SOLIDS NOTES 5, George G.

Chase, The University of Akron

5. FLUIDIZATION 5.1 The Phenomenon of Fluidization When a fluid is pumped upward through a bed of fine solid particles at a very low flow rate the fluid percolates through the void spaces (pores) without disturbing the bed. This is a fixed bed process. If the upward flow rate is very large the bed mobilizes pneumatically and may be swept out of the process vessel. At an intermediate flow rate the bed expands and is in what we call an expanded state. In the fixed bed the particles are in direct contact with each other, supporting each others weight. In the expanded bed the particles have a mean free distance between particles and the particles are supported by the drag force of the fluid. The expanded bed has some of the properties of a fluid and is also called a fluidized bed. As shown in Figure 5-1, the velocity of the fluid through the bed opposite to the direction of gravity determines whether the bed is fixed, expanded, or is swept out. There is a minimum fluidization velocity, Vom, at which the bed just begins to fluidize. When the

(a) Slow Flow Rate, Fixed Bed, VOm > VO

(b) High Flow Rate, Mobilized Bed, u t < VO

(c) Intermediate Flow Rate, Fixed Bed, VOm < VO < u t

Figure 5-1. Fixed, mobilized, and expanded beds. The fixed bed (a) occurs when the approach velocity, Vo, is much smaller than the minimized fluidization velocity, Vom. The pneumatically mobilized bed (b) occurs when the approach velocity is much greater than the particle terminal velocity, ut, and the expanded bed (c) occurs when the approach velocity is intermediate between the minimum fluidization velocity and the terminal velocity.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

approach velocity, Vo (otherwise known as the empty tank velocity, given by the fluid volumetric flow rate divided by the cross-sectional area of the vessel), is greater than or equal to the minimum fluidization velocity and it is less than the terminal velocity of the particles Vom Vo < u t then the bed forms a fluidized bed. When Vo < Vom then the bed remains as a fixed bed. At the other extreme, when Vo ut , the bed mobilizes. In many liquid-solid systems an increase in velocity above Vom results in a smooth progressive expansion of the bed. Large scale instabilities and heterogeneities are not observed. A bed such as this is called a homogeneous fluidized bed. This is typically observed when the fluid and solids have similar intrinsic densities. When there is a large difference in the densities of the fluid and solid phases an increase in fluid velocity typically causes large bubbles or other such instabilities. Several types of instabilities are described by Kunii and Levenspeil, Figure 1 page 2 (D. Kunii and O. Levenspeil, Fluidization Engineering, 2ed., Butterworth-Heineman, Boston, 1991). In turbulent and pneumatically mobilized beds a significant part of the bed may be carried out of the vessel. For steady-state operations the particles must be recovered such as with a cyclone (Kunii & Levenspeil, Figure 2). A spouted bed is a variation on the fluidized bed in which the flow of the fluid is localized along the center axis and the solids move downward along the vessel walls (Kunii & Levenspeil, Figure 3). Fluidized beds display a number of liquid-like properties: Lighter objects float on top of the bed (ie., objects less dense than the bulk density of the bed), The surface stays horizontal even in tilted beds, The solids can flow through an opening in the vessel just like a liquid, The beds have a static pressure head due to gravity, given by 0 gh , Levels between two similar fluidized beds equalize their static pressure heads.

There are a number of ways in which to design and operate gas-fluidized systems for continuous operations. Figure 5-2 shows a counter current column and a cross flow system.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

SOLIDS IN

GAS OUT GAS OUT

SOLIDS IN

SOLIDS OUT
GAS IN

GAS IN

OUT CROSS FLOW

COUNTER CURRENT COLUMN

Figure 5-2. Counter current and cross flow methods of continuous contacting in fluidized bed designs.

5.2 Comparison of Contacting Methods Kunii and Levenspiel (ibid, Figure 7) provide a table comparing different types of fluidized beds to the fixed bed. Beds include: Fixed bed Moving bed Bubbling/turbulent bed Fast fluidized bed Rotary cylinder Flat hearth

The advantages of fluidized beds include: Liquid like behavior, easy to control and automate, Rapid mixing, uniform temperature and concentrations, Resists rapid temperature changes, hence responds slowly to changes in operating conditions and avoids temperature runaway with exothermic reactions, Circulate solids between fluidized beds for heat exchange, Applicable for large or small scale operations, Heat and mass transfer rates are high, requiring smaller surfaces.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

The disadvantages of fluidized beds include: Bubbling beds of fine particles are difficult to predict and are less efficient, Rapid mixing of solids causes non-uniform residence times for continuous flow reactors, Particle comminution (breakup) is common, Pipe and vessel walls erode due to collisions by particles.

5.3 Uses of Fluidization The uses for fluidized beds are limited to our imaginations. Typical uses include Reactors Cracking hydrocarbons coal gasification carbonization calcination

heat exchange Drying operations Coating (example, metals with polymer) Solidification/Granulation Growth of particles Adsorption/desorption Bio fluidization others

5.4 Geldart Classification of Particles Geldart (Powder Technology, 7, 285-292, 1973) observed the nature of particles fluidizing. He categorized his observations by particle diameter versus the relative density difference between the fluid phase and the solid particles. (HANDOUT 5.1). Geldart identified four regions in which the fluidization character can be distinctly defined. Group A particles are characterized by Bubbling bed fluidization, The bed expands considerably before bubbling occurs, Gas bubbles rise more rapidly than the rest of the gas, Bubbles spit and coalesce frequently through the bed, Maximum bubble size is less than 10 cm, Internal flow deflectors do not improve fluidization, Gross circulation of solids occurs.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

10

B SAND-LIKE (BUBBLING BED) (EASY TO FLUIDIZE) A AERATABLE BED (EASIEST TO FLUIDIZE) C COHESIVE (DIFFICULT TO FLUIDIZE)

g )
1
3

D SPOUTABLE BED

(g / cm )

0.1 10 100

dp

(m )

1000

10000

Figure 5-3. Geldart classification of fluidized beds. Particle properties are related to the type of fluidized beds. (Geldart, Powder Technology, 7, 258-292,1973).

Group B particle beds are the most common. These beds Are made of coarser particles than group A particles and more dense, Form bubbles as soon as the gas velocity exceeds Vom, Form small bubbles at the distributor which grow in size throughout the bed, Have bubble sizes independent of the particle size, and Have gross circulation. Are difficult to fluidize and tend to rise as a slug of solids, Form channels in large beds with no fluidization, and Tend to be cohesive. Are very large, dense particles, Form bubbles which coalesce rapidly and grow large, Form bubbles which rise slower than the rest of the gas phase, Form beds whose dense phase surrounding the bubbles has low voidage, Cause slugs to form in beds when the bubble size approaches the bed diameter, and Spout from the top of the bed easily.

Group C particles

Group D particles

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SOLIDS NOTES 5, George G. Chase, The University of Akron

Kunii and Levenspeil present a more generalized diagram (ibid, Figure 16) for classifying fluidization regimes. They plot a dimensionless particle diameter, d p * versus a dimensionless velocity u * where

( p ) g dp*= dp 2 and
2 u* = u p g
1 3

3 4

CD Rep

(5-1)

4 Rep = 3 CD

(5-2)

With the data arranged this way they identify several interesting features including: Geldarts classification, Terminal velocity, ut , Minimum fluidization velocity, umf , and Types of fluidization (spouted beds, bubbling, fast fluidized beds and pneumatic transport).

5.5 Prediction of Minimum Fluidization A minimum velocity is needed to fluidized a bed. If the velocity is too small the bed stays fixed and operates as a packed bed.

Recall the Ergun Equation is presented in dimensionless form in Eq.(4-25) which relates the pressure drop to the flow rate through a packed bed. At the onset of fluidization the particles are still close enough together that the pressure drop is related to the velocity by the Ergun Equation. Also, a free body diagram tells us that the force due to pressure drop is also related to the net weight of the solids in the bed
P A = p 1 f

)(

)( A L ) gg
f

(5-3)

where the right side of Eq.(5-3) is the weight of the solids minus the buoyant force due to the displaced fluid. The subscripts f mean that the quantity is for a fluidized bed. If we consider a total mass balance on the solids, assuming that no solids are entrained and carried out of the bed, then the total mass of solids is constant given by

M solids = p 1 f AL f = constant

(5-4)

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SOLIDS NOTES 5, George G. Chase, The University of Akron

At different fluidization rates the porosity, , and the bed height, L , vary but the rest of the terms in Eq.(5-4) are constants. This means that at the porosities and bed heights at flow rates 1 and 2 are related by

(1 ) L = (1 ) L .
1 1 2 2

(5-5)

For liquids and for gases, as long as the pressure drop is small, the fluid phase density is constant. Hence, the right hand side of Eq.(5-3) is constant and thus the pressure drop in a fluidized bed is constant independent of the velocity. Experimental data show this to be true. A typical plot of the pressure drop versus the velocity is shown in Figure 5-4. Substitution of Eq.(5-3) into Eq.(4-25) gives the modified Ergun Equation for fluidized beds

180(1 f ) 1.80 2 Rep f + Rep f = N GA 3 2 f 3 f

(5-6)

where Rep f =

Vof d p
3 p g dp

(5-7)

and

N GA =

(5-8)

DENSE PACKED (FIRST TIME BED IS FLUIDIZED)

P
LOOSE PACKED
PACKED BED OPERATION FLUIDIZED BED OPERATION

Vm

Figure 5-4. Typical pressure drop versus velocity plot for fluidized beds. Initially if the bed is densely packed the pressure drop overshoots the fluidization pressure until the particles separate and fluidize.
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SOLIDS NOTES 5, George G. Chase, The University of Akron

For small Rep f < 1 , such as with very small particles, we can neglect the Rep f 2 term and get the Blake-Kozeny expression

180(1 f
2 3 f

Rep f = N GA

for Rep f < 1

(5-9)

or

Vof =

2 ( p )g 3f 2 dp

180

(1 )
f

(5-10)

which relates the fluidization velocity to the void volume fraction of the expanded bed. To estimate the onset of fluidization, we can estimate the minimum fluidization conditions. The minimum fluidization porosity, m , can be estimated from Figure 4-1 for loose packing and known sphericity, . Using this value for m we can solve the Ergun Equation, Eq.(5-6) for the minimum fluidization velocity, Vo m . When m and are not known, we can still estimate the minimum fluidization velocity. The modified Ergun Equation, Eq.(5-6) is rewritten as
K 2 Rep m + K 1 Rep m = N GA
2

(5-11)

where K 1 =

180(1 m ) 1.8 and K 2 = 3 3 2 m m

Wen and Yu (AIChE J, 12(3), 610-612, 1966) noted that K 1 and K 2 stay nearly constant over a wide range of particles and for 0.001 < Rep m < 4000 ; thus giving a prediction of
Vo mf with a 34% standard deviation.

Equation (5-11) can be solved for the minimum fluidization velocity, provided K 1 and K 2 are known, gives

Rep m

K1 K1 1 = + K N GA 2K 2K 2 2 2

(5-12)

K1 1 for which Wen and Yu determined = 0.0408 . = 33.7 and K2 2K 2

Since the work of Wen and Yu, others have determined values for K 1 and K 2 . Table 5-1 summarizes values for fine and coarse particles.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

Table 5-1. Values for constants in Wen and Yus correlation, Eq.(5-12). PARTICLES

K1 2K 2
33.7 28.7

1 K2

SOURCE

Fine Coarse

0.0408 0.0494

Wen and Yu, AIChE J, 12(3), 610-612, 1966. Chitester et.al., Chem. Eng. Sci., 39,253,1984.

5.6 Wide Size Distributions of Particles The previous discussion applies predominately to beds of narrow size distribution of particles. Now lets consider what happens when there is a large size distribution of particles in a fluidized bed.

In such a bed the minimum fluidization velocity, Vo m , must be determined for the particular size distribution in actually in the bed. This may differ significantly from the size distribution in the fresh feed due to elutriation of fines, attrition, or agglomeration of particles. One can estimate Vo m by using the average particle size (a permeability average is most appropriate). However, as fluid flows upward and the flow is increased, the fine particles in the voids between the larger particles will fluidize before the larger particles. This partial fluidization will occur at a smaller velocity than the average Vo m . Estimating Vo m for a wide size range of particles is analogous to measuring the boiling point of a liquid mixture. The boiling point is not fixed, but varies with the composition. To obtain a conservative estimate, to fluidize the whole bed, Vo m should be estimated for the largest particle. You must also check the terminal velocity of the smallest particles to make sure that you do not entrain fines and carry them out of the top of the bed. If a bed of particles has a bimodal distribution, it has two size ranges as for example given in Figure 5-5. Several fluidization conditions can exist for fluidized beds with bimodal size distributions. These conditions are shown in Figure 5-6. (HANDOUT 5.2)

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SOLIDS NOTES 5, George G. Chase, The University of Akron

Bimodal Distribution Number

Particle Size
Figure 5-5. Bimodal distribution of particle sizes showing two peaks (modes) in the number of particles of each size.

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SOLIDS NOTES 5, George G. Chase, The University of Akron

dp small

dp small

dp large

dp large FLOW

dp avg

(a) Complete segregation of particles into a region of predominately small particles and a region of predominately large particles. The segregation may also be characterized by an abrupt change in bed porosity.

dp small dp mixed

dp small dp mixed

dp large

dp large FLOW

dp avg

(b) Partial segregation into two regions with different particle sizes separated by a layer of mixed particle sizes.

dp mixed dp mixed.

dp avg

FLOW

(c) No segregation of particles. The average particle size may gradually vary throughout the depth of the bed. Figure 5-6. Fluidized beds with bimodal size distribution.

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