Local solid mixing in gas–solid fluidized beds

Diffusivity of the solid particles in a 152-mm ID gas–solid fluidized bed was determined at different regimes of fluidization. The gas was air at room temperature and atmospheric pressure and the solids were 385 μm sand or 70 μm FCC particles. The experiments were done at superficial gas velocities from 0.5 to 2.8 m/s for sand and 0.44 to 0.9 m/s for FCC (in both bubbling and turbulent regimes). Movement of a tracer was monitored by radioactive particle tracking (RPT) technique. Once the time-position data became available, local axial and radial diffusivity of solids were calculated from these data. Calculated diffusivities are in the range of 3.3×10⁻³ to 5.6×10⁻² m²/s for axial and 2.6×10⁻⁴ to 1.5×10⁻³ m²/s for radial direction. The results show that the diffusivities, both axial and radial, increase with superficial gas velocity and are linearly correlated to the axial solid velocity gradient. Solid diffusivity in a bed of FCC was found to be higher than that of a bed of sand at the same excess superficial gas velocity.     

Performance of solid–gas reaction heat transformer system with gas valve control

Single-stage solid–gas reaction heat transformer system with the reactive salts of CaCl₂ and MnCl₂ was investigated. The system performances with gas valve control (closed protocol) were measured and compared with those without gas valve control (open protocol). The reasons of these differences were discussed. It was concluded that specific heating power (SHP), coefficient of performance (COP) and exergic COP (COP_ex) of the experimental set-up were improved with gas valve control. From the theoretical analysis, it was concluded that the improvement of system performances was mainly due to the difference of gas pressure in system operation, while not the multi-step reactions between CaCl₂ and NH₃. Further improvements of the performances of experimental set-up were also proposed. It was concluded that conducting heat recovery process would increase system COP and COP_ex, and converting to novel two-stage system with reactive salts of CaCl₂, MnCl₂ and FeCl₂ would increase temperature lift ΔT.     

Supersonic attrition nozzles in gas–solid fluidized beds

Gas–solid fluidized beds are used in both catalytic and non-catalytic processes, and some of the industrial applications are fluid catalytic cracking, polyethylene production, drying and classification, coating, and granulation. In some applications, the size distribution of the bed particles must be controlled in order to maintain good fluidization, and attrition nozzles can be used for this purpose. Supersonic attrition nozzles are more efficient than subsonic nozzles, and, in this study, different geometries of the Laval nozzle, a convergent–divergent (C–D) nozzle, have been investigated. The geometry of this type of nozzles gives supersonic velocities under the right operating conditions.     

Profiles of solid fraction and heterogeneous phase structure in a gas–solid airlift loop reactor

The time-averaged and transient local solid fractions in a gas–solid airlift loop reactor (ALR) were investigated systematically by experiments and CFD simulations. To demonstrate the macro-flow pattern, the time-averaged local solid fractions in four regions of the ALR were measured by optical fiber probe under the conditions of different superficial gas velocities and particle circulation fluxes. The experimental results show that the lateral distribution of time-averaged local solid fraction is a core-annulus or heterogeneous structure in the three regions (draft tube, bottom region, particle diffluence region), but a uniform lateral distribution in the annulus. The operating conditions have different effects on the lateral distribution of time-averaged local solid fraction in each region. In the CFD simulation, a modified Gidaspow drag model considering the formation of particle clusters was incorporated into the Eulerian–Eulerian CFD model with particulate phase kinetic theory to simulate and analyze the transient local solid fraction and the two-phase micro-structures in the gas–solid ALR. The predicted values of solid fraction were compared with the experimental results, validating the drag model. The contours of transient flow field indicate that the flow field of the ALR should be divided into five flow regions, i.e., draft tube, annulus, bottom region, particle diffluence region and constrained back-mixing region, which further improves the understanding of the airlift reactor where only four divisions were determined from the experiments. The transient local solid fraction and its probability density function profoundly reveal the two-phase micro-structures (dilute phase and emulsion phase or cluster phase in the constrained back-mixing region) and explain the heterogeneous phenomenon of solid fraction in the ALR. The dilute phase tends to exist in the center of bed, while the emulsion phase mainly appears in the wall region. The results also indicate that the gas–solid ALR has the common characteristic of aggregative fluidization similar to that in normal fluidized beds. The simulated two-phase transient micro-structures provide the appropriate explanations for the experimental core-annulus macro-structures of time-averaged local solid fraction.     

Evaporative liquid jets in gas–liquid–solid flow system

Some aspects of the fundamental characteristics of evaporative liquid jets in gas–liquid–solid flows are studied and some pertinent literature is reviewed. Specifically, two conditions for the solids concentration in the flow are considered, including the dilute phase condition as in pneumatic convey and the dense phase condition as in bubbling or turbulent fluidized beds. Comparisons of the fundamental behavior are made of the gas–solid flow with dispersed non-evaporative as well as with evaporative liquids.For dilute phase conditions, experiments and analyses are conducted to examine the individual phase motion and boundaries of the evaporative region and the jet. Effects of the solids loading and heat capacity, system temperature, gas flow velocity and liquid injection angle on the jet behavior in gas and gas–solid flows are discussed. For dense phase conditions, experiments are conducted to examine the minimum fluidization velocity and solids distribution across the bed under various gases and liquid flow velocities. The electric capacitance tomography is developed for the first time for three-phase real time imaging of the dense gas–solid flow with evaporative liquid jets. The images reflect significantly varied bubbling phenomenon compared to those in gas–solid fluidized beds without evaporative liquid jets.     

A grain size distribution model for non-catalytic gassolid reactions

A new model to describe the non-catalytic conversion of a solid by a reactant gas is proposed. This so-called grain size distribution (GSD) model presumes the porous particle to be a collection of grains of various sizes. The size distribution of the grains is derived from mercury porosimetry measurements. The measured pore size distribution is converted into a grain size distribution through a so-called pore-tosphere factor whose value is also derived from the porosimetry measurements. The grains are divided into a number of size classes. For each class the conversion rate is calculated either according to the shrinking core model, involving core reaction and product layer diffusion as rate-determining steps or according to a new model in which some reaction at the grain surface is assumed to be limiting. The GSD model accounts for the phenomenon of pore blocking by calculating the maximum attainable conversion degree for each size class. In order to verify the model, two types of precalcined limestone particles with quite different microstructures were sulphided as well as sulphated. Furthermore, a single sample of sulphided dolomite was regenerated with a mixture of carbon dioxide and steam. For each reaction good agreement was attained between measured and simulated conversion vs. time behaviour.     

Hydrodynamics of gas–solid flow in the circulating fluidized bed reactor for dry flue gas desulfurization

Process design and scale-up require a fundamental understanding of the hydrodynamics of gas–solid flow in the circulating fluidized bed flue gas desulfurization (CFB-FGD) reactor although the CFB system has been widely used in flue gas desulfurization and flue gas cleaning processes. The hydrodynamics in the CFB-FGD reactor model was investigated by pressure measurements and specially designed sampling probe based on three dimensionless groups for practicable similarity of industrial CFB-FGD process. The results show that the pressure drop in the venturi section is predominant as high as 60% of the total pressure drop and the total pressure drop significantly increases with the increasing external solid circulating rates at the same superficial gas velocity. Moreover, the measurements of radial solid mass fluxes show that the flow pattern in the CFB-FGD reactor is a typical core–annulus flow and this flow structure prevails until the top of the reactor. Reflux ratios are used to quantitatively evaluate the internal solid reflux in the reactor and the values in the low section of the reactor are much higher than those in the upper section.     

Measuring gas hold-up in gas–liquid/gas–solid–liquid stirred tanks with an electrical resistance tomography linear probe

An electrical resistance tomography (ERT) linear probe was used to measure gas hold-up in a two-phase (gas–liquid) and three phase (gas–solid–liquid) stirred-tank system equipped with a Rushton turbine. The ERT linear probe was chosen rather than the more commonly used ring cage geometry to achieve higher resolution in the axial direction as well as its potential for use on manufacturing plant. Gas-phase distribution was measured as a function of flow regime by varying both impeller speed and gas flow rate. Global and local gas hold-up values were calculated using ERT data by applying Maxwell's equation for conduction through heterogeneous media. The results were compared with correlations, hard-field tomography data, and computational fluid dynamic simulations available in the literature, showing good agreement. This study thus demonstrates the capability of ERT using a linear probe to offer, besides qualitative tomographic images, reliable quantitative data regarding phase distribution in gas–liquid systems.     

Methanol synthesis in a countercurrent gas—solid—solid trickle flow reactor. An experimental study

The synthesis of methanol from CO and H₂ was executed in a gas—solid—solid trickle flow reactor. The reactor consisted of three tubular reactor sections with cooling sections in between. The catalyst was Cu on alumina, the adsorbent was a silica—alumina powder and the experimental range 498–523 K, 5.0–6.3 MPa and 0.2–0.33 molar fraction of CO. Complete conversion in one pass was achieved for stoichiometric feed rates, so that the gas outlet could be closed. The experimental results are compared with the model presented in the previous paper [Westerterp, K.R. and Kuczynski, M. (1987) Chem. Engng Sci.42,]; agreement is close over the entire conversion range from 15% to 100%.     

Investigation of electrostatic charge distribution in gas–solid fluidized beds

Over the past few decades there have been numerous attempts to measure electrostatic charges in gas–solid fluidized bed reactors; these charges have been prone to cause reactor downtime from electrostatic phenomena. In this study, a new system was developed that aimed to quantifying the electrostatic charge generation in three key areas within a gas–solid fluidized bed simultaneously: the bed particles, the particles that adhered to the column wall, and the particles that were entrained from the column. A unique online Faraday cup method was used to measure the electrostatic charge of the particles. The system was operated with dry air at two fluidizing gas velocities, one in the bubbling and the other in the slugging flow regime. An industrial polyethylene resin with a wide particle size range was utilized in all experiments. Results showed the occurrence of bi-polar charging in both flow regimes with entrained fines being mainly positively charged, whereas the bed particles and those attached to the column wall carrying a net negative charge. The charge-to-mass ratio (q/m) of the entrained fines in the bubbling regime was significantly higher than in the slugging regime. It was discovered that particles with a certain size range were predominantly adhering to the column wall with a significantly higher q/m than the other bed particles. These findings led to a proposed mechanism for the migration of particles within the fluidization column due to the effect of electrostatic charge generation.     

Modeling steady-state heterogeneous gas–solid reactors using feedforward neural networks

A new method for solving gas–solid heterogeneous reactors is proposed. Mass balance inside the pellet (numerical integration of a differential equations system) is replaced by an analytical function, which functionality corresponds to an adequate trained three-layer feedforward neural network. The global reaction rate evaluated by using this function includes the complex phenomena of simultaneous diffusion and chemical reaction into the solid. The methodology was successfully applied to the steam reforming of methane. Both methods are compared. Results of the reactor simulation are very similar in both cases but the one that used neural networks is about 20 times faster. The method proposed could also be applied to any type of two-phase heterogeneous reactors.     

Validation of an anisotropic model of turbulent flows containing dispersed solid particles applied to gas–solid jets

A mathematical model of turbulent flows containing dispersed solid particles is described together with its application to gas–solid jets. Flow fields are predicted by solution of the density-weighted transport equations expressing conservation of mass and momentum, with closure achieved through the k–? turbulence model and a second-moment closure. The particle phase is calculated using a Lagrangian particle tracking technique which involves solving the particle momentum equation in a form that accounts for the spatial, temporal and directional correlations of the Reynolds stresses experienced by a particle. The two phases are coupled via modification of the fluid-phase momentum equations. Predictions of the complete model are validated against available experimental data on a number of single-phase and two-phase, gas–solid jet flows with various particle loadings, and both mono- and poly-dispersed particle size distributions. Overall, predictions of the models compare favourably with the data examined, with results obtained from the anisotropic second-moment turbulence closure being superior to eddy viscosity-based predictions.     

Minimum superficial fluid velocity in a gas–solid swirled fluidized bed

A swirl flow is achieved in a bed of solids by passing air through multiple fluid inlets, which are tangentially located at the base of a flat-based circular column. The minimum superficial velocities needed to achieve swirling of the bed are measured experimentally under varied conditions. An empirical correlation for the minimum swirl velocity has been proposed. The results indicate that a stable swirling regime operation of the bed is possible. There exists an upper limit of static bed depth beyond which stable swirling of entire bed is not possible. The minimum swirl velocities are found to be 1.2–1.3 times the minimum fluidization velocities predicted for conventional fluidized beds.     

Hydrodynamic simulations of gas–solid spouted bed with a draft tube

Flow behavior of particles in a two-dimensional spouted bed with a draft tube is studied using a continuous kinetic-friction stresses model. The kinetic stress of particles is predicted from kinetic theory of granular flow, while the friction stress is computed from a model proposed by Johnson et al. (1990). A stitching function is used to smooth from the rapid shearing viscous regime to the slow shearing plastic regime. The distributions of concentration and velocities of particles are predicted in the spouted bed with a draft tube. Simulated results compare with the vertical velocity of particles (Zhao et al., 2008) measured and in the spout bed with draft plates and solid circulation rate (Ishikura et al., 2003) measured in the spouted bed with a draft tube. The impact of the friction stress of particles on the spout, annulus, fountain and entrancement regions is analyzed in gas–solid spouted bed with a draft tube. Numerical results show that the gas flow rate through the annulus increases with the increase of the entrainment zone. The solids circulation rate decreases with the decrease of inlet gas velocity and the height of the entrainment zone. The effect of spouting gas velocity on distributions of concentration, velocity and particle circulation is discussed.     

Total and gas convective heat transfer from a vertical tube to a mixed particle gas—solid fluidized bed

Experimental data were obtained for the average gas convective and total heat transfer coefficients for a vertical tube immersed in an air-fluidized bed of narrowly as well as widely distributed particle size mixtures. The gas convective heat transfer coefficient was determined by measuring the rate of mass loss from a vertical naphthalene tube 0.0262 m in diameter and 0.1012 m in length and using a heat and mass transfer analogy. These data were obtained at a bed temperature of about 330 K and superficial velocity of 0.1 to 1.1 m/s. The total heat transfer coefficients were measured under identical conditions using an electrically heated vertical tube. The total heat transfer coefficient decreased with an increase in particle diameter from 0.237 to 1.35 mm. The addition of fines was found to increase the total heat transfer coefficient. The gas convective heat transfer coefficient increased with increase in particle size and fluidizing velocity. The dependence of the gas convective heat transfer coefficient on gas velocity was more pronounced for large particles. The addition of fines resulted in decrease in gas convective coefficient. The relative contribution of the gas convective component of heat transfer coefficient was found to increase with increase in particle diameter. Its dependency on fluidizing velocity was found to be more complex. The experimental data were compared with the existing heat transfer models and correlations.     

Simulation and experiment of gas–solid flow field in short-contact cyclone reactors

A short-contact cyclone reactor has been designed for the particular case of fluid catalytic cracking. The new type reactor mainly includes two parts: a reaction chamber and a separation chamber. So the cracking reactions and the separations between the products and catalysts could occur respectively and simultaneously. A three dimensional model was used to representing key parts of a laboratory cyclone reactor. The Eulerian–Eulerian computational fluid dynamics model with the kinetic theory of granular flow was adopted to simulate the gas–solid two-phase flow. The particle concentration distribution and pressure drop were measured by a PV-6A particles velocity measure instrument and a U-manometer, respectively. Simulated results show that in the reaction chamber solids can be transformed into a homogeneous dispersed flow, particles’ concentration becomes uniform gradually while catalysts flowing down, the concentration is a little higher near the wall because of boundary effect. After the gas–solid flowing into the separation chamber, the gas phase is separated with solids completely. The new reactor has a good contact and separation effect. Simulated results make a reasonable agreement with the experimental findings.     

Simulation of gas–solid two-phase flow in the annulus of drilling well

This paper investigates the hydrodynamic behavior of gas–solid two-phase flow in the annular space of an air drilling well under different arrangements by using three-dimensional approach. Two-fluid model is used to solve the governing equations in the Eulerian–Eulerian framework. Effect of eccentricity and drill pipe rotation on the pressure drop, volume fraction and velocity profile are examined. The results are compared with available data in the literature and good agreement is found. The results show that the presence of solid particles in the annulus change the air velocity profile significantly and create two off-center peaks velocity close to the walls instead of one peak velocity in the middle. Eccentricity of drill pipe makes more accumulation of the cuttings in the smaller space of the annulus. Increasing the eccentricity increases pressure drop due to impact of particles with annulus wall and also particles collision with each other. Rotation of the drill pipe shifts maximum air velocity location toward smaller space of the annulus which results more uniform cutting distributions in the annulus and improvement in their transportations. Pressure drop in the annulus increases as eccentricity and rotation of drill pipe increase.     

Discrete particle simulation of solids motion in a gas–solid fluidized bed

The solids motion in a gas–solid fluidized bed was investigated via discrete particle simulation. The motion of individual particles in a uniform particle system and a binary particle system was monitored by the solution of the Newton's second law of motion. The force acting on each particle consists of the contact force between particles and the force exerted by the surrounding fluid. The contact force is modeled by using the analogy of spring, dash-pot and friction slider. The flow field of gas was predicted by the Navier–Stokes equation. The solids distribution is non-uniform in the bed, which is very diluted near the center but high near the wall. It was also found that there is a single solids circulation cell in the fluidized bed with ascending at the center and descending near the wall. This finding agrees with the experimental results obtained by Moslemian. The effects of the operating conditions, such as superficial gas velocity, particle size, and column size on the solids movement, were investigated. In the fluidized bed containing uniform particles better solids mixing was found in the larger bed containing smaller size particles and operated at higher superficial gas velocity. In the system containing binary particles, it was shown that under suitable conditions the particles in a fluidized bed could be made mixable or non-mixable depending on the ratios of particle sizes and densities. Better mixing of binary particles was found in the system containing particles with less different densities and closer sizes. These results were found to follow the mixing and segregation criteria obtained experimentally by Tanaka et al.     

A model for a countercurrent gas—solid—solid trickle flow reactor for equilibrium reactions. The methanol synthesis

The theoretical background for a novel, countercurrent gas—solid—solid trickle flow reactor for equilibrium gas reactions is presented. A one-dimensional, steady-state reactor model is developed. The influence of the various process parameters on the reactor performance is discussed. The physical and chemical data used apply to the case of low-pressure methanol synthesis from CO and H₂ with an amorphous silica—alumina as the product adsorbent. Complete reactant conversion is attainable in a single-pass operation, so that a recycle loop for the non-converted reactants is superfluous.In the following article the installation and experiments for which this theory was developed will be described.     

Euler multiphase-CFD simulation on a bubble-driven gas–liquid–solid fluidized bed

An integrated flow model was developed to simulate the fluidization hydrodynamics in a new bubble-driven gas–liquid–solid fluidized bed using the computational fluid dynamic (CFD) method. The results showed that axial solids holdup is affected by grid size, bubble diameter, and the interphase drag models used in the simulation. Good agreements with experimental data could be obtained by adopting the following parameters: 5 mm grid, 1.2 mm bubble diameter, the Tomiyama gas–liquid model, the Schiller–Naumann liquid–solid model, and the Gidaspow gas–solid model. At full fluidization state, an internal circulation of particles flowing upward near the wall and downward in the centre is observed, which is in the opposite direction compared with the traditional core-annular flow structure in a gas–solid fluidized bed. The simulated results are very sensitive to bubble diameters. Using smaller bubble diameters would lead to excessive liquid bed expansions and more solid accumulated at the bottom due to a bigger gas–liquid drag force, while bigger bubble diameters would result in a higher solid bed height caused by a smaller gas–solid drag force. Considering the actual bubble distribution, population balance model (PBM) is employed to characterize the coalescence and break up of bubbles. The calculated bubble diameters grow up from 2–4 mm at the bottom to 5–10 mm at the upper section of the bed, which are comparable to those observed in experiments. The simulation results could provide valuable information for the design and optimization of this new type of fluidized system.