型对一种催化裂化沉降器内的油气流动状况进行了全尺寸的数值模拟.在计算过程中未对沉降器的复杂结构进行简化,所建立的几何模型包括沉降器内部区域和两级旋风分离系统内部区域的全部流动空间.计算结果表明:粗旋分离器排气管出口的油气呈旋转射流状态喷出,弥漫于庞大的沉降器空间,流动缓慢,经历了较长的停留时间后才能进入顶旋分离器;大量油气在高温下长时间的停留将导致沉降器内大量结焦,对催化裂化的安全长周期运行造成隐患.     

催化裂化沉降器内两端敞开型旋风分离器内气相流动规律

研究考察了催化裂化沉降器内两端敞开型旋风分离器内油气流动规律.用CFX软件采用DSM模型进行了数值模拟,并与用五孔探针测试的流场进行了比较,表明DSM模型有良好的预测精度.在此基础上,采用标量输运方程研究了气体在旋风分离器内的停留时间分布规律.实验和模拟结果均表明,该类旋风分离器内流场与常规旋风分离器的有很大的不同,升气管和料腿均存在回流区,升气管回流区最大可波及分离空间,对分离空间流场有很大干扰.气体示踪模拟结果表明,由入口进入旋风分离器,由升气管、料腿排出的气体的停留时间近似呈对数正态分布;升气管、料腿回流区内气体停留时间呈双峰分布;升气管回流区的存在可使总气体平均停留时间增大约5%～10%;料腿直径的减小以及灰斗的存在均可增大由升气管排出的气量并使升气管、料腿回流区大幅减小,进而减小粗旋风分离器内气体总平均停留时间.     

带隔流筒旋流快分系统新型工业催化裂化沉降器内气相流场的数值模拟

采用RNG k-e湍流模型模拟带隔流筒旋流快分系统工业催化裂化沉降器内的气相流场,基于沉降器内气相流场的分析,考察了压力平衡管截面尺寸及封闭罩直径对封闭罩内外气量分配的影响. 结果表明,进入封闭罩外的汽提油气量随平衡管截面边长增加而增大,随封闭罩直径增加而减小. 封闭罩阻止了分离系统内油气进入沉降器中. 压力平衡管通过抽吸作用将封闭罩外的汽提油气快速引出沉降器,使封闭罩外的汽提油气在沉降器内的总停留时间降至13 s以下. 平衡管截面边长小于310 mm时,汽提气的引出分为两路;平衡管截面边长大于310 mm时,汽提气全部进入封闭罩外部,且分离系统内的少量油气向下流出分离系统至沉降器内. 封闭罩直径为3.8 m时,99%以上的油气都进入封闭罩外部.     

Liquid phase mixing and gas hold-up in a multistage-agitated contactor with co-current upflow of air/viscous fluids

A hydrodynamic study is carried out in a multistage-agitated contactor with cocurrent upflow of air/viscous fluids. The liquid phase backmixing is characterized through a residence time distribution study in various viscous fluids (up to 20 mPa s). The liquid Reynolds number with respect to the impeller applied in the investigation ranges from 1000 to 50 000. A cascade of stirred tanks with back flow model satisfactorily fits all experimental residence time distribution curves in the present study. It is found that the increase in the liquid viscosity reduces the backmixing in the liquid phase due to its dampening effect on turbulence. The presence of the gas phase helps in reducing the backmixing by the straightening effect and entrainment effect in a co-current operation manner. The gas hold-up measured in the present study is comparable to the literature data. A new type of correlation taking into account the influence of the gas phase is proposed to predict the backmixing in a multistage-agitated contactor.     

An experimental study of oil recovery from sewage sludge by low-temperature pyrolysis in a fluidised-bed

Pyrolysis of activated sewage sludge was investigated under inert conditions in a fluidised-bed to study the effects of temperature and gas residence time on the product distribution and composition with an aim to maximise the oil yield. The temperature was varied from 300 to 600 °C and the gas residence time from 1.5 to 3.5 s. Three groups of products were produced, namely, a non-condensable gas (NCG) phase, a solid phase (char) and a liquid phase (oil). A maximum of 30% oil yield (wt% daf of sludge fed) was achieved at a pyrolysis temperature of 525 °C and a gas residence time of 1.5 s. Higher temperatures and longer gas residence times favoured the formation of NCG, suggesting that secondary cracking reactions had occurred. The oil obtained was analysed using GC-MS and H NMR to determine the oil's composition and structure, a unit structure of the oil was proposed which consisted of aromatic rings connected by hydrocarbons with -OH functional groups attached.     

重油催化裂化沉降器结焦历程分析

沉降器结焦需具备2个条件:存在易结焦物质,存在结焦的环境和条件。在重油催化裂化沉降器中结焦物质包括油气组分、油液滴和催化剂颗粒,结焦的环境和条件指沉降器内的物料流场、温度场和浓度分布情况。分析了沉降器中气相组分、油液滴和催化剂颗粒等结焦物质的结焦历程,提出为了定量掌握结焦历程中各个过程的细节有待于进一步进行研究的问题。     

Residence time distribution measurements in a pulsed baffled tube bundle

Experimental flow pattern and associated residence time distribution measurements are reported for a tube bundle where periodic baffles and fluid oscillation may be present. When there is no fluid oscillation, high Reynolds number flow conditions are required to give sharp residence time distributions. When baffles are present, fluid oscillation can give sharp residence time distributions for modest low net flow Reynolds numbers. These observations extend our previous results and also show the viability of the system, for example in use as a reactor or heat exchanger where a multi-tube configuration might be required.     

Average Crossflow Velocity in Laminar Flow Systems with Periodic Finned Surfaces

Experimental and CFD studies of the enhanced average crossflow velocity in a laminar flow system were performed. The experiments were carried out using working fluid with a kinematic viscosity of 1.8·10^–6 m²/s. A steady flow Reynolds number in the laminar range of 0 < Re < 400 and oscillation Reynolds number in the range 0 < Re_osc < 1000 were studied. The range of oscillation amplitude and frequency were 0.2 mm < A < 1.0 mm and 5 Hz < f < 90 Hz respectively. Three experimental configurations were studied, i.e., oscillating finned surface in a fluid at rest, which is similar to a batch configuration, steady finned flow and oscillating finned flow configurations. The acquired images were analyzed using particle image velocimetry (PIV) software. The study is also supported by CFD simulations using the software suit CFX 11.0 from ANSYS GmbH, Germany. The results of the flow visualization and PIV analyses reveal the formation of periodic vortices and increased transverse transport. The maximum enhancement of the average crossflow velocity was obtained at κ = 3. The oscillation parameters and shape of the fins have a significant influence on the flow patterns and the crossflow effects. A triangular finned geometry gives better performance considering the enhanced average crossflow velocity. In general, efficient fluid mixing is possible due to the complex flow structures generated.     

Thermal decomposition of hydrazine in sub- and supercritical water at 25 MPa

Supercritical water flow-through test facility (SCW-TF) for the study of hydrothermal fluids is described. The hydrodynamic behavior of the flow-through reactor is examined from ambient to supercritical water conditions by performing residence time distribution measurements. The results indicate that at 25 MPa, the employed reactor configuration exhibits plug flow behavior with a small extent of dispersion over the temperature range from 298 to 773 K. The experimentally determined effective volume of the reactor was used for the calculation of mean residence times of the fluid in the “hot zone” of the flow-through system. The thermal stability of hydrazine in aqueous solution was examined along the 25 MPa isobar from 473 to 725 K. The obtained first-order rate constant for the thermal decomposition of hydrazine increases from 3.73 × 10⁻⁴ s⁻¹ at 473 K to about 0.31 s⁻¹ at 725 K.     

催化裂化沉降器新型高效旋流快分器内气固两相流动

用CFX软件对催化裂化沉降器新型旋流快分器的气相流场进行了三维模拟,湍流模型采用雷诺应力输运方程模型.计算结果与用五孔探针测试的气相流场实验结果吻合很好.采用离散轨道模型对该旋流快分器内颗粒的运动情况进行了计算,并由此估算了旋流快分器的分级效率和总分离效率.模拟结果表明：该新型旋流头可消除现有旋流头喷出口附近的短路流,更有利于提高旋流快分器的效率.两种结构形式的旋流快分器分离效率的计算对比说明：在旋流头处加入一个内构件,是很有价值的改进.     

Numerical simulation of effect of inlet configuration on square cyclone separator performance

This paper presents a numerical study of the gas-solid flow in square cyclone separators with three types of inlet configuration. Three-dimensional Reynolds Stress Model (RSM) was used to simulate the turbulent flow of gas phase and a Lagrangian equation was used to simulate the particle motion. The resulting velocity, separation efficiency and pressure drops were verified by comparison with measured data. The effect of inlet configurations on the turbulent dynamics in the cyclone and the separation efficiency and pressure drop was analyzed. Results showed that inlet configurations influenced the turbulent dynamics in the cyclone and led to different pressure drop and separation efficiency. The separator with double declining inlets (DDI) had the minimum pressure drop and similar efficiency to the separator with double normal inlets (DNI). The separator with single normal inlet (SNI) had the best separation efficiency and the maximum pressure drop. When a baffle was installed in the inlet of separator SNI, the pressure drop increased by about 191% and 34% for the separator with a straight (SNI-1) and curved (SNI-2) baffle respectively on the basis of the pressure drop of separator SNI. The cut and critical diameter of particles were 2 μm and 14 μm for separator SNI-1 and 4 μm and 14 μm for separator SNI-2, while they were 8 μm and 30 μm for separator SNI at the same inlet conditions.     

Characterisation of fluid mixing in novel designs of mesoscale oscillatory baffled reactors operating at low flow rates (0.3-0.6 ml/min)

For the first time two mesoscale oscillatory baffled designs (central and integral baffles with their volumes of 5.2 ml and 4.4 ml, respectively) were experimentally characterised at net flow rates as low as 0.3 ml/min (Re_n ∼ 1.25), giving a residence time of around 15-17 min over a wide range of oscillation conditions. The purpose was to identify the lower limits of operability, thereby determining the maximum residence time per unit reactor volume for these mesoscale units. The characteristics of fluid flow were found to be strongly affected by Strouhal number at these low net flows. For the integral baffles, the oscillation conditions exhibited little influence on the fluid mixing. For the central baffles, there were three distinct flow regimes, depending on Strouhal numbers which affect the fluid characteristics differently. At two regimes of Sts, St ≥ 0.8 and 0.13 ≤ St ≤ 0.2, an increase in frequency did not alter the axial dispersion. At St ≥ 0.8, the fluid experienced less uniform mixing, representing by right-skewed residence time distribution (RTD) curves. At 0.20 ≤ St ≤ 0.13, the fluid mixing was significantly improved, indicated by narrow and symmetrical RTD curves with Re_o up to 700. At 0.4 ≤ St ≤ 0.27 and St ≤ 0.1, the degree of plug flow was a function of Re_o. The maximum number of tanks achieved at these low flow rates was in the range 30-35, occurring at a velocity ratio (Re_o/Re_n) of 39-40.     

Drag on a sphere in a spherical dispersion containing Carreau fluid

The drag on a rigid sphere in a spherical dispersion containing Carreau fluid is investigated theoretically based on a free surface cell model for Reynolds number in the range [0.1,100], Carreau number in the range [0,10], the power-law index in the range [0.3,1], and the void fraction in the range [0.271,0.999]. The influences of the particle concentration, the nature of the Carreau fluid, and Reynolds number, on the drag coefficient are examined. We show that the drag coefficient declines with the decreasing particle concentration, and the reversal of the flow field in the rear region of a sphere is enhanced by the shear-thinning nature of the fluid. An empirical relation, which correlates the drag coefficient with the void fraction (= 1 − particle concentration), the nature of the Carreau fluid, and Reynolds number, is proposed.     

Deposition rates during the early stages of pyrolytic carbon deposition in a hot-wall reactor and the development of texture

Pyrolytic carbon layers were deposited from methane/oxygen/argon mixtures on planar substrates (silicon wafers) at a total pressure of 100 kPa, a maximum gas residence time of 2 s and a temperature of 1100 °C. The depositions were performed in a hot-wall reactor with the substrate oriented parallel to the gas flow. Particular attention was paid to factors that influence the reproducibility of the deposited layers. Scanning and transmission electron microscopy were applied to study the thickness profiles and the texture of the carbon layers. The surface topography was investigated by atomic force microscopy. For pyrolytic carbon deposited without oxygen, an alteration from medium- to high-textured carbon is observed with increasing residence time. Islands are observed on the surface of the layer whose size increases with the texture. For pyrolytic carbon deposited with 3% oxygen, lower deposition rates were obtained and a strong modification of the texture is found compared to gas mixtures without oxygen.     

Mechanisms and kinetics of homogeneous secondary reactions of tar from continuous pyrolysis of wood chips

The change of mass and composition of biomass tar due to homogeneous secondary reactions was experimentally studied by means of a lab reactor system that allows the spatially separated production and conversion of biomass tar. A tarry pyrolysis gas was continuously produced by pyrolysis of wood chips (fir and spruce, 10-40 mm diameter) under fixed-bed biomass gasification conditions. Homogeneous secondary tar reactions without the external supply of oxidising agents were studied in a tubular flow reactor operated at temperatures from 500 to 1000 °C and with space times below 0.2 s. Extensive chemical analysis of wet chemical tar samples provided quantitative data about the mass and composition of biomass tar during homogeneous conversion. These data were used to study the kinetics of the conversion of gravimetric tar and the formation of PAH compounds, like naphthalene.It is shown that, under the reaction conditions chosen for the experiments, homogeneous secondary tar reactions become important at temperatures higher than 650 °C, which is indicated by the increasing concentrations of the gases CO, CH₄, and H₂ in the pyrolysis gas. The gravimetric tar yield decreases with increasing reactor temperatures during homogeneous tar conversion. The highest conversion reached in the experiments was 88% at a reference temperature of 990 °C and isothermal space time of 0.12 s. Hydrogen is a good indicator for reactions that convert the primary tar into aromatics, especially PAH. Soot appears to be a major product from homogeneous secondary tar reactions.     

Liquid backmixing in oscillatory flow through a periodically constricted meso-tube

This paper deals with the measurement and modelling of axial liquid dispersion in a 4.5 mm internal diameter tube provided with smooth-periodic constrictions (meso-tube) in steady and oscillatory flow conditions. The residence time distribution (RTD) in the meso-tube was monitored for a range of fluid oscillation frequency (f) and amplitude (x₀) at laminar flow. The RTD response was modelled with three hydrodynamic models: (i) tanks-in-series, (ii) tanks-in-series with backflow and (iii) plug flow with axial dispersion. The steady flow through the meso-tube at flow rates up to 21.30 ml/min resulted in broad RTDs, mainly due to the parabolic velocity profile. The use of fluid oscillations allowed a fine-control of the axial liquid dispersion in the meso-tube due to generation of secondary flow in the regions between the constrictions. The axial dispersion coefficient D was reduced by up to 13-fold in comparison with the steady flow situation. Values of x₀ ≤ 1 mm and f = 10 Hz generally resulted in a maximum reduction in axial dispersion through, therefore maximum improvements in RTD. The tanks-in-series model was generally not capable of predicting RTDs in the meso-tube. The potential of this platform for the continuous, sustainable production of added-value products is herein demonstrated.     

Biomass pyrolysis experiments in an analytical entrained flow reactor between 1073 K and 1273 K

Experiments are performed in an entrained flow reactor to better understand the kinetic processes involved in biomass pyrolysis under high temperatures (1073-1273 K) and fast heating condition (>500 K s⁻¹). The influence of the particle size (0.4 and 1.1 mm), of the temperature (1073-1273 K), of the presence of steam in the gas atmosphere (0 and 20 vol%) and of the residence time (between 0.7 and 3.5 s for gas) on conversion and selectivity is studied. Under these conditions, the particle size is the most crucial parameter that influences decomposition. For 1.1 mm particles, pyrolysis requires more than 0.5 s and heat transfer processes are limiting. For 0.4 mm particles, pyrolysis seems to be finished before 0.5 s. More than 70 wt% of gas is produced. Forty percent of the initial carbon is found in CO; less than 5% is found in CO₂. The hydrogen content is almost equally distributed among H₂, H₂O and light hydrocarbons (CH₄, C₂H₂, C₂H₄). Under these conditions, the evolution of the produced gas mixture is not very significant during the first few seconds, even if there seems to be some reactions between H₂, the C₂ and tars.     

Measurement of solid particle residence time in a cyclone reactor: A comparison of four methods

This paper describes four simple methods for measuring short residence times (down to 0.1 s) of solid particles in a cyclone reactor: detection of a single particle by use of phototransistors; analysis of the impact of a pulse of particles on piezocrystal probes; study of the profile of the vertical component of the particle velocities by use of a camera; measurement of the space time of the particles by a hold-up method. These four approaches lead to similar results for two kinds of solids (wood sawdust and sand) in a 12.5 × 10⁻² m diameter cyclone reactor operating with carrier gas residence times ranging from 0.5 to 5 s. A simple relationship is proposed for calculating the mean residence time of the particles (which increases with the gas flow rate) as a linear function of their theoretical free fall time through the cyclone and of the gas Reynolds number at the reactor inlet.     

Smart RTD for multiphase flow systems

A relatively new concept is presented for evaluation of the fluid age distribution a = a(x,t) within the interior of an apparatus. In the standard RTD approach, the tracer study is performed and the residence time distribution is obtained. In the new approach denoted as SRTD, the fluid age is considered as the field quantity and the governing equation is formulated for its spatio-temporal distribution within the flow domain. There are only few studies devoted to this alternative approach, which typically concern only the single-phase flow systems. In this contribution we investigate its applicability also to multiphase systems. In the case of a bubble column, both the RTD and SRTD concepts are employed and discussed. The results are calculated numerically and compared with the experimental observations.     

Texture and nanostructure of pyrocarbon layers deposited on planar substrates in a hot-wall reactor

Pyrocarbon layers were deposited from methane on planar substrates (pyrolytic boron nitride) at a temperature of 1100 °C and residence times of 0.1, 0.5 and 2.5 s. The depositions were performed in a hot-wall reactor with the substrates oriented parallel to the gas flow. Transmission electron microscopy was applied to study the texture and the structure of the carbon layers on a micrometer and nanometer scale. The texture is influenced by the residence time. An alteration from medium- to high-textured carbon is observed from short to long residence times. The nanostructure of high- and medium-textured pyrocarbon is characterized by domains whose sizes do not generally differ.