Hydrodynamics of the Stripper Section of Fluid Cokers

The hydrodynamics of fluid bed cokers were studied by analyzing pressure fluctuations and particle motion in a half‐column cold model, geometrically and dynamically similar (with key dimensionless groups matched) to the stripper section of two commercial fluid cokers. Superficial gas velocity and solids circulation strongly affected the hydrodynamics. The pressure drop over the top section of the stripper decreased at high solids circulation fluxes and high gas velocities due to flooding. Flooding occurred prematurely when fouling was simulated. Steam redistribution did not improve stripper performance for the conditions investigated. However, steep sheds on the top row, aeration behind the solids exit and standpipe aeration all improved solids circulation, leading to reduced fouling in two commercial fluid cokers.     

Features of the motion of gel particles in a three-phase bubble column under foaming and non-foaming conditions

Features of the motion of gel particles in a three-phase bubble column with non-foaming and foaming gas–liquid systems,determined by using experiments of radioactive particle tracking(RPT),have been compared.The tracer used is a gel particle which resembles typical immobilized biocatalyst.The tracer trajectory is analyzed to extract relevant information for design purposes.The solid velocity field,turbulence parameters,dispersion coefficients,mixing times and flow transitions are determined and compared.The presence of foam significantly affects many quantified parameters,especially within the heterogeneous flow regime.The hydrodynamic stresses are reduced in the presence of foam,especially close to the disengagement.The dispersion coefficients also decrease,and the solid mixing time is only slightly affected by the presence of foam.Gas holdup,inferred both from RPT experiments and from gamma ray scanning,is higher for foaming systems and leads to a shift in the transition gas velocity towards higher values.     

3D simulation of the effects of sphericity on char entrainment in fluidised beds

The paper presents a 3-dimensional simulation of the effect of particle shape on char entrainment in a bubbling fluidised bed reactor. Three char particles of 350 μm side length but of different shapes (cube, sphere, and tetrahedron) are injected into the fluidised bed and the momentum transport from the fluidising gas and fluidised sand is modelled. Due to the fluidising conditions, reactor design and particle shape the char particles will either be entrained from the reactor or remain inside the bubbling bed. The sphericity of the particles is the factor that differentiates the particle motion inside the reactor and their efficient entrainment out of it. The simulation has been performed with a completely revised momentum transport model for bubble three-phase flow, taking into account the sphericity factors, and has been applied as an extension to the commercial finite volume code FLUENT 6.3.     

Monte Carlo real coded genetic algorithm (MC‐RGA) for radioactive particle tracking (RPT) experimentation

Radioactive particle tracking (RPT) technique is a non‐invasive velocimetry technique, extensively applied to study hydrodynamics of dense multiphase systems. In this technique, the position of a radioactive tracer particle, designed to mimic the phase of interest, is followed as a Lagrangian marker of point velocity. Computational limitations encountered during tracer particle position reconstruction (which is an inherently slow process) have thus far restricted the use of this versatile technique only to small‐scale process vessels. Here, we present a noteworthy improvement over the classical Monte Carlo algorithm for tracer particle position reconstruction, whereby we enhance the convergence and computational speed of the algorithm using Real Coded Genetic Algorithm optimization. This modification results in drastic reduction in computational time required for detector parameter estimation, and altogether eliminates the need for the “distance‐count map,” which was earlier inherent to RPT experimentation. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2850–2863, 2017     

A study of solid behavior in spouted beds using 3-D particle tracking

A non-invasive γ-ray emission system, employing eight NaI detectors, has been developed to follow the motion of a single radioactive particle in a three-dimensional spouted bed reactor. The count-rates measured simultaneously by the detectors are converted into tracer coordinates (x, y, z) using a pre-established calibration model which accounts for every physical and geometrical aspects involved in the spouting facility. Typically four hundred thousands successive coordinates, obtained over 3.5 hours of particle tracking, are used for determining the average particle velocity field and other hydrodynamic quantities such as the cycle time distribution, the spout shape and the solid exchange distribution at the spout boundary, which could not be evaluated accurately using any available techniques.     

Effect of particle tethering and Scale‐Up on solid–liquid mass transfer in Three‐Phase fluidized beds of light particles

Solid–liquid mass transfer in three‐phase fluidized beds with low‐density particles was studied using a tethered benzoic acid particle dissolution technique. Two columns with air, water and polypropylene cylinders were used for experiments. The solid–liquid mass transfer coefficient was found to increase with column diameter but decrease with tether length. The effect of tethering on solid particle movements was also evaluated using radioactive particle tracking (RPT) technique. RPT showed that tethered particles exhibited slower movements. Statistical analysis suggests that tether lengths 3 times the column radius are sufficient to reduce the effects of tethering.     

Intelligent fitting of minimum spout‐fluidised velocity in spout‐fluidised bed

The experiments were carried on to study the minimum spout‐fluidised velocity in the spout‐fluidised bed. It was found that the minimum spout‐fluidised velocity increased with the rise of static bed height, spout nozzle diameter, particle density, particle diameter, fluidised gas velocity but decreased with the rise of carrier gas density. Based on the experiments, least square support vector machine (LS‐SVM) was established to predict the minimum spout‐fluidised velocity, and adaptive genetic algorithm and cross‐validation algorithm were used to determine the parameters in LS‐SVM. The prediction performance of LS‐SVM is better than that of the empirical correlations and neural network.     

Monitoring the particle-wall contact in a gas fluidized bed by RPT

Particle-wall contact behavior of the solids in a gas-solid fluidized bed was experimentally studied using the radioactive particle tracking (RPT) technique in which the position of a radioactive tracer is monitored when moving freely in the bed. The solids were sand particles, fluidized by air at room temperature and atmospheric pressure at various superficial velocities, covering both bubbling and turbulent regimes of fluidization. The motion of individual particles near the wall of the bed was studied based on the position of the tracer. The contact time, contact distance and contact frequency of the particles at the wall were evaluated. It was found that the distribution functions of these three parameters become wider by increasing the superficial gas velocity. Axial profiles of contact time and contact distance were also studied in this work. Axial profiles of the overall heat transfer coefficient in the fluidized bed were estimated based on the formulas reported in the literature and the experimental particle-wall contact time evaluated in the present study. Based on such profiles, in order to benefit from the maximum heat transfer coefficient along the bed, it is recommended to place the heat exchanging surface in the middle of the bed, i.e., not very close to the gas distributor as well as far from the top of the dense bed.     

Radioactive particle tracking in a lab‐scale conical fluidized bed dryer containing pharmaceutical granule

Radioactive particle tracking (RPT) has been used to study the motion of the particulate phase in a bench‐scale conical fluidized bed containing dried pharmaceutical granule. RPT revealed that there is a distinct circulation pattern of the granule with particles moving upwards at high velocities near the centre of the bed and falling slowly near the walls. There was also a localized region near the centre of the bed where particles moved downward rapidly. The particle size distribution (PSD) of the granule had an appreciable impact on particle motion with a wide PSD leading to larger fluctuations in particle velocity as well as poorer granule mixing.     

The effect of bed materials on the solid/bubble motion in a fluidised bed

Gas fluidisation provides good mixing and contact of the gas and particle phases as well as good heat transfer. These attractive features are achieved by the high degree of bubble-induced particle circulation within the bed. Bubble and particle motion vary with bed materials and operating conditions, as investigated in the present study, by the use of the non-intrusive positron emission particle tracking (PEPT) technique. The selected materials were spherical polyethylene and glass particles.The data obtained by the PEPT technique are used to determine the particle velocities and circulation pattern. Bubble rise velocities and associated sizes can be inferred from the particle velocity data, since particles travel upwards mostly in the bubble wake. The results indicate that the flow structure and gas/solid motion within the fluidised beds were significantly different, even at the same value of the excess gas velocity, U-U_mf. The solid circulation pattern within the beds differ: if for glass beads, a typical UCDW-pattern existed (upwards in the centre of the bed, downwards near the wall), the pattern in the polyethylene bed is more complex combining a small zone of UWDC movement near the distributor and a typical UCDW-pattern higher up the bed. Transformed data demonstrate that at the same value of excess gas velocity, U-U_mf, the air bubbles in the polyethylene fluidised bed were smaller and rose more slowly than in the fluidised bed of glass beads, thus yielding a longer bubble residence time and improved gas/solid contact. For polyethylene beads, the size and rise velocity of air bubbles did not increase monotonically with vertical position in the bed as would be predicted by known empirical correlations, which however provide a fair fit for the glass beads data. Bubble sizes and solid circulation patterns are important parameters in the design of a fluidised bed reactor, and vary with the bed material used.     

An investigation into the effect of biomass particle size on its torrefaction

Present work examines an important practical aspect of torrefaction that is, the effect of size and shape of biomass on torrefaction. Experiments were conducted on different sizes of Poplar and Oak wood in directly heated torrefaction reactors. Experiments were conducted with 13, 19 and 25 mm diameter Poplar wood with lengths varying from 8 to 65 mm long. Most of the experiments were conducted at 250°C for 60 min in a directly heated convective reactor with limited few in a fluidised bed reactor. Results showed increase in mass and energy yield with increasing particle length but opposite with particle diameter. © 2012 Canadian Society for Chemical Engineering     

Attrition of porous glass particles in a fluidised bed

Fluidisation is frequently accompanied by unwanted attrition of the bed material. This paper focuses on the mechanical aspects of fines creation by attrition in fluidised beds supported by multi-orifice distributor plates. The attrition rates of low-density porous glass particles were measured; these particles show abrasive wear behaviour rather than breakage. Positron emission particle tracking (PEPT) was used to follow particle motion in three dimensions within the fluidised bed. For a single orifice distributor with background fluidisation, the attrition rate increased exponentially with increasing orifice gas velocity. For a multi-orifice distributor, however, attrition rates were roughly proportional to excess gas velocity, except near to a critical ratio of particle to orifice diameter; as this ratio approached 2, attrition was observed to increase by an order of magnitude. A method is proposed for estimating attrition rates from a combination of small-scale experimental results and theoretical calculations of distributor jet entrainment rates.     

CFD modelling of the fast pyrolysis of biomass in fluidised bed reactors. Part B: Heat, momentum and mass transport in bubbling fluidised beds

The fluid-particle interaction inside a 150 g/h fluidised bed reactor is modelled. The biomass particle is injected into the fluidised bed and the heat, momentum and mass transport from the fluidising gas and fluidised sand is modelled. The Eulerian approach is used to model the bubbling behaviour of the sand, which is treated as a continuum. Heat transfer from the bubbling bed to the discrete biomass particle, as well as biomass reaction kinetics are modelled according to the literature. The particle motion inside the reactor is computed using drag laws, dependent on the local volume fraction of each phase. FLUENT 6.2 has been used as the modelling framework of the simulations with the whole pyrolysis model incorporated in the form of user-defined function (UDF). The study completes the fast pyrolysis modelling in bubbling fluidised bed reactors.     

Measurements and numerical predictions of gas vortices formed by single bubble eruptions in the freeboard of a fluidised bed

Gas vortices generated in the freeboard of a bubbling fluidised bed have become the centre of increasingly more research due to the advances in experimental technology. The behaviour of gas flow in the freeboard of a bubbling fluidised bed is of interest for applications such as the gasification of coal where reactions of gas mixtures, as well as gas–particle heat and mass transfer take place. Knowledge of the hydrodynamics of the gas within the freeboard can be hard to characterise, especially the detailed behaviour of gases escaping from bubbles that erupt at the bed surface. In the present study, experiments were conducted on a rectangular three-dimensional gas–solid fluidised bed. The experiments used a particle imaging velocimetry (PIV) measurement technique to visualise and measure the gas flow within the freeboard after a single bubble eruption. A computational study was carried out using Eulerian–Eulerian, kinetic theory of granular flow approach with a quasi-static flow model and with LES used to account for gas turbulence. Results from a three dimensional simulation of the experimental fluidised bed were compared with experimental velocity profiles of gas flow in the freeboard of the gas–solid fluidised bed after a bubble eruption. The CFD simulations showed a qualitative agreement with the formation of the gas vortices as the bubble erupted. Consistent with experimental findings the CFD simulations showed the generation of a pair of vortices. However, the simulations were unable to demonstrate downward flow at the centre of the freeboard due to particles in free fall after a bubble eruption event was observed in the experiments. Velocity profiles from the CFD data are in reasonably good agreement with the characteristic trends observed in the experiments, whereas the CFD model was able to predict the gas vortices phenomena and the velocity magnitudes were over-predicted.     

CFD modelling of the fast pyrolysis of biomass in fluidised bed reactors, Part A: Eulerian computation of momentum transport in bubbling fluidised beds

The fluid-particle interaction inside a 150 g/h fluidised bed reactor is modelled. The biomass particle is injected into the fluidised bed and the momentum transport from the fluidising gas and fluidised sand is modelled. The Eulerian approach is used to model the bubbling behaviour of the sand, which is treated as a continuum. The particle motion inside the reactor is computed using drag laws, dependent on the local volume fraction of each phase, according to the literature. FLUENT 6.2 has been used as the modelling framework of the simulations with a completely revised drag model, in the form of user defined function (UDF), to calculate the forces exerted on the particle as well as its velocity components. 2-D and 3-D simulations are tested and compared. The study is the first part of a complete pyrolysis model in fluidised bed reactors.     

Modelling of binary fluidization of coal and ash and validation using radioactive particle tracking and densitometry

Binary fluidization finds wide application in a variety of gas–solid catalytic and non-catalytic industrial fluidization systems. In the present study, a three-dimensional transient computational fluid dynamics (CFD) model was used to model the binary fluidization of coal and ash in a laboratory-scale cold flow fluidized bed. In parallel, phase velocity measurements using radioactive particle tracking (RPT) and gamma-ray densitometry were performed, which provided a rich database for validation of the CFD model. RPT being a time-resolved Lagrangian technique, it was possible to extract velocity fluctuations and their correlations in addition to the mean velocity profiles. The latter provided additional validation for the CFD model, in addition to the typical validation that is done with time-averaged profiles of phase velocity and volume fraction. The robust validation procedure opens up the possibility of expanding this model to a pilot plant-scale fluidized bed.     

Decreasing the Sampling Time Interval in Radioactive Particle Tracking

The study of the movement of solids in multiphase reactors using radioactive particle tracking is currently limited to fairly modest particle velocities because of count‐rate limitations of the detection system. In this work, this restriction was overcome by increasing the activity of the radioactive tracer, by decreasing the sampling time interval and by modifying the particle tracking software to recognize which detectors were saturated and to use only the data from the remaining unsaturated detectors. Higher tracer activity resulted in lower standard deviation of the calculated tracer coordinates.     

Velocity measurements in convective boiling flow using radioactive particle tracking technique

The design, performance, and safety analysis of nuclear reactors, in particular boiling water reactors, requires information about the vapor–liquid flow dynamics. Such data are necessary for stand-alone analysis of the thermal hydraulics, as well as to serve as a database for validation of computational fluid dynamics models. Challenges in collecting such data are magnified in the context of flow boiling, which is known to be a complex, multi-scale problem. The present work focuses on investigating the two-phase flow dynamics of convective boiling flows on a test section equipped with different heater rods arrangements. Noninvasive radioactive particle tracking (RPT) has been used for measuring liquid velocity field, mean flow patterns, and turbulent kinetic energy of the liquid phase. A novel tracer particle reconstruction algorithm based on support vector regression has been applied in this study. This is the first application of RPT for measuring liquid velocity fields in convective boiling flows.     

An extended radioactive particle tracking method for systems with irregular moving boundaries

The aim of this paper is to present an extension of the original non-intrusive radioactive particle tracking method (RPT) to any geometries with irregular moving boundaries. The principal advantage of RPT over other non-intrusive methods is that it enables the visualization of rather large systems. However, the underlying reconstruction algorithm is limited to cylindrically shaped systems such as fluidized beds and columns. It excludes a wide variety of systems involving multiphase flows such as, for instance, spherical reactors, cyclones and powder silos, hoppers and blenders, all of which are thus currently out of reach of current RPT capabilities. This work addresses these limitations and proposes an approach that solves the inverse map problem to reconstruct the tracer position with time by using a mesh of unstructured cells to discretize the system geometry and kinematics. The anisotropy induced by the gas-solid interface is discussed and taken into account in the proposed model. To show the possibilities and assess the performance of the developed technique, the flow of particles in a 16-qt V-blender is mapped and the mean velocity field is computed.