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A three-dimensional computational fluid dynamics (CFD) model, using an Eulerian-Eulerian two-fluid model
which incorporates the kinetic theory of granular flow, was developed to describe the gas-solid two-phase
flow in fluidized-bed polymerization reactors. Corresponding simulations were carried out in a commercial
CFD code Fluent. The entire flow field in the reactors was calculated by the model. The predicted pressure
drop data were in agreement with the classical calculated data. In addition, the model was used to describe
the solid holdup distributions, the bubble behaviors, and the solid velocity vectors in the free and agitated
fluidized-bed polymerization reactors, respectively. The effects of the addition of an agitator on the gas-solid
flow behaviors were preliminarily investigated via the model. The simulation results showed that the addition
of an agitator can strengthen the fluidization efficiency and reduce the operation stability of the bed. However,
the simulation results also showed that the total fluidization quality of the free fluidized bed was higher than
that of the agitated fluidized bed at a superficial gas velocity of 0.5 m s-1.
1. Introduction
Polyolefins can be produced in various types of reactors, such
as autoclave, continuous stirred tank, tubular loop, or fluidized
bed (FBR). The last one is certainly the most important because
of its simple construction and excellent heat- and mass-transfer
characteristics.1 For instance, various technologies, including
Hypol, Innovene, Unipol, Spheripol, etc., are designed to
produce polypropylene. Among them, there are different reactor
arrangements in essence.2-4 FBR is one of their central reactors,
which is generally used to produce high-impact polypropylene.4
In the fluidized-bed olefin polymerization reactor, small catalyst
and/or polymer particles react with monomers to form polymer
particles in the gas phase, and the polymer particles are produced
as a solid suspension in the gas stream.2-5 Accordingly, the
reacting system is considered to be a mixture of gas and solid
phases, namely, a gas-solid two-phase system. For efficient
operation and to accomplish the desired results, it is imperative
that a good fluidization quality is achieved to ensure good
gas-solid contact, uniformity of temperature, and minimum gas
bypassing. For these reasons, computational fluid dynamics
(CFD) is becoming more and more an engineering tool to predict
flows in various types of apparatuses on the industrial scale.6-8
Furthermore, CFD is an emerging technique and holds great
potential in providing detailed information on complex fluid
dynamics.9-11
In general, two different categories of CFD models are used,
namely, the Lagrangian and Eulerian models.6-8 The Lagrangian
model solves equations of motion for each particle, taking into
account particle-particle collisions and the forces acting on the
particle, whereas the Eulerian model considers full interpenetrating continua subject to continuity and momentum equations.
Considerable attention has been devoted in recent years to the
application of CFD to gas-solid FBRs.9-17 A comprehensive
review has been published on these CFD models and experiments applied to FBRs.18 Most authors have used Eulerian
models, including continuity and momentum equations for two
interpenetrating continua, one representing the gas and the other
* To whom correspondence should be addressed. Tel.: +86-5922187190. Fax: +86-592-2187231. E-mail: luozh@xmu.edu.cn.
4071
Figure 1. FBR configurations: (a) free FBR; (b) agitated FBR; (c) stirrer.
(R F ) + (RsFsb
V s) ) 0
t s s
(2)
The momentum balance equations for the gas and solid phases
can be written as
(R F b
V ) + (RgFgb
V gb
V g) ) -Rgp + g + Kgl(V
bs t g g g
b
V g) + RgFgg (3)
(R F ) + (RgFgb
V g) ) 0
t g g
(1)
g ) Rgg(V
bg + V
bgT)
(4)
(R F b
V ) + (RsFsb
V sb
V s) ) -Rsp - ps + s +
t s s s
Kls(V
bg - b
V s) + RsFsg (5)
2
s ) Rss(V
bs + V
bsT) + Rs s - s V
bsI
3
(6)
3.2. KTGF. The two-fluid model requires constitutive equations to describe the rheology of the solid phase, i.e., the
viscosity and pressure gradient of the solid phase. When the
particle motion is dominated by collision interaction, concepts
from fluid kinetic theory can be introduced to describe the
effective stresses in the solid phase resulting from particle
streaming (kinetic contribution and direct collisions) collision
contribution.9,7,35-37 Constitutive relations for the solid-phase
stress based on the kinetic theory concepts have been derived
by Lun et al.36 Moreover, their equations have been accepted
widely and are also applied in this work.
ps ) RsFss[1 + 2g0Rs(1 + es)]
4
s ) Rs2Fsdsg0(1 + es)
3
(7)
(8)
where
g0 )
1
1 - (Rs /Rs,max)/1/3
(9)
4072
1
s ) ss
3
(10)
-3
g/pa s
910.0
21.56
1.081 10-5
CD )
15FsdsRss
12
16
(41 1 + 2(4 - 3)Rsg0 +
4(41 - 33)
5
15
33)Rsg0
Fg/kg m-3
where
Fs/kg m-3
3
24
R Re
1+
RgRes
20 g s
[ (
Res )
12(1 - es2)g0
ds
FsRs2s1.5
(14)
gs ) -3Kgss
(15)
(16)
Vs - b
V g|
Fgds | b
g
Rs(1 - Rg)g
(13)
(22)
(23)
(12)
where
1
) (1 + es)
2
0.687
) ]
(17)
Rgds
Vs - b
V g|
7 RsFg | b
4
ds
(24)
where
s,col
s,kin )
4
) RsFsdsg0(1 + es)
5
10dsFss
4
1 + (1 + es)Rsg0
96Rs(1 + es)g0
5
s,fr )
(18)
2
ps sin
2I2D
(19)
(20)
Umf )
(21)
g
dsFg
{[
33.72 + 0.0434
ds3Fg(Fs - Fg)g
g2
0.5
- 33.7
(25)
4073
value
turbulence model
granular viscosity
granular bulk viscosity
frictional viscosity
angle of internal friction
granular temperature
drag law
coefficient of restitution for particle-particle collisions
inlet boundary condition
outlet boundary condition
wall boundary condition
initial bed height
initial volume fraction of the solid phase
operating pressure
inlet gas velocity
rotating speed
oulet pressure
maximum iterations
convergence criteria
time step
k- (RNG, dispersed)
Gidaspow et al.40
Lun et al.36
schaeffer
30
algebraic
Gidaspow et al.40
0.9
velocity inlet
pressure outlet
no slip for air, specularity coefficient 0 for the solid phase16,17
0.39 m
0.63
1.40 106 Pa
0.5 m s-1
10 rpm (available in the stirred model)
1.013 25 105 Pa
30
1 10-3
1 10-3 s
at Re < 0.4, UT )
(Fs - Fg)ds2g
18g
4(Fs - Fg)2g
225Fgg
(26)
0.5
(27)
ds
3.1(Fs - Fg)gds
Fg
0.5
(28)
where
Re )
dsFgUT
g
(29)
(30)
(31)
Figure 2. Pressure drop versus flow time in the free FBR at an initial flow
velocity of 0.5 m s-1.
4074
Figure 3. Pressure drop versus flow time in the agitated FBR at an initial
flow velocity of 0.5 m s-1.
Figure 4. Average solid volume holdup versus the height of the horizontal
plane from the bottom of the free FBR at an initial flow velocity of 0.5
m s-1 and a flow time of 10 s.
Figure 5. Average solid volume holdup versus the height of the horizontal
plane from the bottom of the agitated FBR at an initial flow velocity of 0.5
m s-1 and a flow time of 10 s.
4075
Figure 6. Solid volume holdup distribution in the free FBR at an initial flow velocity of 0.5 m s-1 and a flow time of 10 s.
Figure 7. Solid volume holdup distribution in the free FBR at an initial flow velocity of 0.5 m s-1 and a flow time of 10 s.
Figure 8. Solid volume holdup distribution of the vertical plane across the vertical axis in the free FBR at an initial flow velocity of 0.5 m s-1 versus flow
time.
4076
Figure 9. Solid volume holdup distribution of the vertical plane across the vertical axis in the agitated FBR at an initial flow velocity of 0.5 m s-1 versus
flow time.
Figure 10. Visual representations of bubble formation in the free FBR at an initial flow velocity of 0.5 m s-1.
Figure 11. Visual representations of bubble formation in the agitated FBR at an initial flow velocity of 0.5 m s-1.
4077
Figure 12. Solid velocity vector profiles in the free FBR at an initial flow velocity of 0.5 m s-1 and a flow time of 10 s.
are similar to each other and their profiles are shown at 4.6,
4.8, 10 s in Figure 8. Figure 10 shows the typical 3D diagrams
of bubble evolution from formation, deformation, to breakup
and gives 3D visualization results. According to Figure 10, one
knows that the bubble-like cirque with narrow top and wide
bottom can be obtained at 4.0 s and its shape continues to change
because of granular actions following the flow proceeding.
Simultaneously, it is split into many small bubbles along the
axial aspect. For instance, both the volume and height of the
bubbles at 4.2 s are larger than those at 4.0 s. One also observes
many small bubbles along the axial aspect of the bubble at 4.2 s
in Figure 10. Furthermore, according to Figure 10, one can find
that the bubble continues to rise along its axial aspect and it
has been split into eight small bubbles with similar shape and
different volume at 4.4 s. In addition, the obtained small bubbles
can also rise.
Compared to the bubble behaviors in the free FBR shown in
Figures 8 and 10, the bubble behaviors shown in Figures 9 and
11 are similar. However, because of the addition of a stirrer,
the first bubble obtained in the agitated FBR is unstable and
there are many small bubbles to form, along with the formation
of the first bubble. In practice, the stirrer breaks up the early
bubbles, which leads to an increase of the charge capacity of
the granules in bubbles. Furthermore, some air whorls come
into being by the edge of the stirrer and can also leave the stirrer
to form small bubbles. Some of the small bubbles can be
incorporated to form big bubbles. Therefore, there are still many
small bubbles in the agitated FBR at 10 s in Figure 9. Although
the small bubbles can strengthen the fluidization efficiency, they
reduce the operation stability of the bed because of the addition
of the agitator.
5.4. Solid Velocity Vector. The rising motions of the rotating
torus in the free and agitated FBRs are also simulated via the
above model. The simulated velocity vectors for the solid phase
in a vertical plane across the vertical axis in the two FBRs are
shown in Figures 12 and 13, respectively.
Figure 12 shows that there is an obvious circular upflow in
the vertical plane due to the bubble motion. There are some
small dimensional circular regions (small circulations) in the
bottom of the free FBR. For the dimension of the whole FBR,
the solid phase is lifted up from its middle position and comes
back along with the breakup of the bubbles due to gravitation.
The fallen granules can flow down along the wall. Therefore,
the above results can also lead to the formation of big circular
upflows, namely, big circulations. The combined action of the
small and big circulations leads to a good mixing result in the
free FBR. However, a vortex appears between the small and
big circulations, namely, in the middle of the free FBR. It is
harmful to the matter and heat transfers between the quiescent
regions and the bottom of the FBR.
Figure 13 shows that there is no vortex to be formed in the
middle of the agitated FBR because of the addition of the stirrer.
One knows that the motion of the granules in the agitated FBR
is mainly influenced by two actions. The granules can be lifted
up because of the action of the gas phase along the vertical
axis and can also be rotated in the agitated FBR because of the
action of the stirrer. Besides, other actions including granule
gravitation can also influence their motion. Accordingly, as
shown in Figure 13, most granules in the agitated FBR lift up
along the right side of the vertical plane across the vertical axis
and collide with the fallen granules to form a vortex. Some
granules flow back to the bottom of the agitated FBR. In
addition, some granules inside the fractured bubbles also fall
back to the bottom of the agitated FBR.
6. Conclusions
In this study, a 3D CFD model was developed to describe
the gas-solid two-phase flow in fluidized-bed polymerization
reactors.ThemodelincorporatedKTGFwiththeEulerian-Eulerian
approach. The pressure drop data calculated according to the
classical equation were employed to verify the model. The
predicted pressure drop data were found to agree well with the
classical calculated data. Furthermore, the hydrodynamic characteristics of the entire flow field in the free and agitated FBRs,
such as the pressure drop, solid holdup distribution, bubble
behavior, and solid velocity vector profile, were investigated
via the above model, respectively. Particular attention was paid
to the effect of the addition of the agitator on the gas-solid
flow behavior.
The simulated results show that both of the flow fields in the
free and agitated FBRs as a function of the flow time can be
divided into four periods. Namely, the start-up period ( ) 0 s),
slow drop period (0 s < < 4.0 s), vibration period (4.0 s e
4078
Figure 13. Solid velocity vector profiles in the agitated FBR at an initial flow velocity of 0.5 m s-1 and a flow time of 10 s.
ds ) particle diameter, m
D ) pipe diameter, m
es ) particle-particle restitution coefficient
ew ) particle-wall restitution coefficient
g ) gravitational acceleration, m s-2
jjI ) identity matrix
I2D ) second invariant of the deviatoric stress tensor
Kgs ) interphase exchange coefficient, kg m2 s-1
p ) pressure, Pa
ps ) particulate phase pressure, Pa
Res ) particles Reynolds number
t ) flow time, s
Umf ) minimum fluidization velocity
Ut ) particle terminal velocity
Vg ) gas velocity, m s-1
Vs ) solid velocity, m s-1
Vs,w ) solid velocity at the wall, m s-1
Rg ) volume fraction of the gas phase
Rs ) volume fraction of the solid phase
Rs,m ) maximum volume fraction of the solid phase
) voidage
) specularity factor
g ) viscosity of the gas phase, Pa s
s ) solids shear viscosity, Pa s
s,col ) solids collisional viscosity, Pa s
s,kin ) solids kinetic viscosity, Pa s
s,fr ) solids frictional viscosity, Pa s
) angle of internal friction, deg
s ) granular temperature, m2 s-2
s ) collisional dissipation of energy, m2 s-2
jjg ) shear stress of the gas phase, N m-2
jjs ) shear stress of the solid phase, N m-2
s ) solid bulk viscosity, Pa s
Fg ) gas density, kg m-3
Fs ) solid density, kg m-3
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