A FLOWSHEET MODEL OF A WELL-MIXED FLUIDIZED BED DRYER: APPLICATIONS IN CONTROLLABILITY ASSESSMENT AND OPTIMIZATION

A model of a well-mixed fluidized-bed dryer within a process flowsheeiing package (SPEEDUP(tm)) has been developed and applied to a parameter sensitivity study, a steady-state controllability analysis and an optimization study. This approach is more general and would be more easily applied to a complex flowsheet than one which relied on stand-alone dryer modelling packages. The simulation has shown that industrial data may be fitted to the mode outputs with sensible values of unknown parameters. For this case study, the parameter sensitivity study has found that the heat loss from the dryer and the critical moisture content of the material have the greatest impact on the dryer operation at the current operating point. An optimization study has demonstrated the dominant effect of the heat loss from the dryer on the current operating cost and the current operating conditions, and substantial cost savings (around 50% ) could be achieved with a well-insulated and airtight dryer, for the specific case studied here.     

DRYING CHARACTERISTICS OF CORN IN FLUIDIZED BED DRYER

A batch fluidized bed dryer was carried out for corn drying. Drying characteristics of corn were investigated The experimental results indicated that moisture transfer inside a corn kernel was controlled by internal diffusion by the following conditions : inlet hot air temperatures of 120 - 200 °C, superficial air velocities of 2.2- 4 m/s, bed depths of 4 - 12 cm, fraction of air recycled of 0.5 -0.9 and initial moisture content of corn of 43 % dry-basis. The Wang and Sing equation could describe in accordance with the results. Inlet hot air temperature and specific air flow rate were independent variables for drying constant model in the Wang and Singh equation.     

DRYING CHARACTERISTICS OF CORN IN FLUIDIZED BED DRYER

ABSTRACT

A batch fluidized bed dryer was carried out for corn drying. Drying characteristics of corn were investigated The experimental results indicated that moisture transfer inside a corn kernel was controlled by internal diffusion by the following conditions : inlet hot air temperatures of 120 - 200 °C, superficial air velocities of 2.2- 4 m/s, bed depths of 4 - 12 cm, fraction of air recycled of 0.5 -0.9 and initial moisture content of corn of 43 % dry-basis. The Wang and Sing equation could describe in accordance with the results. Inlet hot air temperature and specific air flow rate were independent variables for drying constant model in the Wang and Singh equation.     

DRYING OF WASTE SLUDGES IN A FLUIDIZED BED DRYER WITH A MIXER

Sludge wastes are a very attractive source of many valuable compounds such as nitrogen, phosphorus and organic matter. One of the interesting methods of sludge utilization is dewatering and drying. In this paper some problems of drying of two types of sludge wastes of different form and origin are presented. One of the sludges—a brewery by-product— contains spent grain suspension of brewer's yeast and diatomaceous earth. The second one is a by-product of a biotechnological process which contains mainly lime, protein, many microelements and some microorganisms. Moisture content of both sludges is about 65-70% w/w. The laboratory experiments of sludge drying in the fluidized bed dryer with a mixer, fluidized bed hydrodynamics, and the effects and advantages of sludge drying are shown.     

DRYING OF WASTE SLUDGES IN A FLUIDIZED BED DRYER WITH A MIXER

ABSTRACT

Sludge wastes are a very attractive source of many valuable compounds such as nitrogen, phosphorus and organic matter. One of the interesting methods of sludge utilization is dewatering and drying. In this paper some problems of drying of two types of sludge wastes of different form and origin are presented. One of the sludges—a brewery by-product— contains spent grain suspension of brewer's yeast and diatomaceous earth. The second one is a by-product of a biotechnological process which contains mainly lime, protein, many microelements and some microorganisms. Moisture content of both sludges is about 65–70% w/w. The laboratory experiments of sludge drying in the fluidized bed dryer with a mixer, fluidized bed hydrodynamics, and the effects and advantages of sludge drying are shown.     

OPTIMIZATION OF HETEROGENEOUS CATALYTIC PROCESSES IN FLUIDIZED BED

A number of large-scale chemical processes is carried out in fluidized-bed reactors (FBR). Optimization of processes in FBR is thus of great importance both for the increase of efficiency of the existing plants and for the design of new ones. Selection of optimal conditions for exothermic processes should recognize conditions for heat removal and multiplicity and stability of stationary states rather than just the reaction kinetics and fluidized bed hydrodynamics. Mathematically this problem is rather cumbersome. A process in FUR is described by the boundary problem for differential equations while statement of an optimization problem requires some additional limitations to be imposed on concentrations at the input and output of the reactor, on temperature, design parameters etc. One should take special notice of the limitation on the process stability which (owing to great reverse thermal agitation) is much more important in FBRs than in packed-bed reactors.     

OPTIMIZATION OF HETEROGENEOUS CATALYTIC PROCESSES IN FLUIDIZED BED

A number of large-scale chemical processes is carried out in fluidized-bed reactors (FBR). Optimization of processes in FBR is thus of great importance both for the increase of efficiency of the existing plants and for the design of new ones. Selection of optimal conditions for exothermic processes should recognize conditions for heat removal and multiplicity and stability of stationary states rather than just the reaction kinetics and fluidized bed hydrodynamics. Mathematically this problem is rather cumbersome. A process in FUR is described by the boundary problem for differential equations while statement of an optimization problem requires some additional limitations to be imposed on concentrations at the input and output of the reactor, on temperature, design parameters etc. One should take special notice of the limitation on the process stability which (owing to great reverse thermal agitation) is much more important in FBRs than in packed-bed reactors.     

外循环流化床生物反应器的特性及应用

针对固定化增殖细胞发酵酒精的特点,研制与开发了一种新型外循环流化床生物反应器和大规模制备固定化细胞颗粒的方法和装置。考查了固定化细胞颗粒流化特性,外循环速度对液相停留时间分布的影响,宏观发酵动力学及固定化增殖细胞发酵酒精的特点及历程。设计并完成了665L 中试规模的放大试验,连续运转近3个月。实验结果表明:以未处理无灭菌的废甘蔗糖蜜为原料,用海藻酸钙包埋的固定化酵母颗粒连续发酵酒精,终酒精浓度为8～10%(v/v),对糖收率>92%,反应器生产能力达12kg/(m~3·h)。     

THE DESIGN AND PERFORMANCE OF CONTINUOUS WELL-MIXED FLUIDIZED BED DRYERS - AN ANALYTICAL APPROACH

Abstract

In a previous study, a unified approach to the calculation of the size and energy consumption of well-mixed fluidized bed dryers was developed. A computer code was written and a parametric study undertaken to determine the effects of the principal operating variables. The results were shown to depend on the form of the drying kinetics. The present paper describes the formulation of an analytical model of a well-mixed fluidized bed dryer, which applies for materials that exhibit linear falling-rate drying. These materials are typified by small hygroscopic particles, which are frequently dried in such equipment. Equations are presented that enable the drying time, specific energy consumption, heater duty and bed area to be calculated. The predictions of these equations agreed well with previously published experimental findings and with the results of computer simulations for a typical solid (ion exchange resin) exhibiting the required drying characteristics.     

INVESTIGATION ON THE INCIPIENT FLUIDIZATION AND HEAT TRANSFER IN A CENTRIFUGAL FLUIDIZED BED DRYER

Based on the continuum theory, a physical model of gas-solid two phase flow in a centrifugal fluidized bed has been proposed. A set of governing equations to describe the fluidization state are obtained and solved numerically after some simplifying. The quantitative experimental study on the characteristics of the incipient fluidization in the centrifugal fluidized bed is performed to examine the proposed model. Gas-solid two phase heat transfer in CFB during a drying process is also conducted. The influences of bed thickness, particle diameter, physical properties of particle, rotating speed of the bed and the gas superficial velocity on heat transfer characteristics are examined. A correlation that can be used to calculate the heat transfer coefficients in the drying process in CFB is obtained.     

INVESTIGATION ON THE INCIPIENT FLUIDIZATION AND HEAT TRANSFER IN A CENTRIFUGAL FLUIDIZED BED DRYER

Abstract

Based on the continuum theory, a physical model of gas-solid two phase flow in a centrifugal fluidized bed has been proposed. A set of governing equations to describe the fluidization state are obtained and solved numerically after some simplifying. The quantitative experimental study on the characteristics of the incipient fluidization in the centrifugal fluidized bed is performed to examine the proposed model. Gas-solid two phase heat transfer in CFB during a drying process is also conducted. The influences of bed thickness, particle diameter, physical properties of particle, rotating speed of the bed and the gas superficial velocity on heat transfer characteristics are examined. A correlation that can be used to calculate the heat transfer coefficients in the drying process in CFB is obtained.     

THE DESIGN AND PERFORMANCE OF CONTINUOUS WELL-MIXED FLUIDIZED BED DRYERS - AN ANALYTICAL APPROACH

In a previous study, a unified approach to the calculation of the size and energy consumption of well-mixed fluidized bed dryers was developed. A computer code was written and a parametric study undertaken to determine the effects of the principal operating variables. The results were shown to depend on the form of the drying kinetics. The present paper describes the formulation of an analytical model of a well-mixed fluidized bed dryer, which applies for materials that exhibit linear falling-rate drying. These materials are typified by small hygroscopic particles, which are frequently dried in such equipment. Equations are presented that enable the drying time, specific energy consumption, heater duty and bed area to be calculated. The predictions of these equations agreed well with previously published experimental findings and with the results of computer simulations for a typical solid (ion exchange resin) exhibiting the required drying characteristics.     

DISPERSION AND FLUCTUATION OF FLUIDIZED PARTICLES IN A LIQUID-SOLID FLUIDIZED BED

Axial dispersion coefficient and fluctuating frequency of fluidized particles have been determined in a liquid-solid fluidized bed by resorting to the relaxation method from the histograms of pressure fluctuation in the bed. Dependence of the axial dispersion coefficient and fluctuating frequency of fluidized particles on the liquid flow rate and particle size, and further on the bed porosity has been discussed. The axial dispersion coefficient and fluctuating frequency of particles have attained their maxima with increasing liquid flow rate and bed porosity, and those values increase with an increase in particle size under fully fluidized concitions. It also has been found that the axial dispersion coefficient shows its maximum at the liquid flow rate where the fluctuating frequency of particles reaches its maximum point.     

EXPERIMENTAL RESEARCH ON MASS TRANSFER IN A CENTRIFUGAL FLUIDIZED BED DRYER

Abstract

The influences of bed thickness, particle diameter, rotating speed of the basket and operating gas velocity on the mass transfer between gas and particles in the centrifugal fluidized bed dryer (CFBD) were examined. The experimental correlation used to calculate the mass transfer coefficient in the centrifugal fluidized bed dryer was obtained.     

流态化结晶过程中晶体生长的湍流传质模型

根据流态化结晶过程的流体处于湍流运动的事实,将多相湍流理论应用于晶体的生长过程,建立该过程的湍流传质动力学模型.模型计算与实验数据比较表明,湍流传质模型对扩散传质控制的晶体生长过程是可靠的.     

DESIGN,TESTING, AND OPTIMIZATION OF VIBRO-FLUIDIZED BED PADDY DRYER

The objectives of this research were to design, construct and test a prototype of vibro-fluidized bed paddy dryer with a capacity of 2.5–5.0 t/h and develop a mathematical model that determines optimum operating parameters. Experimental drying conditions were: air flow rate, 1.7 m³/s; bed velocity, 1.4 m/s; average drying air temperature, 125–140°C; residence time of paddy approximately 1 minute; bed height, 11.5 cm; fraction of air recycled, 0.85 and vibration of intensity, 1 (frequency, 7.3 Hz and amplitude, 5 mm). Moisture content of paddy with a feed rate of 4821 kg/h was reduced from 28 to 23% d.b. Specific primary energy consumption (SPEC) was 6.15 MJ/kg-water evaporated. Electrical power of blower motor and vibration motor was 55% as compared to electrical power of blower motor used in fluidized bed drying without vibration. Comparison between the experimental and simulated results showed that the mathematical model could predict fairly well. To find out optimum operating parameters, the grid search method was employed with criteria based on acceptable moisture reduction and quality and minimum energy consumption.

     

APPLICATION OF DRIFT-FLUX MODEL IN LIQUID-SOLID CIRCULATING FLUIDIZED BED

Solids circulation rate and solids holdup are experimentally investigated in a liquid-solid circulating fluidized bed that covers a wide range in solid and liquid flow rates, particle size, and density. The drift-flux model, which is extensively used to describe the flow behavior of gas-liquid systems, is modified in the present work and for the first time applied to the experimental data of a liquid-solid circulating fluidized bed. The distribution parameter C_o is evaluated using the drift-flux model from the present experimental data and also from the data available in the literature. It is found from the analysis that the value of the distribution parameter lies in the range of 0.78 to 0.99, which is a reverse trend to the liquid-gas system. The weighted average drift velocity (u_sj) is well correlated to the terminal velocity of the particle. The solid holdup predicted using this model agrees with the experimental results.     

A MATHEMATICAL MODEL FOR CONTINUOUS DRYING OF GRAINS IN A SPOUTED BED DRYER

ABSTRACT

A mathematical model for a continuous spouted bed dryer has been presented to predict moisture content, air and grain temperatures as well as energy consumption. To better understand the interactive influence of processes in each region of the spouted bed, solution schemes for the spout and downcomer were treated separately. The behavior of dryer was investigated experimentally and found that the dryer behaved differently from an ideal plug flow. The drying rate as simulated by the model is almost constant during grain movement in the dryer. Absence of airflow in the downcomer leads to a tempering process that takes place in the downcomer while intense heat and mass transfer occurs mainly in the spout due to the high airflow rate there. Furthermore, by considering the predicted grain temperature history as one of the indicators of product quality, one can, in principle, design appropriate successive processes in a continuous spouted bed dryer to minimize product damage.     

EFFECT OF PARTICLE SIZE DISTRIBUTION ON LOCAL VOIDAGE IN A BENCH-SCALE CONICAL FLUIDIZED BED DRYER

ABSTRACT

The effect of particle size distribution (PSD) on local voidage has been investigated in a conical fluidized bed containing dried placebo pharmaceutical granule. For each of the five PSDs examined, the static bed height was varied between 0.12 and 0.17 m and the superficial gas velocity was varied between 0.05 and 0.75 m/s. The local voidage was measured using a twin-plane electrical capacitance tomography (ECT) system. A wide PSD containing 12 wt% solids with a diameter of 2 mm or larger resulted in two different types of gas flow: an annular gas flow up to a gas velocity of 0.50 m/s and a centrally concentrated gas flow above 0.50 m/s. The mixtures containing less coarse material exhibited a centrally concentrated gas flow surrounded by a dense phase at the walls of the bed over the entire range of gas velocities and bed heights examined. Consideration of previous work by other researchers suggests that the behavior of the wide PSD mixture is due to segregation at the lower velocities. The local voidage was sensitive to small changes in static bed height. For the wide PSD mixture at a fixed gas velocity, the gas tended to spread more uniformly over the bed cross-section as static bed height increased. The opposite was true of the other mixtures, i.e., the gas flow became more centralized with increasing bed height.     

A MATHEMATICAL MODEL FOR CONTINUOUS DRYING OF GRAINS IN A SPOUTED BED DRYER

A mathematical model for a continuous spouted bed dryer has been presented to predict moisture content, air and grain temperatures as well as energy consumption. To better understand the interactive influence of processes in each region of the spouted bed, solution schemes for the spout and downcomer were treated separately. The behavior of dryer was investigated experimentally and found that the dryer behaved differently from an ideal plug flow. The drying rate as simulated by the model is almost constant during grain movement in the dryer. Absence of airflow in the downcomer leads to a tempering process that takes place in the downcomer while intense heat and mass transfer occurs mainly in the spout due to the high airflow rate there. Furthermore, by considering the predicted grain temperature history as one of the indicators of product quality, one can, in principle, design appropriate successive processes in a continuous spouted bed dryer to minimize product damage.