Hydrodynamics of cocurrent downflow circulating fluidized bed (CDCFB)

This paper presents an experimental study on the hydrodynamics of cocurrent downflow gas—solid suspension in a 140 mm i.d. Circulating Fluidized Bed (CDCFB) reactor. The influence of gas velocity and solid circulating rate on axial pressure drop, radial profiles of solid concentration and particle velocity has been examined. It is shown that solid flow in CDCFB is much more uniform than that in the riser.     

A circulating fluidised bed

Induced particle circulation was studied in a 0.3 m diam. air fluidised bed of sand with central draught tubes of 0.2 m and 0.15 m diam. and 0.6 m and 1.2 m in length. A “two-dimensional” bed, 0.3 m in width, of similar cross-section, was also used to study catalyst particle circulation. Superficial gas velocities of up to 0.4 m/s of air were supplied to the base of the draught tube to induce particle circulation rates in the annular downcomer of up to 400 kg/m² s. The circulation rate was shown to be affected by the gap height between the distributor and the draught tube, but was not affected by the draught tube length of height of bed above it. A model was developed to predict the circulation rate, assuming that the driving force for circulation was the density difference between draught tube and annulus and that energy was dissipated by particle shear at the walls. The theory is in reasonable agreement with the experimental results. A tentative model for predicting the shear stress at the wall of a flowing fluidised bed is presented.     

Investigation of pressure drop in a cocurrent downflow three-phase moving bed

Based on a self-established cold-flow experimental device, the pressure drop in a cocurrent downflow three-phase moving bed was investigated under a wide range of gas, liquid, and solid flow rates during dynamic and steady-state operation. The results showed that for the startup of the bed, since the first bed layer packed by fall-falling of particles had lower voidage, it would take at least one bed volume time to make the voidage in the bed reach the steady-state. Under steady-state conditions, the pressure drop increased with the increase of gas and liquid mass flow rates, liquid viscosity, and decreased with the increase of solid flow rate. Furthermore, it was found that the liquid distribution became more uniform due to particle movement. The experimental data obtained in this study was used to develop a correlation to predict the pressure drop in a three-phase moving bed with an average relative error of 9.32%.     

Slip velocity characteristics in the riser of circulating fluidised bed

Experiments were carried out in a conventional circulating fluidised bed to measure the axial pressure profile and total pressure drop, which covered a wide range of operating conditions. Material belonging to the Geldart A (fine material) as well as the Geldart B (course material) categories have been used in the present work. Slip velocity is determined from the total pressure drop and noticed that the slip velocity is much higher than the free fall velocity of single particle for Geldart A type material, while it is approximately equal to the free fall velocity of single particle for the Geldart B type materials. A model is developed for slip velocity taking into account all the hindrance effects: particle-particle, and particle-wall, and particle agglomeration. Predictions of the present model are validated with the data due to present study and the data reported in the literature.     

Reactive bed materials for improved biomass gasification in a circulating fluidised bed reactor

Reactive bed materials for the optimisation of the biomass gasification in a fast internally circulating fluidised bed (FICB) reactor system were tested under sulphur-free (S-free) and H₂S enriched conditions in a micro-scale fluidised bed reactor. In the experiments, the bed materials (natural olivine, (Fe_xMg_1-x)₂SiO₄, perovskite-type oxides, Ba_0.3Sr_0.7Fe_0.9Mn_0.1O_3-δ and La_0.65Sr_0.35Cr_0.5Mn_0.5O_3-δ, Gd_0.1Ce_0.9O₂ and a natural calcite, CaCO₃) were examined under realistic redox-cycling conditions to study their oxygen capacity and release, their catalytic activity towards toluene reforming as well as their mechanical and chemical stability.It was found that the synthesised materials outperform the natural materials as reactive bed materials for the FICFB process under S-free atmosphere. Gd_0.1Ce_0.9O₂ has better catalytic properties, perovskites show a higher oxygen storage capacity. However, in the presence of H₂S, the perovskite loose their oxygen capacity, while calcite can form a sulphide/sulphate cycle which allows for significant oxygen capacity. Additionally, the catalytic activity goes up. Therefore, under real conditions, the two natural materials, calcite and to a lower extent olivine, have clear advantages with respect to price, catalytic activity and oxygen capacity.     

Numerical simulation of coal gasification at circulating fluidised bed conditions

This paper presents modelling results for a new pressurised fluidised bed gasifier concept, called the Power High-Temperature Winkler gasifier (PHTW gasifier). The numerical simulation of the steam/oxygen blown and lignite-fuelled power plant gasifier is performed on the 4800 t/day (1000 MW) at a pressure of 33 bar. The formation of flow pattern, turbulence, product gas composition, temperature, and radiation heat transfer were investigated. Influence of diameter variation on the flow patterns at constant operating conditions is presented. A comparison between the calculation and literature data of similar fluidised bed systems shows good conformance. To anticipate the solid's behaviour, particle concentration, particle size change due to pyrolysis and surface reactions, and particle tracks were modelled using an Eulerian–Lagrangian approach. While varying the total particle mass flow, the pressure drop as a function of reactor height was observed.     

Liquid holdup in gas-liquid cocurrent downflow through packed beds

The average in situ volume fraction of the liquid phase for gas-liquid cocurrent downflow through packed beds is correlated to the input volume fraction of the liquid and the bed geometry. The range of operation is delineated into a high-interaction regime and a low-interaction regime based on the influence of the gas rate on the liquid holdup. Experimental data of the present investigation using air-water and air-CMC solutions, as well as that reported in literature covering a wide range in variables, are considered in the development of correlations for total and dynamic liquid holdup.     

Radial liquid distribution in cocurrent two-phase downflow in packed beds

Radial liquid distribution was measured experimentally for cocurrent, two-phase downflow in packed beds. The effects of bed length, water and air flow rates, and type of packing were determined. The experimental data were obtained in the gas-continuous, transition and pulsing trickling-flow regimes. For all finite air rates, the liquid velocity profiles were approximately flat with the maximum average velocity occurring at the center of the packed column. Increasing the air rate increased the center liquid velocity. The gas rate effect was more pronounced in shorter beds. At higher gas rates the liquid rate had less effect on the radial liquid distribution than at lower gas rates. Operation at higher liquid rates resulted in a flatter radial liquid veilocity profile. It was observed that the bed of pellets operated at high liquid rate and low gas rate was unstable. Increasing the bed height increased the stability of the system and a better liquid distribution was obtained. The effects of water flow rate, bed length, and packing type on the shape of the liquid velocity profiles were minor.     

Residence time distribution of sorbent particles in a circulating fluidised bed boiler

The residence time distribution of limestone sorbent particles has been studied in order to increase the understanding of the conditions for sulphur capture in fluidised bed boilers. Two methods were used. The ‘steady state method’ involves the study of residence time for various particle size fractions. The ‘transient method’ is based on the transient increase in the amount of sorbent carryover with the fly ash, following initial limestone addition to a fresh bed (i.e. a bed with little or no sorbent). For the boiler investigated both methods gave similar results, showing that the major fraction of the sorbent, 80–85%, had a residence time of one hour or more.     

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.     

Flow structure and thickness of annular downflow layer in a circulating fluidized bed riser

Flow structures were determined in a circulating fluidized bed (CFB) riser (0.203 m i.d.×5.9 m high) of FCC particles (d_p=70 μm, ρ_s=1700 kg/m³). A momentum probe was used to measure radial momentum flux profiles at several levels and to distinguish between upward and downward flow regions. Time-mean dynamic pressure (ΔP_m) decreases towards the wall in the range U_g=5-8 m/s, G_s=10-340 kg/m² s. The thickness of the annular downflow layer based on ΔP_m=0 reaches a maximum with increasing height. The annular downflow layer disappears locally with increasing solids mass flux (G_s) at a constant gas velocity, with achievement of the dense suspension upflow (DSU) regime. A new correlation is developed to predict the time-mean thickness of solids down-flowing layer based on solids mass flux and momentum flux. It successfully accounts for the variation of the annular layer thickness with height and G_s, and covers a wide G_s range right up to near the onset of the DSU regime.     

Yeast fermentation in a cocurrent downflow contacting reactor (CDCR)

The growth kinetics and mass transfer characteristics of Saccharomyces cerevisiae in a cocurrent downflow contacting reactor (CDCR) were studied for various glucose concentrations at constant air and liquid flow rates. Increasing glucose concentration increased the biomass concentration thus resulting in an increase in the volumetric oxygen uptake rate. The volumetric mass transfer coefficient, k_La, however, decreased with increasing glucose concentration. It was observed that the growth of S cerevisiae in the CDCR would fit the classical Monod kinetics and the maximum specific growth rate was determined to be 0.545 h⁻¹. © 2000 Society of Chemical Industry     

Numerical study of cluster and particle rebound effects in a circulating fluidised bed

Gas-particle flows in a vertical two-dimensional configuration appropriate for circulating fluidised bed applications were investigated numerically. In the computational study presented herein the motion of particles was calculated based on a Lagrangian approach and particles were assumed to interact through binary, instantaneous, non-frontal, inelastic collisions including friction. The model for the interstitial gas phase is based on the Navier-Stokes equations for two-phase flows. The numerical study of cluster structures has been validated with experimental results from literature in a previous investigation. Numerical experiments were performed in order to study the effects of different cluster and particle rebound characteristics on the gas-particle flow behaviour.Firstly, we investigated the hard sphere collision model and its effect on gas-particle flow behaviour. The coefficient of restitution in an impact depends not only on the material properties of the colliding objects, but also on their relative impact velocity. We compared the effect of a variable restitution coefficient, dependent on the relative impact velocity, with the classical approach, which supposes the coefficient of restitution to be constant and independent of the relative impact velocity.Secondly, we studied the effects of different cluster properties on the gas-particle flow behaviour. Opposing clustering effects have been observed for different particle concentrations: within a range of low concentrations, groups of particles fall faster than individual particles due to cluster formation, and within a well-defined higher concentration range, return flow predominates and hindered settling characterises the suspension. We propose herein a drag law, which takes into account both opposing effects and have compared the resulting flow behaviour with that predicted by a classical drag law, which takes into account only the hindered settling effect.     

Halide aerosols in circulating fluidised bed co-combustion. Role of coal bound kaolin

An experimental campaign was carried out with a circulating fluidised bed (CFB) pilot scale combustor to study the role of coal bound kaolin in the fate of solid recovered fuel (SRF) originated halide aerosols. A combustion experiment was carried out with SRF-Spruce Bark mixture as a reference. High kaolinite coal and paper pigment kaolin, one at a time, were mixed with the SRF-Bark in increasing proportions until dp < 1 μm fine particles were absent as measured from 780 °C combustion gases by means of a dilution probe and low pressure impactor (LPI). This fine particle mode was absent after mixing sufficiently either coal or kaolin with SRF-Bark and only traces of water soluble alkali metal salts were found in the CFB fly ash. These conditions were achieved when kaolin was mixed with the SRF-Bark for 52 times on a molar basis compared to the Na + K initially found in the aerosols. This proportioning was found to be the same for the additive kaolin and coal bound kaolinite. Na and K in the fly ash seem to be bound chemically to the kaolin as alkali aluminosilicates rather than in water soluble alkali sulphates. This is indicated by their solubility behaviour.     

Gas quenching probe and field measurements of gaseous cadmium in a 12-MWth circulating fluidised bed combustion boiler

A probe-based technique for measurement of gas phase metal species in flue gas at high temperatures has been developed. This paper deals with work carried out to test and evaluate the technique through field measurements of cadmium species during co-combustion of sewage sludge and other solid fuels in a circulating fluidised bed combustion boiler. During the measurements of vaporous cadmium forms, solid fly ash samples were also collected at the measurement positions. Chemical composition data from these fly ash samples were used to discuss the influence that the fly ash filter cake built up on the probe tip can have on the measurements. Additionally, the solid samples were examined by means of X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques to have a better insight into the problem. Using the data from the field measurements and/or from the integrated measurements and weighing devices of the boiler the mass balance of cadmium from the combustion process was calculated by different methods. The calculation results were fairly consistent. In one method, data from the field measurements was used. This method gave the mass balance for cadmium in the process Cd_out/Cd_in=113.6%, which was a very good result considering that it involved the analysis of trace amount of metals in full-scale measurements.     

Gas-Liquid mass transfer in fixed beds with two-phase cocurrent downflow: Gas/newtonian and non-newtonian liquid systems

New data of gas-liquid mass transfer for cocurrent downflow through packed beds of porous and non-porous particles are presented. Mass transfer parameters for air/carbon dioxide/water, air/carbon dioxide/carboxymethylcellulose solution and air/carbon dioxide/sodium hydroxide systems were evaluated by least square fit of the calculated CO₂ concentration profiles in gas phase to the experimental values. The volumetric liquid-side mass transfer coefficient increases with the increase of the flow consistency index of the liquid. A comparison of the volumetric liquid-side mass transfer coefficient values evaluated with and without taking into account the axial dispersion shows that the influence of the liquid axial dispersion is significant at low liquid velocity and high CMC concentrations, and the influence of the gas axial dispersion is insignificant.     

Modelling a circulating fluidized bed riser reactor with gas—solids downflow at the wall

A predictive model was developed for the fully developed zone of a circulating fluidized bed (CFB) riser reactor operating in the fast fluidization regime that overcomes limitations of existing models. The model accounts for the upward flow of gas and solids in the core and downward flow of the two phases in the annulus. Additionally, a numerical solution methodology for the simulation of a riser reactor employing the hydrodynamic model was devised. A simulation was performed using the fast, main Claus reaction to demonstrate the effects of backmixing in the fast fluidization regime. It was found that the molar flow rates of the reactants leaving a fast fluidized CFB riser reactor were significantly higher than those leaving an identical reactor operating in the pneumatic transport regime.     

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.     

Gas mixing in a turbulent fluidized bed reactor

A series of experiments has been conducted to study mixing and hydrodynamic behaviour of a downward facing sparger in a turbulent fluidized bed reactor. Using pressure measurement techniques, two flow discharge modes were identified around the sparger by injecting a gas tracer into the bed. These are bubbling and jetting conditions. Experimental results show that, under bubbling conditions, bubbles tend to keep their identity, while under jetting conditions a highly turbulent heterogeneous area is formed around the injection point. Due to attrition and erosion of internal heating or cooling surfaces in industrial reactors, the dominant discharge mode is the bubbling pattern. Therefore, in this investigation, the bubbling pattern is studied by measuring the radial and axial dispersion of gas tracer injected to a hot fluidized bed reactor of 20 cm diameter of FCC and sand particles. A three‐phase model is also proposed in order to predict the mixing length. In addition, the effect of sparger configuration on tracer gas mixing was examined for FCC particles.