The Use of Positron Emission Particle Tracking in the Study of Multiphase Stirred Tank Reactor Hydrodynamics

This paper describes the use of positron emission particle Tracking (PEPT) in the analysis of local particle and fluid velocities in solid‐liquid stirred tank reactors agitated with a Rushton turbine and an upward‐pumping pitched blade turbine. PEPT captures the full three‐dimensional characteristics of hydrodynamics and mixing in stirred vessels, allowing the analysis of the two‐phase flow fields. Furthermore, by comparing the liquid and particle velocities, the spatial and temporal variation of the relative particle‐liquid velocity can be estimated. Such information reveals considerable heterogeneity in the vessel and facilitates the evaluation of impeller design, particularly with the aim of minimizing mass transfer limitations.     

Flow of solids in an interconnected fluidized beds system investigated using positron emission particle tracking

The technique of Positron Emission Particle Tracking (PEPT) is applied to analyse non‐intrusively solids flow in a laboratory scale Interconnected Fluidized Beds system. It is shown that, with a high performance tracking system, it is possible to extract from the data not only the Eulerian ensemble average velocity field, but also to reconstruct density profiles and to calculate mass flows in a solids circulation system. The most interesting flow characteristics inside the Interconnected Fluidized Bed system are highlighted. Although the data analysis is largely Eulerian, a first approach to a Lagrangian analysis has been performed through the computation of velocity autocorrelation functions. Characteristic frequencies of the solids movement could not be identified, but the velocity autocorrelations did provide insight in the dynamics of the solids movement.     

Using positron emission particle tracking (PEPT) to study the turbulent flow in a baffled vessel agitated by a Rushton turbine: Improving data treatment and validation

Positron emission particle tracking (PEPT) is a relatively new technique allowing the quantitative study of flow phenomena in three dimensions in opaque systems that cannot be studied by optical methods such as particle image velocimetry (PIV) or laser Doppler anemometry (LDA). Here, velocity measurements made using PEPT in two sizes of baffled vessel (∼0.20 m and ∼0.29 m diameter) and two different viscosity fluids agitated by a Rushton turbine are compared for the first time directly in depth with some studies reported in the literature made by LDA for the turbulent regime in the equivalent geometry. Initially, the paper considers how the Lagrangian data obtained by PEPT can be converted into Eulerian in order to make the comparison most effective. It also considers ways of data treatment that improve the accuracy of both the raw PEPT data and the velocities determined from it. It is shown that excellent agreement is found between the PEPT and literature results, especially for the smaller vessel, except for the radial velocity just off the tip of the blade in the plane of the disc of the Rushton turbine. This difference is attributed to the very rapid changes in both magnitude and direction that occurs in that region and also to the different way of ensemble averaging in the two techniques. In addition, the results for the absolute velocities normalised by the impeller tip velocity for all the rectangular cross-section toroidal cells in each size of vessel and each fluid and a range of agitator speeds are compared in the form of frequency histograms. In this analysis, the velocities for each run are obtained from PEPT based on tracking a particle for 30 min and the mean and mode of the velocities each decrease slightly with decreasing scale and Reynolds number. The possible reasons for this variation in the mode and the mean are discussed. Overall, it is concluded that for the radial flow Rushton turbine the PEPT technique can be used to obtain accurate velocity data throughout the entire complex three-dimensional turbulent flow field in an agitated, baffled vessel except very close to the impeller in the radial discharge stream.     

Positron emission particle tracking (PEPT) compared to particle image velocimetry (PIV) for studying the flow generated by a pitched-blade turbine in single phase and multi-phase systems

Positron emission particle tracking (PEPT) is a new technique allowing the quantitative study of flow phenomena in three dimensions in opaque systems that cannot be studied by techniques based on optical methods such as particle image velocimetry (PIV) or laser Doppler anemometry (LDA). It has previously been used for studying solid particle motion in various systems used in particulate processing. Here, for the first time, velocity measurements made using PEPT with a down-pumping pitched blade turbine (PBTD) are compared directly with those made by PIV in water in the same equipment. It is shown that excellent agreement is found between the two methods except just below the impeller in the discharge. However, this difference is attributed to the different type of data collected and the different way of ensemble-averaging in the two techniques. Similar results were found at higher agitator speeds with both the PBTD and an up-pumping PBT (PBTU) where a small amount of surface aeration occurred. Measurements in solid liquid systems with surface aeration at 0.5 wt% solids or higher were not possible with PIV, but excellent results were obtained with PEPT for both the PBTD and PBTU in a 5 wt% suspension. It is concluded that this calibration study shows that the PEPT technique can be used to obtain accurate velocity data throughout all of the complex three-dimensional flow field in a range of mechanically agitated, turbulent, multi-phase systems previously not amenable to quantitative analysis.     

Numerical study of polyethylene burning in counterflow: Effect of pyrolysis kinetics and composition of pyrolysis products

The burning behavior of polyethylene in the counterflow of oxidizing air has been studied numerically with a coupled model describing feedback heat and mass transfer between gas‐phase flame and polymeric solid fuel. A 2‐dimensional elliptic equation in axisymmetric formulation (revealing the cylindrical shape of the polymer sample used in the experiment) has been employed to simulate heat transfer in solid fuel, and a set of 1‐dimensional hyperbolic equations has been used to determine the solid‐to‐gas conversion degree of the pyrolysis reaction. Four sets of products compositions and two modifications for the kinetic parameters of solid fuel pyrolysis reaction have been taken into account. Gas‐phase formulation is presented by set of 1‐dimensional conservation equations for multi‐component flow with detailed kinetic mechanism of combustion. The profiles of temperature and species concentrations in the flame zone have been calculated and compared with the results of experimental study of combustion of ultrahigh molecular weight polyethylene. Higher hydrocarbon composition (dodecane) has been found to show the best agreement between the temperature and species concentration profiles with the measurements, especially for the low‐level mass fractions of the by‐product components—propylene, butadiene, and benzene.     

Solids behaviour in a dilute gas-solid two-phase mixture flowing through monolith channels

This paper reports, for the first time, the solids behaviour in a dilute gas-solid two-phase mixture flowing through monolith channels. The non-intrusive positron emission particle tracking (PEPT) technique was used in the work, which allowed investigation of three-dimensional solids motion at the single suspended particle level. Processing of the PEPT data gave solids velocity and occupancy in the monolith channels. The results showed a non-uniform radial distribution of both the solids velocity and concentration. The highest axial solids velocity occurred in monolith channels located in the central part of the column, whereas the highest solids concentration took place at a position approximately 0.7 times the column radius. The axial distribution of the axial solids velocity showed an entrance region with a length of approximately 33 times the hydrodynamic diameter of a monolith channel under the conditions of this work. Analysis of the PEPT data also gave distributions of particle residence time and tortuosity in terms of solids motion. The distributions were approximately Gaussian-type with the tortuosity distribution more skewed toward the right hand side. The peak residence time and tortuosity decreased with increasing superficial gas velocity and the distributions were broadened at lower superficial gas velocities. The results of this work also provided a possible explanation to our previously observed early laminar-to-turbulent flow transition in monolith channels.     

Particle‐resolved PIV experiments of solid‐liquid mixing in a turbulent stirred tank

Particle Image Velocimetry (PIV) experiments on turbulent solid‐liquid stirred tank flow with careful refractive index matching of the two phases have been performed. The spatial resolution of the PIV data is finer than the size of the spherical, uniformly sized solid particles, thereby providing insight in the flow around individual particles. The impeller is a down‐pumping pitch‐blade turbine. The impeller‐based Reynolds number has been fixed to Re = 10⁴. Overall solids volume fractions up to 8% have been investigated. The PIV experiments are impeller‐angle resolved, that is, conditioned on the angular position of the impeller. The two‐phase systems are in partially suspended states with an inhomogeneous distribution of solids: high solids loadings near the bottom and near the outer walls of the tank, much less solids in the bulk of the tank. The liquid velocity fields show very strong phase coupling effects with the particles increasingly attenuating the overall circulation patterns as well as the liquid velocity fluctuation levels when the solids volume fraction is increased. © 2017 American Institute of Chemical Engineers AIChE J, 63: 389–402, 2018     

Mixing and solid‐liquid mass transfer characteristics in a three phase pulsed plate column with packed bed of solids in interplate spaces—a novel aerobic immobilized cell bioreactor

BACKGROUND: The pulsed plate column (PPC) with packed bed of solids in the interplate spaces finds use as a three phase aerobic bioreactor and is a potential heterogeneous catalytic reactor. Good knowledge of the extent of mixing in the liquid phase and solid‐liquid mass transfer coefficient are essential for modeling, design and optimization of these columns. The present work aims at the study of liquid phase mixing and solid–liquid mass transfer characteristics in a three phase PPC. RESULTS: Residence time distribution studies were performed. Dispersion number was found to increase with increase in liquid superficial velocities, frequency of pulsation, amplitude of pulsation and the vibrational velocities. Increase in frequency and amplitude of pulsation, and hence increase in vibrational velocity, resulted in increase of the solid–liquid mass transfer coefficient. CONCLUSIONS: The mixing behaviour in this contactor approximated a mixed flow behaviour. The three phase PPC was found to outperform many other kinds of three phase contactors in terms of solid liquid mass transfer characteristics. Empirical correlations developed can be used for the determination of solid–liquid mass transfer coefficients for three phase PPC and hence can facilitate the design, scale‐up and modeling of these columns, when used as chemical or biochemical reactors. Copyright © 2011 Society of Chemical Industry     

CFD simulation of gas and solids mixing in FCC strippers

The gas and solid mixing in fluid catalytic cracking strippers with and without internals were investigated using computational fluid dynamics simulations. The Eulerian–Eulerian two‐fluid model coupled with the modified Gidaspow drag model was used to simulate the gas‐solid flow behavior. The grid independency study and the comparison of 2D and 3D simulations were carried out first. The residence time distribution model and axial dispersion model were utilized to obtain the parameters indicating the back‐mixing degree, such as mean residence time, dimensionless variance and Peclet number of gas and solids. Moreover, the influence of bubble size and gas/solid flow distribution on the mass transfer between the bubble and emulsion phase were also analyzed. The results show that the baffles in the V‐baffle stripper can efficiently enhance the gas and solids mixing, reduce the back‐mixing degree of gas and solids, strengthen the mass transfer between the bubble and emulsion phase, and hence improve the stripping efficiency. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Phase distributions in a gas–liquid–solid circulating fluidized bed riser

The distributions of the three phases in gas–liquid–solid circulating fluidized beds (GLSCFB) were studied using a novel measurement technique that combines electrical resistance tomography (ERT) and optical fibre probe. The introduction of gas into a liquid–solid circulating fluidized bed (LSCFB), thus forming a GLSCFB, caused the increase of solids holdup due to the significantly decreased available buoyancy with the lower density of the gas, even with a somewhat increased liquid velocity due to the decreased liquid holdup giving space for the gas holdup. The gas passed through the riser in the form of bubbles, which tended to flow more through the central region of the riser, leading to more radial non‐uniformity in radial holdup of the phases. The gas velocity has the most significant effect on the gas phase holdup. While the gas velocity also has an obvious effect to the solids holdups, the liquid flow rate had a much more considerable effect on the phase holdups. The solids circulation rate also had a significant effect on the phase holdups, with increasing solids circulation rate causing much more increased solids holdup in the central region than close to the wall. A correlation was developed for the relative radial distributions of solids holdup in GLSCFB, as such radial profiles were found similar over a wide range of operating conditions, like those in a typical gas–solid circulating fluidized beds (GSCFB). Finally, the axial solids profiles in a GLSCFB was found to be much closer to those in an LSCFB which are very uniform, than those found in a GSCFB which are less uniform and sometime having a S shape. Water was used as the continuous and conductive phase, air was the gas phase and glass bead and lava rock particles were used as the solid and non‐conductive phase.     

Transition from Low Velocity to High Velocity in a Three Phase Fluidized Bed

The onset liquid velocity demarcating the conventional and the circulating fluidization regimes of three‐phase fluidized beds was determined by measuring the time required to empty all particles in a batch fluidized bed at various liquid and gas velocities. Experiments were performed in a gas‐liquid‐solid circulating fluidized bed of 2.7 m in height using glass beads of 0.508 mm in diameter as solid phase and air and tap water as the fluidizing gas and liquid, respectively. The results show that gas velocity is a strong factor on the onset liquid velocity. Higher gas velocity yields a lower onset liquid velocity. It is also demonstrated that the onset liquid velocity has the same value as particle terminal velocity in a gas‐liquid mixture. Within the gas‐liquid‐solid circulating fluidization regime, the solids circulation rate is increased with the total liquid velocity and the auxiliary liquid velocity.     

LDA measurements of near wall powder velocities in a high shear mixer

In this study, a new method has been developed to measure particle velocity distributions in the near wall region of a high shear mixer by using Laser Doppler Anemometry (LDA). The velocities along the side of the granulator have been measured at different impeller speeds and it has been found that it is possible to obtain tangential and axial velocity data in the dense powder flow up to 4 mm in depth. Moreover, it has been found that the tangential velocity component increases slightly with distance from the wall in the near wall region, indicating a partial slip boundary condition for the solid phase at the vessel wall. It is also shown that the tangential velocity decreases with increased vertical distance to the impeller. The velocity fluctuations, represented by root mean square (rms) velocities, also decrease with increased vertical distance to the impeller and the tangential and axial rms components are found to be of the same order of magnitude.     

Particle motion in L-valve as observed by positron emission particle tracking

L-valves are widely used in circulating fluidized beds (CFB) to control the solid circulation rate. Positron emission particle tracking (PEPT) is used to view and study the real-time particle motion in the L-valve. The paper presents experimental results of the solid motion and solid flux in the L-valve, G_s, as a function of the superficial injection air velocity, U. Results are compared with earlier work. The size of the L-valve is 4.5 cm I.D. Two different experimental configurations (L-valve discharge in a CFB riser and free discharge) were used. The L-valve flow regime is stable until approximately 6 U / U_mf, with proportionality between solid flux and U / U_mf. At a higher U / U_mf, unsteady fluctuations in the solid flow gradually increase due to cavity formation around the L-valve elbow. Increasing the air flow even further, a maximum flow is reached, corresponding to the maximum discharge rate through the cyclone or hopper apex. PEPT has also confirmed the existence of a dune flow. For the first time, it gives quantitative data of the velocity profile of the dune flow which is governed by two important factors. The first factor is the distance of solids from the base of the L-valve, with solid velocity increasing away from the base. The second factor is the location of solids with respect to the dune, i.e. solid velocity is minimum at the base of the dunes and maximum at the top of the dunes. The average voidage in the L-valve is approximately constant and independent of U.     

TWO-DIMENSIONAL TRANSIENT NUMERICAL SIMULATION OF SOLIDS AND GAS FLOW IN THE RISER SECTION OF A CIRCULATING FLUIDIZED BED

A computational fluid dynamics software (CFX) was modified for gas/particle flow systems and used to predict the flow parameters in the riser section of a circulating fluidized bed (CFB). Fluid Catalytic Cracking (FCC) particles and air were used as the solids and gas phases, respectively. Two-dimensional, transient, isothermal flows were simulated for the continuous phase (air) and the dispersed phase (solid particles). Conservation equations of mass and momentum for each phase were solved using the finite volume numerical technique. Two-dimensional gas and particle flow profiles were obtained for the velocity, volume fraction, and pressure drop for each phase. Calculations showed that the inlet and exit conditions play a significant role in the overall mixing of the gas and particulate phases and in the establishment of the flow regime. The flow behavior was analyzed based on the different frequency of oscillations in the riser. Comparison of the calculated solids mass flux, solids density and pressure drop with the measured pilot-scale PSRI data (reported in this paper) showed a good agreement.     

Hydrodynamic modeling of a circulating fluidized bed

Hydrodynamics plays a crucial role in defining the performance of circulating fluidized beds (CFB). The numerical simulation of CFBs is very important in the prediction of its flow behavior. From this point of view, in the present study a dynamic two dimensional model is developed considering the hydrodynamic behavior of CFB. In the modeling, the CFB riser is analyzed in two regions: The bottom zone in turbulent fluidization regime is modeled in detail as two-phase flow which is subdivided into a solid-free bubble phase and a solid-laden emulsion phase. In the upper zone core-annulus solids flow structure is established. Simulation model takes into account the axial and radial distribution of voidage, velocity and pressure drop for gas and solid phase, and solids volume fraction and particle size distribution for solid phase. The model results are compared with and validated against atmospheric cold bed CFB units' experimental data given in the literature for axial and radial distribution of void fraction, solids volume fraction and particle velocity, total pressure drop along the bed height and radial solids flux. Ranges of experimental data used in comparisons are as follows: bed diameter from 0.05-0.418 m, bed height from 5-18 m, mean particle diameter from 67-520 μm, particle density from 1398 to 2620 kg/m³, mass fluxes from 21.3 to 300 kg/m²s and gas superficial velocities from 2.52-9.1 m/s.As a result of sensitivity analysis, the variation in mean particle diameter and superficial velocity, does affect the pressure especially in the core region and it does not affect considerably the pressure in the annulus region. Radial pressure profile is getting flatter in the core region as the mean particle diameter increases. Similar results can be obtained for lower superficial velocities. It has also been found that the contribution to the total pressure drop by gas and solids friction components is negligibly small when compared to the acceleration and solids hydrodynamic head components. At the bottom of the riser, in the core region the acceleration component of the pressure drop in total pressure drop changes from 0.65% to 0.28% from the riser center to the core-annulus interface, respectively; within the annulus region the acceleration component in total pressure drop changes from 0.22% to 0.11% radially from the core-annulus interface to the riser wall. On the other hand, the acceleration component weakens as it moves upwards in the riser decreasing to 1% in both regions at the top of the riser which is an important indicator of the fact that hydrodynamic head of solids is the most important factor in the total pressure drop.     

Film‐surface diffusion during the adsorption of acid dyes onto activated carbon

A mass transport model has been developed and applied to the adsorption of three acid dyes onto activated carbon in three single component systems. The mass transfer model is based on two rate controlling mass transfer steps, namely external film mass transfer and homogeneous solid‐phase surface diffusion (HSD). Almost all previous film‐HSD models have been based on numerical solutions to the diffusion equation using orthogonal collocation or Crank–Nicolson finite difference solutions. However, in the present model a semi‐analytical solution to the solid surface diffusion equation is presented, yielding a sophisticated solution of the differential equations. The solutions provide a good correlation between the experimental concentration–time decay curves by incorporating the Langmuir equilibrium isotherm to describe the solid phase surface dye concentrations. However, the surface diffusivities show a dependence on the carbon particle surface coverage and these diffusivities have been correlated using a Darken relationship. Copyright © 2004 Society of Chemical Industry     

Two-dimensional transient numerical simulation of solids and gas flow in the riser section of a circulating fluidized bed

A computational fluid dynamics software (CFX) was modified for gas/particle flow systems and used to predict the flow parameters in the riser section of a circulating fluidized bed (CFB). Fluid Catalytic Cracking (FCC) particles and air were used as the solids and gas phases, respectively. Two-dimensional, transient, isothermal flows were simulated for the continuous phase (air) and the dispersed phase (solid particles). Conservation equations of mass and momentum for each phase were solved using the finite volume numerical technique. Two-dimensional gas and particle flow profiles were obtained for the velocity, volume fraction, and pressure drop for each phase. Calculations showed that the inlet and exit conditions play a significant role in the overall mixing of the gas and particulate phases and in the establishment of the flow regime. The flow behavior was analyzed based on the different frequency of oscillations in the riser. Comparison of the calculated solids mass flux, solids density and pressure drop with the measured pilot-scale PSRI data (reported in this paper) showed a good agreement.     

Measurement of Local Phase Holdups in a Two‐ and Three‐Phase Bubble Column

A new invasive sensing probe for the measurement of local phase holdups in two‐ and three‐phase reactors is described. The local gas and solids holdups in a bubble column with a volume of V = 2 m³ at varying operating conditions (gas velocity, sparger design, solids content and density) are measured by means of differential pressure measurement in combination with either time domain reflectometry or electrical conductivity measurement. The phase distribution profiles at two‐ and three‐phase operating conditions are described. The influence of the sparger design on the shape of these profiles, the influence of the solid phase on the gas distribution, the solids distribution and the gas‐stow effect above the sparger because of a dense particle layer are capable of experimental proof for the first time.