Adaptado de Lee (1995); Dai et al. (2001); Ilkili & Aydin (2011); Zhang et al. (2008); Li et al.

(2004)

Reator Temperatu leo Carvo Gs Referncia

ra
Leito Fluidizado 700 38.0 32 30 (Lee , 1995)

Leito Fluidizado 450 52 28 15 (Dai et al., 2001)

Circulante
Leito fixo 500 40 48 12 (Ilkili & Aydin,
2011)
Vcuo 550 47,1 36,9 16 (Zhang et al., 2008)

Forno rotativo 500 45,1 41,3 13,6 (Li et al., 2004)

(ANTONIOU e ZABANIOTOU, 2013)

Tempo Gs le Negro de
Tipo de reator T C de (%m/ o fumo
Forno rotativo 550 residn
30 min m)67 (%m/
- (%m/m)
33
Leito fixo 400- - 2,8- 36-62 31,6-51
Leito fixo 460
700 5 min 17- - 36
Leito fixo 1000 120 - - -
Leito fixo 300- min
30 min 7,6- 4,8- 44-84
Leito fixo 700
1000 1 min 19- 38,5
- -
Leito fixo 550- 60 min 7,4- 47,2- 41,5-42
Leito fixo 800
550- 60 min 7,8
7,6- 48,4
55,1-56 33,2-
Leito fixo 800
500 30 min 8,8
16- 35-44 33,8
39-40
Leito fixo 425- - 25
1- 25-31 32-33
Leito fixo 610
500 150 3,5
- - -
Leito fixo 350- min
15 min 20- 30-38 33-50
Leito fixo 550
350- 5-30 29
4 54 42
Leito fixo 450
720 min
120 - - -
Leito fixo 570 60min
min 4, 57,1 38,7
Leito fixo 300- 120 3
2,4-14,8 3,6- 26,4-94
Leito fixo 720
390- min
- 5- 58,8
01/mar 20-92
Leito fixo 890
400- 120 73
2,4- 30-42,8 51,3-64
Leito fluidizado 700
400- min
- 4,4- - -
Leito fluidizado 500
360- 1,5 8- 30-52 27-40
Ablativo continuo 810
550 seg.
0,6 40- - -
10
Ablativo continuo 550 seg.
0,6 - - -
Flash 500- seg.
- - - -
700
Cataltico 430 - 16 33,6 50,4
Cataltico 500 30 min 16- 10 -46 37
Cataltico 300- - 47
0,4-16,6 1,8- 55,6-96
Cataltico 400
700 - - 28,2
- -
Plasma 1500 10 min - - 40-76,8

Tabela 3.2 - Composio do leo piroltico de pneus (OPP) e do leo diesel (OD)

leo Piroltico de leo

Pneus Diesel
Composi
o Aydin & Ilkili, Sharma & Banar et Ucar et
2012 Murugan, al., al.,
elementar 2015 2012 2005
Carbono
(% 86,87 86,92 79,61 86,5
Hidrogni 10,07 10,46 10,04 13,2
o
Nitrogni 1,18 0,65 0,94 <1
o
Enxofre 0,91 0,95 0,11 <0,70
Oxignio 1,17 1,02 9,30 --
Adaptado de Aydin & Murugan (2012); Sharma & Murugan (2015); Banar et al. (2012) e Ucar(2005)

Tabela 3.3 - Propriedades do leo piroltico de pneus (OPP) e leo diesel (OD)

leo Piroltico de leo

Pneus Diesel
Propriedade Aydin & Sharma & Banar et Ucar et
s Ilkili, Murugan, al., al.,
Poder 2012 2015 2012 2005
43,3 38, 42,66 45,1
Calorifico
4 1
Massa
[MJ/kg]
especfica 945 913 830 820-860
3
[kg/m ]
Viscosida
3,8 3,3 1,01* 2-4,5**
de
** 5* **
Temperatura
[cSt]
de Ponto de 50 49 65 >55
o
Fulgor [ C]
Adaptado de Aydin & Murugan (2012); Sharma & Murugan (2015); Banar et al. (2012) e Ucar(2005)
o
* : 20 C
 o
** : 40 C
o
*** : 50 C

Planta de pirlise

As principais partes do sistema so:

1. O reator, propriamente dito, constitudo pelo plenum, a regio do leito e a regio do
freeboard. Acima do plenum situa-se a placa de distribuio de ar;
2. O sistema de alimentao de combustvel tipo rosca-sem-fim com silo de alimentao
e dosador de biomassa;
3. O sistema de distribuio de ar constitudo por ventilador radial CR-8, medidor de
vazo tipo placa de orifcio, tubulaes e acessrios e o distribuidor tipo de bicos ou
borbulhadores;
4. O sistema de limpeza para a coleta do particulado slido elutriado do reator, neste
caso, duas baterias de ciclones. Na primeira bateria encontra-se uma vlvula de
amostragem que permitiu a coleta contnua dos finos de carvo;
5. Esteira para o transporte da biomassa at o sistema silo-dosador;
6. Queimador para os gases produzidos no processo;
7. Separador dos lquidos da pirlise
O reator de leito fluidizado foi construdo em ao carbono com chapas de 3,17 mm e
dimetro exterior de 577 mm, revestido internamente de isolamento trmico refratrio
at uma altura correspondente altura do freeboard, sendo neste caso de
aproximadamente 3900 mm. O dimetro interior do reator de 417 mm e a espessura do
concreto refratrio de 80 mm.
O ar foi fornecido por um ventilador radial modelo CR-8 pela base da placa de
distribuio visando-se garantir a sua distribuio uniforme na seco do leito. A placa
de distribuio de ar, do tipo de bicos de ar, foi projetada para evitar os possveis
entupimentos que ocorrem quando se utilizam placas perfuradas, alm de ter outras
vantagens. Seu dimetro exterior, considerando a flange, de 630 mm. O sistema est
composto de 69 bicos de ar de 12 mm de dimetro interno situados triangularmente em
toda a seco transversal da placa. A placa tem uma espessura de 9,52 mm. A altura dos
bicos de 111 mm e a altura at os orifcios de sada de cada bico de 103 mm. Cada
bico de ar tem 4 orifcios de sada do ar de 4 mm de dimetro situados a 45.
Nesta regio foi acoplado tambm o alimentador de combustvel do tipo rosca
sem-fim, de passo constante e 280 mm de dimetro, o qual funciona como injetor da
biomassa para o interior do reator, acoplado ao conjunto motor eltrico-redutor e,
completando o sistema com o reservatrio de combustvel sendo alimentado (silo). O
ponto de injeo de combustvel ao leito est situado no prprio volume do leito a 70
mm a partir dos orifcios dos bicos, de maneira que para qualquer altura do leito
ensaiada a injeo feita dentro do leito fluidizado de inertes;
Acima da seo do leito est localizada a regio do freeboard, definida como
regio compreendida desde a superfcie do leito fluidizado at uma altura onde a
porosidade da suspenso gs-slido alcana valores em torno de 1. A regio do
freeboard definida tambm como sendo a distncia (altura axial) at onde chegam as
partculas que so jogadas desde a superfcie do leito, por arraste (partculas com
velocidade terminal maior que a velocidade superficial do gs), ou devido s exploses
que ocorrem na superfcie do leito (regime de bolhas), fixando assim, a altura mnima
que deve ter o
reator para evitar a extrao do seu interior das partculas que o compem
(TDHTransport Disengaging Height);

Exemplo Simulao
 Wilcox home ChE design home Profession General Properties Equipment Separation
Aspen + HYSYS & UniSim Costs Safety Case studies Excel MATLAB Experiment Design

Simulation of a fluidized bed reactor

See Chapter 17 in Perry's, the Fluidization chapter in Kirk-Othmer, and Fluidization,
Solids Handling, and Processing.
The problem with fluidized bed reactors is that they do not correspond to any of the
easily-modeled ideal reactors. While most of the gas flows upward through the liquid-like
suspended particles, some passes through in bubbles with scant contact with any catalyst
particles. In addition, there is generally some circulation and turbulent back-mixing.
Since process simulators are not set up to model this, one must use one of the approximate
methods indicated below. You can model a fluidized-bed reactor as a:
Plug flow reactor with a non-reacting bypass stream to account for bubbles and
circulation. (If the overall reactor conversion efficiency is known, determine the
required volume for a plug flow reactor and divide by this efficiency.) A step-by-step
example is given below for HYSYS & UniSim, with other simulators such as Aspen
Plus being very similar. Use the Plug Flow Reactor unit. Usually assume the inlet and
outlet T are the same, i.e. isothermal conditions. This is a good approximation because
the volumetric heat capacity of the circulating particles is so much larger than that of
the gas, and because of the very high heat transfer coefficient to heating or cooling
surfaces. Set Design Parameters Delta P to User Specified (not 0) and Cooling Direct
Q Value, enter temperatures in Worksheet Conditions. Vary T, P and Rating Total
Volume until you get the best performance, as indicated in Performance Plots for T
and Compositions. Record the calculated Qr (<0 for exothermic reaction) for use later
to calculate the required flow of coolant, and the heat exchange area inside the reactor.
The outlet pressure must be less than the inlet pressure. The pressure drop is
approximately the weight of catalyst per cross sectional area. In a real reactor, the
inlet gas temperature will be different from the outlet temperature, but it will be
rapidly heated to the outlet T by the circulating particles. One must add a fictitious
heater to bring the feed stream up to the reactor T just prior to the fictitious split off of
the bypass stream, which recombines with the reactor effluent. Record the Q fh (>0 for
heating of the feed) in order to calculate the heat exchange duty inside the reactor (Q r
+ Qfh). The fictitious heat exchanger, plug flow reactor, and bypass stream constitute
the actual reactor.
Series of stirred-tank reactors (CSTRs), e.g. fluidized-bed catalytic cracker (FCC)
Series of parallel plug flow reactors and stirred tank reactors (see Simulation of a
fluidized-bed steam reformer). By emulsion phase in this and other papers on
fluidized-bed reactors is meant the portions containing large amounts of suspended
particles; these portions behave as a liquid.
Computational fluid mechanics: Detailed numerical computations can be carried out
for fluid mechanics, particle motion, reaction kinetics, heat and mass transport, etc.
While research papers have been published illustrating this, and while companies are
no doubt pursuing it, thus far it remains beyond ready use by students.
 Example: Production of maleic anhydride by partial oxidation
of n-butane using air with a vanadium phosphate catalyst.
Selected references for the ALMA process:
1. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, Fluidized bed oxidation of n-butane: a new
commercial process for maleic anhydride, in New Developments in Selective Oxidation,
edited by G. Centi and F. Trifir (Elsevier, Amsterdam 1990) pp 537 - 552.
2. S.C. Arnold, G.D. Sucium, L. Verde, A. Neri, Use fluid bed reactor for maleic anhydride
from butane, Hydrocarbon Processing (September 1985) 123-126.
3. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, Fluidized bed oxidation of n-butane: a new
commercial process for maleic anhydride, Chimica & Industria (Milano) 72 (1990) 604-
609.

The advantages of a fluidized-bed reactor over a packed bed are claimed to be the following:
1. Avoids hot spots. (Fluidized beds are nearly isothermal because the heat capacity of the
solid catalyst particles far exceeds that of the gas, and because the solids circulate.)
2. Enables use of separate feed streams for n-butane and air, so that one can operate overall
within the combustible range. (Again, this is because the high heat capacity of the gas
particles would prevent a flame from propagating, i.e. deflagration. In addition, the heat
transfer coefficient to the cooled wall or tubes is extremely high.) This reduces the air
requirement, the compressor size and power, the reactor size, and the size of the
downstream separation equipment, and permits use of an incinerator for the waste gas with
production of valuable steam.
3. Cost is much lower than for tubular reactors cooled by a molten salt.
4. The size can be much larger. From reference 2, The maximum capacity with a single
reactor vessel is 20-25,000 metric tons per year. Such a reactor vessel has over 25,000
tubes which must be filled with precision each time a new catalyst charge is loaded.
5. Easy to load and unload.
6. Can generate valuable steam while cooling the reactor.

Reference 1 above indicates that the catalyst particles used in the ALMA fluidized bed are type
A (Geldart classification), and are very nearly spherical. We assume that these particles are
mostly silicon oxide (for abrasion resistance), incorporating or coated with vanadium phosphate.
We first determine the approximate operating parameters of a fluidized-bed reactor for maleic
anhydride, using the material, particularly the figures, in Kirk-Othmers section on fluidization.
1. Determine a reasonable density for the catalyst particles, in kg/m 3. Determine a reasonable
particle size, in mm, using Figure 4 of K-O.
2. Determine a reasonable void fraction () from Figures 7 and 10 with turbulent flow.
3. Determine a reasonable range for the superficial gas velocity U (velocity as if there were no
particles present, i.e. the volumetric flow rate of the gas divided by the cross-sectional area),
in m/s. (Use Figures 8b and 10, for example.)
4. From Figure 11a, find a reasonable heat transfer coefficient at 200 kPa between the bed and
the wall or immersed tubes, in w/m2.K.
5. Find a reasonable value for the Transport Disengaging Height (TDH) and the reactor
diameter, from Figure 17.
6. Determine a reasonable density for the catalyst particles, in kg/m 3. Determine a reasonable
particle size, in mm, using Figure 4 of K-O.
7. Determine a reasonable void fraction () be, from Figures 7 and 10 with turbulent flow.
8. Determine a reasonable range for the superficial gas velocity U (velocity as if there were no
particles present, i.e. the volumetric flow rate of the gas divided by the cross-sectional area),
in m/s. (Use Figures 8b and 10, for example.)
9. From Figure 11a, find a reasonable heat transfer coefficient at 200 kPa between the bed and
the wall or immersed tubes, in w/m2.K.
10. Find a reasonable value for the Transport Disengaging Height (TDH) and the reactor
diameter, from Figure 17.

Following is approximately what a suitable PFD should be in HYSYS & UniSim, without the
white rectangle, which represents the actual reactor.

Actual reactor
The butane and the air are to be fed separately into the reactor, which can be considered
isothermal. You will simulate it by a plug-flow reactor with 10% bypass to account for back-
mixing and bubbling. You will use several fictitious units to simulate the actual reactor. Carry
out the following steps:
1. In the Basis Environment enter the components for air and n-butane, and select a suitable
thermodynamics package.
2. Find a source for reaction kinetics, e.g. G. Centi, G. Fornasari and F. Trifir, n-Butane
Oxidation to Maleic Anhydride on Vanadium-Phosphorus Oxides: Kinetic Analysis with a
Tubular Flow Stacked-Pellet Reactor, Ind. Eng. Chem. Prod. Res. Dev. 24 (1985) 32-37.
From this, determine the kinetics constants suitable for use in the software. Note that
HYSYS & UniSim assume that the reactions all take place in the gas phase, even though in
this case they all occur on the surface of the catalyst particles (i.e., heterogeneous catalysis).
Thus the kinetics expressions (actually the pre-exponential A values in the numerators)
depend on the void fraction , particle size and porosity. Enter appropriate constants into
the Basis.
3. Create a second basis for water with either the ASME steam or NBS steam package.
4. Go to the Simulation Environment. Set the n-butane flow rate to correspond to that required
for the desired maleic anhydride production rate assuming a reasonable overall yield for the
plant. Assume room T and 1.5 atm.
5. Change the air flow rate such that if the butane and air streams were mixed there would be
4% butane in the mixed gas. (See the references above.)
6. Insert a pump for the butane and a compressor for the air. Specify the outlet pressure only
for the pump, from 200 to 500 kPa.
7. Insert a Set unit and make the compressor outlet pressure equal to the butane pump outlet
pressure. In this way you can change the pressure to the reactor without having to change
the outlet pressures for both compressor and pump.
8. Add a heat exchanger for the butane to increase its temperature as high as possible using
high pressure steam. (Follow applicable heuristics.) Print a plot of temperature (Y) versus
heat flow (X). There should be at least 20 points for the butane (tube) side.
9. Add a heat exchanger for the air using high pressure steam. Use a Set unit to make the exit
temperature equal to that for the butane heat exchanger. Print out a plot of temperature
versus heat flow.
10. Add a fictitious mixer to combine the butane and air streams. (These would be fed
separately into the real reactor, as described in the ALMA references above.)
11. Add a fictitious heater (not a heat exchanger). For now, leave its exit temperature blank.
(Later it will be set equal to the reactor exit temperature, since the reactor is assumed
isothermal. In the actual reactor, the feed streams are rapidly heated by the circulating
catalyst particles.)
12. Add a fictitious splitter, with 10% of the stream going to the bypass.
13. Insert a plug-flow reactor with the following specifications:
a. Design Parameters page. From the Kirk-Othmer fluidization section, the Delta P in a
fluidized bed is approximately the weight of the catalyst divided by the cross-sectional
area, or catalystgh. Use your value for the catalyst density and assume a reasonable
value for bed height h. For Duty Parameters, click Cooling and Direct Q Value. (You
want HYSYS/UniSim to calculate the duty so that you can estimate how much steam
will be produced by the reactor. Since youre assuming isothermal conditions, you
dont want to calculate heat transfer for this fictitious reactor.)
b. Design Heat Transfer. Direct Q Value. Name the Energy Stream whatever you want;
youll be generating steam from boiler feed water in the real reactor.
c. Rating. Set 1 tube, as the water-steam will be inside the tubes while the catalyst and
process gas will be on the shell side. Guess a Volume. The Length and Void Fraction
should be the values used in 13.a above.
d. Set the fictitious heater temperature equal to the reactor effluent temperature.
e. On the reactor Worksheet page, guess an effluent temperature. If the green run icon is
depressed, the reactor should converge.
f. Performance Compositions Plot. Select butane, MA and carbon dioxide as the
components. Change the Component Basis to Molar Flow. From the plot, estimate the
yield of MA. Play around with T, P, volume, length until you get a yield greater than
50% (based on the butane feed stream, since in actuality all of this enters the reactor ---
the bypass is fictional).
g. If necessary, redo step a (reactor pressure drop).
14. Check the superficial gas velocity at the entrance and exit of the reactor, using streams 8
and 12 to get the actual volumetric flow rate of the gas. (Why are these significantly
different?) Make certain these are within the range you found above. If not adjust or the
reactor cross-sectional area until all is okay.
15. Calculate the amount of steam produced by the reactor. First subtract the duty of the
fictitious heater from the reactor duty --- this gives the actual duty of the actual reactor.
Then divide this by the latent heat of evaporation of the steam to be produced (difference
between specific enthalpy of saturated vapor and liquid at the chosen pressure).
16. Estimate the heat transfer area required for the real reactor. Estimate the overall U from the
h found in L-14 for the bed side and from heuristics for the boiling water side.
17. From the area in 17, assume a tube diameter and calculate how many vertical tubes would
have to be inserted in the bed to cool it by generating steam.
18. From Kirk-Othmer, pick a reasonable value for the Transport Disengaging Height.
19. Determine the overall volume of the reactor by adding the volume used in your reactor
calculations, the volume occupied by the steam tubes, and the volume occupied by the
Transport Disengaging Height.
20. Make certain the diameter and height conform to the applicable heuristic for a vessel. If
not, make the appropriate changes in your design.
21. Later, in CAPCOST, cost the reactor both as a vessel (by volume) and heat exchanger (by
heat exchange area), just as for a packed bed reactor with heat transfer.

Created June 21, 2007; last modified December 10, 2009. Please submit all questions,
comments and suggestions to W.R. Wilcox

Disclaimer: The material on these pages is intended for instructional purposes by Clarkson
University students only. Neither Clarkson University nor Professor Wilcox is responsible for
problems caused by using this information.

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