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 behavior and regime transition in a high-density circulating fluidized bed riser

Flow behavior and flow regime transitions were determined in a circulating fluidized bed riser (0.203 m i.d. × 5.9 m high) of FCC particles (, ). A momentum probe was used to measure radial profiles of solids momentum flux at several heights and to distinguish between local net upward and downward flow. In the experimental range covered (; ), the fast fluidization flow regime was observed to coexist with dense suspension upflow (DSU). At a constant gas velocity, net downflow of solids near the wall disappeared towards the bottom of the riser with increasing solids mass flux, with dense suspension upflow achieved where there was no refluxing of solids near the riser wall on a time-average basis. The transition to DSU conditions could be distinguished by means of variations of net solids flow direction at the wall, annulus thickness approaching zero and flattening of the solids holdup versus G_s trend. A new flow regime map is proposed distinguishing the fast fluidization, DSU and dilute pneumatic transport flow regimes.     

Estimate of solid flow rate from pressure measurement in circulating fluidized bed

A method is described to estimate solid mass flow rate based on measurement of pressure drop in horizontal section of circulating fluid bed (CFB). A theoretical model was derived based on momentum balance equation and used to predict the solids flow rate. Several approaches for formulating such models are compared and contrasted. A correlation was developed that predicts the solids flow rate as a function of pressure drop measured in the horizontal section of piping leading from the top of the riser to the cyclone, often referred to as the cross-over. Model validation data was taken from literature data and from steady state, cold flow, CFB tests results of five granular materials with various sizes and densities in which the riser was operated in core-annular and dilute flow regimes. Experimental data were taken from a 0.20 m ID cross-over piping and compared to literature data generated in a 0.10 m ID cross-over pipe. The solids mass flow rate data were taken from statistically designed experiments over a wide range of Froude number , load ratio , Euler number , density ratio , Reynolds number , and Archimedes number . Several correlations were developed and tested to predict the solids mass flux based on measuring pressure drop in the horizontal section of CFB. It was found that load ratio is a linear function of the Euler number and that each of these expressions all worked quite well (R² > 95%) for the data within the range of conditions from which the coefficients were estimated.     

The effect of bubble column diameter on gas holdup in fiber suspensions

Three bubble column diameters (D=10.2, 15.2, and 32.1 cm) are employed to study the scale-up effect on gas holdup in air-water and air-water-cellulose fiber (hardwood, softwood, and BCTMP) systems. The effect of column diameter depends on flow regime and fiber mass fraction. When , gas holdup decreases with increasing column diameter for the transitional and heterogeneous flow regime, and column diameter effects are negligible in the homogeneous flow regime. When , gas holdup is only affected by column diameter in the transitional flow regime for an air-water system and low fiber mass fraction suspensions (C?0.25%); column diameter effects disappear at medium fiber mass fractions (e.g., C=0.8%) but are significant at high fiber mass fractions (e.g., C=1.4%).     

Effect of oxidizing agents on selenate formation in a wet FGD

In a coal combustion process, a considerable amount of selenium is captured in the wet FGD, where it is oxidized from selenite to selenate , which is difficult to remove. Diethyl-p-phenylene-diammonium (DPD) absorptiometric analysis and ion chromatography identified peroxodisulfate ion as the dominant oxidizing agent in the FGD liquor. Selenite was easily oxidized to selenate in the presence of and the oxidation was accelerated as the temperature increased. Addition of Mn²⁺ ion was found to be effective in controlling selenate formation. When Mn²⁺ ion was added, oxidized not selenite to selenate but rather Mn²⁺ to MnO₂, which captured some dissolved selenite.     

Liquid mixing in gas-liquid two-phase flow by meandering microchannels

The influence of the channel radius on the mass transfer in rectangular meandering microchannels (width and height of ) has been investigated for gas-liquid flow. Laser induced velocimetry measurements have been compared with theoretical results. The symmetrical velocity profile, known from the straight channel, was found to change to an asymmetrical one for the meandering channel configuration. The changes in the secondary velocity profile lead to an enhanced radial mass transfer inside the liquid slug, resulting in a reduced mixing length. In the investigated experimental range (superficial gas velocity and superficial liquid velocity ) the mixing time was reduced eightfold solely due to changes in channel geometry. An experimental study on the liquid slug lengths, the pressure drop and their relation to the mass transfer have also been performed. Experimental results were validated by a simulation done in Comsol Multiphysics^®. To obtain information for higher velocity rates, simulations were performed up to . These velocity variations in the simulation indicate the occurrence of a different flow pattern for high velocities, leading to further mass transfer intensification.     

Numerical and experimental investigations of gas-liquid dispersion in an ejector

The effects of the ejector geometry (nozzle diameter and mixing chamber) and the operating conditions (liquid circulating rate, liquid level in column) on the hydraulic characteristics in a rectangular bubble column with a horizontal flow ejector were determined. The gas phase holdup increases with increasing liquid circulating rate but decreases with increasing liquid level in the column. In the multiphase CFD simulation with the mixture model and the experiments, the gas suction rate increases with increasing liquid circulating rate. However, the gas suction rate decreases with increasing the liquid level in the column and nozzle diameter. The predicted values from the CFD simulation are well accord to the experimental data.     

Jet penetration depth in a two-dimensional spout-fluid bed

The jet penetration depth was proposed to be an important parameter to describe the jet action during the chemical process of spout-fluid bed coal gasification. A two-dimensional cold model of a spout-fluid bed coal gasifier with its cross section of and height of 2000 mm was established to investigate the jet penetration depth. Four types of Geldart group D particles were used as bed materials. A multi-channel pressure sampling system and a high-resolution digital CCD camera were employed for experimental investigations. The effects of spouting gas velocity, spout nozzle diameter, static bed height, particle property and fluidizing gas flow rate on the jet penetration depth have been systematically studied by pressure signal analysis and image processing. Experimental results indicate that the jet penetration depth increases with increasing spouting gas velocity and spout nozzle diameter, while it decreases with increasing particle density, particle diameter, static bed height and fluidizing gas flow rate. Additional, a new correlation considered all of the above effects especially static bed height and fluidizing gas flow rate, was developed for predicting the jet penetration depth in spout-fluid beds. The correlation was compared with published experimental data or correlations, which was in well agreement with the present experimental results and some other references.     

Discrete element simulation of a flat-bottomed spouted bed in the 3-D cylindrical coordinate system

A spouted bed is simulated in three dimensions by a discrete element method (DEM) in a cylindrical coordinate system. The numerical scheme is based on a second order finite difference method in space and a second order Adams-Bashforth method for time advancement. Gas-particle interaction is assumed to obey the Ergun equation (for void fraction less than 0.8) and its corrected model by Wen and Yu (for void fraction greater than 0.8). The spouted bed vessel is a flat-bottomed cylinder in height and in diameter. The gas inlet diameter is . Three hundred thousand monosized spheres of diameter are used in the simulation. The typical characteristics of spouted beds, such as spout, annulus and fountain, are reproduced. Particle velocity profiles show good agreement with experimental results and self-similarity of the radial distribution of axial particle velocities is reported. Gas flow patterns are also studied and the effect a vortex ring fixed at the bottom of the vessel is investigated. The simulation is validated through comparisons with results reported in the literature.     

Small bubble formation via a coalescence dependent break-up mechanism

A mechanism has been elucidated for the coalescence-mediated break-up of bubbles in gas-liquid systems. Images taken from dynamic systems (a coalescence cell and laboratory-scale bubble columns) show that in some instances the coalescence of two bubbles is accompanied by the formation of a much smaller daughter bubble. Following the coalescence process an annular wave is formed due to the very rapid expansion of the hole following the instant of film rupture. As the wave moves along the length of the bubble, away from the point of rupture it causes a rippling effect which distorts the newly coalesced bubble and may result in the formation of an unstable extension. Instabilities due to the annular wave pinch off a portion of this extension, resulting in the generation of a small daughter bubble. In coalescence dominated systems the process results in the generation of significant numbers of bubbles much smaller (100- diameter) than the Sauter mean diameter (3-).     

Kinetic theory based computation of PSRI riser: Part I—Estimate of mass transfer coefficient

The PSRI benchmark challenge problem one is modeled using kinetic theory based CFD with the energy minimization multi-scale (EMMS) drag law. These computations give a better comparison than the previous models to measured solids mass flux, solids density and pressure drop.The computer model was also used to calculate axial and radial normal Reynolds stresses, energy spectra, power spectra, granular temperatures, the FCC viscosity and axial and radial dispersion coefficients. The computed cluster sizes agreed with the published empirical correlations. Then, the mass transfer coefficients and the Sherwood numbers are estimated based on particle cluster sizes. The conventional Sherwood number is scaled with the particle cluster diameter. The Sherwood number is the order of 10^-2 and the mass transfer coefficient is the order of . This Sherwood number is two orders of magnitude smaller than the diffusion controlled limit of two based on particle diameter, in agreement with the experimental data for fluidization of fine particles.     

Saturation carrying capacity at high archimedes number of vertical concurrent gas-particle flow

The existing literature data on the saturation carrying capacity for vertical concurrent gas-particle flow are limited to Archimedes numbers Ar below 1000. By experimental measurement and dimensionless analysis the present article extended Ar to 2500 to demonstrate how varies with gas velocity under these high Ar values. The obtained result revealed that is subject to the same kind of correlation with gas velocity irrespective of Ar. The degree that depends on gas velocity, however, generally decreases with raising Ar and it tends to be a constant when Ar becomes higher than 530. This shows in fact that the flows with heavy/large particles or dense/viscous gas possess a low increase in particle-carrying capability with increasing gas velocity until a steady specific capability per m/s is reached at Ar of 530. The article also reanalyzed the influence of column diameter on , demonstrating that the column diameter influence exists only in small columns and for flows with heavy/large particles. The influence is negligible in commercial conveying columns and differs according to Ar in those small columns employed in laboratory studies. All of these findings resulted in an upgraded correlation for , which manifested not only wide applicability to flows in differently sized columns and with Ar of up to 2500 but also better accuracy in the mentioned flow conditions when comparing with several other literature correlations.     

Trickle-bed CFD studies in the catalytic wet oxidation of phenolic acids

An Euler-Euler computational fluid model was developed successfully for the hydrodynamic prediction of a trickle-bed reactor (TBR) designed for advanced wastewater treatment facilities. Catalytic wet air oxidation of phenolic acids was simulated in a TBR by means of computational fluid dynamic (CFD) in the temperature range and pressures . The hydrodynamic model validation was accomplished through the comparison of simulated pressure drop and liquid holdup with experimental data from the literature. In a broad range of gas and liquid flows studied (G=0.10-0.70 and ) at different operation conditions, CFD demonstrated the considerable effect of operating pressure in pressure drop, whereas a minor influence was detected for the liquid holdup. CFD runs were then performed for the catalytic wet air oxidation of aqueous phenolic acids solution. The reactor behaviour was analysed by means of total organic carbon profiles which reflected the influence of temperature, pressure, gas-liquid flows and initial pollutant concentration.     

New approach to the formulation of hydrogel beads by emulsification/thermal gelation using a static mixer

A new approach in the formulation of hydrogel beads by emulsification/in situ thermal gelation using static mixer technology is described. κ-Carrageenan was selected as the model hydrogel. The emulsion generated by a Sulzer SMX6 static mixer consisted of warm κ-carrageenan sol (1.5% w/w in water or ) as the dispersed phase, and ambient temperature sunflower seed oil as the continuous phase. Dispersion followed by in situ gelation of κ-carrageenan droplets was possible within a short residence time (1-) in the static mixer, under defined operational conditions, known as the feasibility region. This region was defined as the zone of operation conditions necessary to obtain discrete gel beads, within a defined range of κ-carrageenan solution injection temperature, volume fraction and total flowrate. The temperature boundaries of the feasibility region were determined by the κ-carrageenan gelation temperature and solution viscosity. The resulting beads had a Sauter mean diameter ranging from 350 to , which decreased with the increase of κ-carrageenan injection temperature, total flowrate and/or the number of static mixer elements. Theoretical values of maximal bead diameter and Sauter mean diameter were calculated on the base of critical Weber number, which was demonstrated through good agreement with the experimental values. It was demonstrated that an existing model for the prediction of gel bead diameter in a SMX static mixer is applicable for the new procedure described in this study.