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I NTERNATIONAL J OURNAL OF C HEMICAL

R EACTOR E NGINEERING
Volume 1 2003 Presentation P1

Modelling of Fluidized Bed Reactors

Joachim Werther∗ Ernst-Ulrich Hartge†


Technical University of Hamburg-Harburg, werther@tu-harburg.de

Technical University of Hamburg-Harburg, Hartge@tu-harburg.de

ISSN 1542-6580
Copyright 2003
c by the authors.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of the publisher, bepress, which has been given
certain exclusive rights by the author.
Modelling of Fluidized Bed Reactors
Joachim Werther and Ernst-Ulrich Hartge

Abstract
The fluidized bed reactor has a lot of advantages: excellent gas-solid con-
tacting, no hot spots even with highly exothermal reactions, good gas-to-particle
and bed-to-wall heat transfer and the ease of solids handling which is particularly
important if the catalyst is quickly ageing. However, the list of disadvantages is
as long: broad residence time distribution of the gas due to dispersion and gas-
bypass in the form of bubbles, broad residence time distribution of solids due to
intense mixing, erosion of bed internals and the attrition of the catalyst particles.
A particular disadvantage of the fluidized bed reactor is its difficult scale-up. The
historical experience with the FCC process is that in the early 40’s of the last cen-
tury this process was successfully scaled up from a 5 cm dia. pilot-scale unit to a
4.5 m dia. bed in the production unit. On the other hand, around 1950 the scale up
of the Fischer-Tropsch synthesis in the fluidized bed failed completely. Modern
process design should be able to avoid such disasters by making use of modeling
and simulation tools. However, a modeling tool which is really helpful in planning
and designing of an industrial fluidized bed reactor has to fulfill a lot of require-
ments. It should be able to describe the influence of the several changes which
are typical for the scale-up process, for example enlargement of bed diameter, bed
height and fluidizing velocity, changes of gas distributor design, introduction of
in-bed heat exchanger tubes and baffles. In the present work a modelling approach
is presented which is able to handle the most important aspects of industrial flu-
idized bed reactors. A particular focus is to describe the relationship between
catalyst attrition, solids recovery in the reactor system and chemical performance
of the fluidized bed reactor. The competing influences of attrition of the catalyst
particles and efficiency of the solids recovery lead to the establishment of a cata-
lyst particle size distribution (PSD) in the bed inventory which in turn influences
via the hydrodynamic characteristics of the fluidized bed the performance of the
chemical reactor. The usefulness of this approach is illustrated with model cal-
culations for a fictituous first order reaction where the fluidized bed is equipped
with different solids recovery systems including one single stage cyclone, several
cyclones in parallel, two- and three-stage cyclone systems, respectively. Model
calculations illustrate the significance of a high efficiency of the solids recovery
in order to keep the fines in the system which is decisive for a high performance
of the reactor. The calculations reveal that it may take months until a quasi steady
state of the bed particle size distribution is obtained.

KEYWORDS: fluidized beds, chemical reactors, modelling


Werther and Hartge: Modelling of Fluidized Bed Reactors 1

Modelling of
Industrial Fluidized Bed Reactors

Joachim Werther and Ernst-Ulrich Hartge


Technical University Hamburg-Harburg,
Hamburg, Germany

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada 1
Published by The Berkeley Electronic Press, 2003
2 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
2

The fluid bed catalytic reactor

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http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 3

Advantages Disadvantages
3

of fluid bed reactors

• excellent gas solid • broad residence time


contacting distribution of the gas due to
dispersion and bypass in
• no hot spots even with
bubbles
highly exothermal
reactions • broad residence time
distribution of solids due to
• good gas-to-particle and
intense solids mixing
bed-to-wall heat transfer
• erosion of internals
• ease of solids handling
• attrition of catalyst particles
• scale-up not easy

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
4 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
4

Historical scale-up experience

1940-42: Fluid Catalytic Cracking (FCC)


 successful scale-up from 5 cm dia. pilot
scale bed to 4.5 m dia. bed in the
production unit

around 1950: Fischer-Tropsch Synthesis in the


fluidized bed
 good results on bench and pilot
scales, technical plant reached only
1,500-2,000 b/d instead of expected
7,000 b/d
Technische Universität Hamburg-Harburg
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 5
5

Fluidized bed reactor modelling and simulation tools

are needed for


- interpretation of data obtained in existing plants
(including lab-scale and pilot plants)
- process scale-up on basis of lab-scale data
- performance optimization for existing plants
- prediction of effects of changes (e.g. change of the
catalyst) in existing plants

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
6 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
6

Bild

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Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 7
7

Bild

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
8 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
8

Modelling industrial fluid bed reactors - requirements

The model must consider


- the large dimensions of industrial fluid bed reactors
(for catalytic bubbling fluidized bed reactors: bed
diameter 3-8 m, bed height 1-5 m)
- design details:
gas distributor, in-bed heat exchanger tubes,
internals (baffles, screens), solids recovery
- the bed particle size distribution which develops
over time under the combined influences of attrition
and efficiency of the solids recovery

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Werther and Hartge: Modelling of Fluidized Bed Reactors 9

Can CFD simulation be used for modelling 9

industrial fluid bed reactors?


Problems:
- complexity of the gas-solid flow limits complexity of the
reaction system which can be handled
- sufficiently accurate modelling of particle-fluid and particle-
particle interaction requires control volumes with sizes in the
cm range in order to detect the flow structures (characterized
by bubbles)
 handling of large geometries of industrial reactors
exceeds presently available computing capacities

CFD simulations are not yet sufficiently developed to be


used as a design tool for industrial fludized bed reactors

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
10 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
10

Fluidized bed reactor system modelling gaseous product

solids loss flux


cyclone
separation
freeboard (no reaction)
transport cyclone attrition
(no reaction)

fluidized bed
bubbling bed
(reaction) return line
catalyst transport
bubble attrition (no reaction)
feed

distributor region
catalyst (reaction)
discharge jet attrition

gaseous reactant
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Werther and Hartge: Modelling of Fluidized Bed Reactors 11
11

Fluidized bed reactor system modelling - tasks

1. Particle population balance for the system


2. Fluid dynamics of the bubbling fluidized bed
3. Catalyst attrition in the fluidized bed
4. Chemical conversion in the fluidized bed
5. Fluid dynamics of the cyclone separator
6. Attrition in the cyclone
7. Calculation of solids loop and chemical
conversion

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Published by The Berkeley Electronic Press, 2003
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12

Particle population balance modelling

- particle size distribution in the system is discretized


- fate of particles in the individual size classes is followed in
different parts of the system (bed, freeboard, cyclone, ...)
- attrition changes the particle‘s size,
assumption: abrasion is the relevant mechanism for attrition of
catalyst particles

• mass balance for size class i:


dmi
= − m& att ,i − m& i ,i −1 + m& i +1,i
dt Technische Universität Hamburg-Harburg
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Werther and Hartge: Modelling of Fluidized Bed Reactors 13

Particle population balance


13

- decrease of particle diameter due to attrition


mass loss due to attrition for a single particle
& att,i
m ρ s ⋅ π ⋅ d3pi
& att,i,p =
m & att,i ⋅
=m
Np,i ∆Q 3,i ⋅ m tot ⋅ 6
decrease ∆dpi of particle size within the time interval ∆t:
& att ,i,p ⋅ ∆ t
m i,p , t + ∆t = m i,p ,t − m

6 π 3 m & att ,i,p ⋅ ∆ t 


d p i, t + ∆t = 3 ⋅  d p i,t − 
π 6 ρs 

6 π 3 ρ ⋅ π ⋅ d
3
∆ t 
= 3 ⋅ & att ,i ⋅
d p i ,t − m
s p i, t
⋅ 
π 6 ∆ Q 3 ,i ⋅ m tot ⋅ 6 ρ s 
 
 m& att ,i ⋅ ∆ t 
∆ d p i = d p i,t - d p i, t + ∆t = d p i,t ⋅ 1 − 3 1 − 
 ∆ Q 3 ,i ⋅ m tot 
 Technische Universität Hamburg-Harburg
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
14 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1

Particle population balance


14

- transfer of mass between size intervals

1. the mass loss due to attrition matt ,i = m& att,i ⋅ ∆t travels


from the size class i into the smallest size class
2. particles in the class i are shrinking by ∆dpi. As a
consequences the mass
∆dpi
m i,i −1 = (m i − m att,i ) ⋅
dp,i +1 − dp i
will travel into the class i-1.

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Werther and Hartge: Modelling of Fluidized Bed Reactors 15
15

Fluid dynamics of the bubbling fluidized bed

growth / splitting of bubbles with diameter dV is described by


1
d 2ε b 3 dV
dV = − (Hilligardt & Werther, 1987)
dh 9π 3λu b
⇑ ⇑
coalescence splitting

with bubble holdup ε b = V& b ub visible bubble flow V& b = ϕ (u − umf )


ϕ ≈ 0.8

bubble rise velocity ub = V& b + 0.71⋅ϑ ⋅ g ⋅ d V

3.2 d0.33
t 0.05 ≤ dt ≤ 1m Geldart group A
ϑ= 0.5
 2.0 dt 0.1 ≤ dt ≤ 1m Geldart group B
(dt = bed diameter)
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16

Fluid dynamics of the bubbling fluidized bed

- extent of splitting is described by the mean duration of bubble


life λ,
λ = 280 umf (Hilligardt & Werther, 1987)
g
- starting size of bubbles dvo
 0.008 ε 13 porous plate
 b
h = h0 : dV0 =  V & 2 0.2
1.3 0 g  at tip of grid jets
  

- specific mass transfer area a


6ε b surface area of (spherical ) bubbles
a= =
dV bed volume

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Werther and Hartge: Modelling of Fluidized Bed Reactors 17

Effects of mean bed particle size on 17

fluid mechanics

Increasing particle size will increase umf


→mean duration of bubble life λ increases
according to λ = 280 umf/g
→frequency of splitting decreases
→splitting becomes less important, i.e. coalescence
dominates
→mean bubble size dV increases
→specific mass transfer area a decreases according
to a = 6 εb / dV

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18

Fluid dynamics in the freeboard


Since reactions in the freeboard are neglected here only the mass flux of bed
solids Gs,∞ which is finally transported into the solids recovery system needs to
be known including the corresponding PSD.
It holds n
Gs ,∞ = ∑ Gsi ,∞
i=0

with Gsi,∞ = Ki* xi, xi = mass fraction of bed inventory in the ith size interval
(mean particle size dpi)
*  u ti  kg
2.5
elutration rate constant K i∞ = 14.5 ⋅ ρ g ⋅ u exp − 5.4 , 2
 um s
(Geldart & Tasirin, 1998)
with uti = terminal velocity of particle dpi

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Werther and Hartge: Modelling of Fluidized Bed Reactors 19
19

Catalyst attrition in the fluidized bed

- attrition occurs in the bulk of the bed as a consequence of


particle-particle collisions and particle-wall impacts induced
by bubbles

→ bubble induced attrition

- in an industrial bed additional attrition will occur at/in the jets


issuing from distributor openings

→ jet induced attrition

- both mechanisms have to be separated

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Bubble induced attriton

(Werther & Reppenhagen, 1999)


20
18
16
3
14 matt,b/m b = Kb* (u-umf)

matt,b/mb, 10 1/s
-8 2 3
12 Kb* = 4.32 10 s /m

-9
10
8
6
4
2
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
excess gas velocity (u-umf), m/s

further investigations lead to


& att,bubble,i = C b ⋅ dpi ⋅ mbi ⋅ (u − umf ) 3
m Cb = material specific
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada attrition constant
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Werther and Hartge: Modelling of Fluidized Bed Reactors 21
21

Jet induced attrition

(Werther & Xi, 1993) . 15


matt,j
& att, j = K j ⋅ ρf ⋅ d2or ⋅ u3or
m
[10-9 kg/s]
10

KKj ==2.68·10-9-9s22/m22
2.68·10 s /m
j

0
0 1 2 3 4 5

ρf ⋅ d2or ⋅ u3or [(kg⋅m )/s ] 2 3

further investigations lead to


m& att , jet ,i = nor ⋅ C j ⋅ d pi ⋅ ρ f ⋅ d or2 ⋅ uor3 nor = number of jets
Cb = material specific
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada attrition constant
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22 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
22

Fluid bed reactor modeling

• in earlier models (e.g. May (1959), van Deemter


(1961), de Groot (1967), de Vries et al. (1972)):
all scale-up effects are included in a single
parameter, e.g. height of a mass transfer unit, which
is difficult to relate to individual design details
• in more recent bubble-based models (e.g. Kunii &
Levenspiel (1969), Werther et al. (1977, ... , 1992)
fluid mechanics are based on semi-empirical
correlations for bubble characteristics
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Werther and Hartge: Modelling of Fluidized Bed Reactors 23
23

Fluidized bed reactor model – general design

Fluidized bed reactor model


(considers mass balances for the species involved)

Fluid mechanics Gas/solid contact Reaction kinetics


submodel submodel submodel

(considers influences of (considers two-phase (considers the reaction


gas and solids properties, structure with bubble / network)
operating conditions, suspension mass
geometry on local flow transfer)
structure)

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Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
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Fluid bed reactor model - assumptions

• Two phases: bubble phase and suspension phase


• Geldart A, B powders, fast bubbles
• interstitial gas velocity in suspension phase approximated
by (umf / εmf)
• plug flow of gas in both phases
• bubbles are assumed to be solids-free, may coalesce and
split
• no change in volumetric gas flow due to reaction
• sorption effects neglected
• mass transfer between phases described by the Sit and
Grace correlation for 3 D freely bubbling bed
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Werther and Hartge: Modelling of Fluidized Bed Reactors 25
25

Fluid bed reactor model – mass balances


for single first order chemical reaction (km = rate constant)

bubble phase:
∂Cb ∂Cb
εb = - (u - umf (1- εb )) - kGa (Cb - Cd )
∂t ∂h

accumulation convection interphase mass transfer

suspension phase
∂Cd ∂Cd
(1− εb ) (εmf + (1− εmf )εp ) = - umf (1− εb ) + kGa (Cb − Cd ) + (1− εb )(1- εmf ) ρskmCd
∂t ∂h
reaction

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Fluid dynamics of cyclone separation

- no detailed flow modelling


- separation process modelled according to Muschelknautz
(VDI-Heat-Atlas, 1997): gas-solid separation is divided into a
series of two detail processes
• spontaneous separation of the surplus solids
mass which exceeds the „critical load“ at the
cyclone inlet
• subsequent „inner separation“ of remaining critical
mass inside the vortex
- modification of the standard design procedure for the present
work with regard to particle population modeling (adaption of
PSD for inner separation)

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Werther and Hartge: Modelling of Fluidized Bed Reactors 27
27

Cyclone induced attrition


(Werther & Reppenhagen, 2000) rc, 10-6 kg/kg
Kc, 10-8 s2/m2
97-A(fresh): 30
85-A(e-cat): 18
97-G(fresh): 12
100
97-A(e-cat): 6

10 rc = K c ⋅ uc,2 in ⋅ µc−0,5
m& att,c = m
& c,in ⋅ rc

3
further investigations lead to 50 100 u 2c,in ⋅ µc−0,5 [m 2
s2 ] 1000
u 2c,in
& att ,c = C c ⋅ dpci ⋅ m
m & c ,in,i ⋅ Cj = material specific attrition constant
,i
µc
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mass flow intoI cyclone
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geometry: dt, distributor, baffles, cyclone design


fresh catalyst: PSD, total mass Calculation of
operating parameters: u, ρf, ν, D
the solids
fluidized bed: fluid dynamics, attrition, conversion
loop
freeboard: entrainment flux, PSD at cyclone inlet

cyclone: attrition, separation

standpipe: plug flow

recalculation of bed inventory

refill of catalyst no
required?

yes
add fresh catalyst Technische Universität Hamburg-Harburg
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Werther and Hartge: Modelling of Fluidized Bed Reactors 29
29

Definition of the test system


• reaction: first order with km = 0.0067 m³ / (kg s)

• gas: 1 bar, 500 °C, ηf and ρf of air, D = 10-5 m² / s, u = 0.45 m / s

• catalyst: FCC type, Geldart group A 1.0


apparent density 1500kg/m3

cumulative mass fractionQ3, -


Cb = 0.4E-3 s2/m4 0.8
Cj = 9.5E-6 s2/m3
Cc = 1.2E-3 s2/m3 0.6
Sauter diameter dps = 46 µm
0.4
fines content: 23 % < 44 µm
0.2
• reactor diameter 3.5 m,
catalyst inventory 14,000 kg 0.0
0 50 100 150 200 250 300 350
• operation: elutriated catalyst will be particle size d p, µm
replaced when riser pressure drop
deviates more
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Test case A: one single standard cyclone

(∆pc = 1600 Pa, uc,in = 17.5 m/s)

15000 1.0

qumulative mass distribution Q3, -


0.8
14500
catalyst inventory, kg

0.6
14000
t=0 bed material
0.4

13500 t = 600 h
0.2

13000 0.0
0 100 200 300 400 500 600 50 100 150 200 250 300 350 400
time, h particle size d, µm

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Werther and Hartge: Modelling of Fluidized Bed Reactors 31
31

Test case A: one single standard cyclone

(∆pc = 1600 Pa, uc,in = 17.5 m/s)

100

0.01
80
bed

Sauter diameter, µm
mass flow, kg/s

1E-3
60
loss flux
1E-4 40 into cyclone
bubble attrition
cyclone attrition
1E-5 20
grid jet attrition
1E-6 0
0 100 200 300 400 500 600 0 100 200 300 400 500 600
time, h time, h

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Test case A: one single standard cyclone

(∆pc = 1600 Pa, uc,in = 17.5 m/s)

0.09 150

-1
specific mass transfer area, a, m
0.08
0.07
t = 600 h t=0
100
bubble size dv, m

0.06
0.05
0.04
0.03 50
0.02 t=0
t = 600 h
0.01
0.00 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0
height h, m height h, m

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Werther and Hartge: Modelling of Fluidized Bed Reactors 33
33

Test case A: one single standard cyclone

(∆pc = 1600 Pa, uc,in = 17.5 m/s)

1.0 1.0
0.9 X, t = 0
0.9 0.8
0.7

Cb/C0, Cd/C0, X
0.8 Cb/C0, t = 600 h
conversion X, -

0.6
X, t = 600 h
0.7 0.5
0.4
0.6 0.3
0.2 Cb/C0, t = 0
0.5 Cd/C0, t = 0
0.1 C d/C0, t = 600 h
0.4 0.0
0 100 200 300 400 500 600 0.0 0.5 1.0 1.5 2.0 2.5 3.0

time, h height h, m

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Test case B: Increase of interphase mass transfer 34

by screens

(∆pc = 1600 Pa, uc,in = 17.5 m/s)


Hscreen = 1m; 2m, screen opening = 0.03 cm
0.09 1.0
0.08 t = 600 h without screens 0.9
t=0 t = 600 h with screens
0.07 0.8
0.7
bubble size dv, m

0.06

conversion X, -
0.6
0.05
0.5
0.04
0.4 t = 600 h without screens
0.03
t = 600 h with screens 0.3
0.02 0.2
0.01 t=0 0.1
0.00 0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0
height h, m height h, m

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 35
35

Effect of screens (Bauer & Werther)

reaction:
maleic anhydride from
C4-fraction of naphta
cracker (Mitsubishi
process)

dt = 0.45 m
u= 0.6 m/s
umf = 0.016 m/s
screen opening 0.04m

X conversion; YMA maleic anhydride yield

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
36 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
36

Test case C: One single high efficiency cyclone

(∆pc = 5000 Pa, uc,in = 32 m/s)

0.08
standard cyclone
80
0.07 standard cyclone, t = 600 h
high efficiency cyclone
Sauter diameter, µm

0.06
60

bubble size dv, m


0.05
high efficiency cyclone, t = 600 h
0.04
40
0.03

20 0.02
0.01 t=0
0 0.00
0 100 200 300 400 500 600 0.0 0.5 1.0 1.5 2.0 2.5 3.0
time, h height h, m

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 37
37

Test case C: One single high efficiency cyclone

(∆pc = 5000 Pa, uc,in = 32 m/s)

1.0
0.9 high efficiency cyclone, 0.01
t=0 loss standard cyc.

cyclone attrition rate, kg/s


0.8 t = 600 h
0.7 1E-3
conversion X, -

loss rate, kg/s


0.6
loss high eff. cyc.
0.5
standard cyclone, 1E-4
0.4 attrition high eff. cyc
t = 600 h attrition standard cyc.
0.3
1E-5
0.2
0.1
0.0 1E-6
0.0 0.5 1.0 1.5 2.0 2.5 3.0 0 100 200 300 400 500 600

height h, m time, h

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
38 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
38

Test case D: 5 cyclones in parallel

(∆pc = 1660 Pa, uc,in = 18 m/s)

100 0.08
90 standard cyclone 0.07
t = 600 h, standard cyclone
80
0.06
Sauter diameter, µm

70

bubble size dv, m


5 cyclones 0.05 t = 600 h, 5 cyclones
60
50 0.04
40 0.03
30
0.02 t=0
20
10 0.01

0 0.00
0 100 200 300 400 500 600 0.0 0.5 1.0 1.5 2.0 2.5 3.0
time, h height h, m

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 39
39

Test case D: 5 cyclones in parallel

(∆pc = 1660 Pa, uc,in = 18 m/s)

1.0
0.9
0.8 t = 600 h, 5 cyclones 0.01
0.7
t=0
standard cyclone
conversion X, -

loss rate, kg/s


0.6
1E-3
0.5
0.4
t = 600 h, standard cyclone
0.3 1E-4 5 cyclones
0.2
0.1
0.0 1E-5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 0 100 200 300 400 500 600
height h, m time, h

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
40 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
40

Test case F: three-stage cyclone separation

first stage: ∆pc = 1600 Pa, uc,in = 17.5 m/s


second stage: ∆pc = 3800 Pa, uc,in = 25 m/s
third stage: ∆pc = 3800 Pa, uc,in = 25 m/s
100 0.08

standard 0.07 t = 600 h, standard


80
0.06
Sauter diameter, µm

2-stage

bubble size dv, m


0.05
60
3-stage 0.04 t = 600 h, 2-stage
40 0.03
t = 600 h, 3-stage
0.02
20
0.01 t=0
0 0.00
0 100 200 300 400 500 600 0.0 0.5 1.0 1.5 2.0 2.5 3.0
time, h height h, m

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 41
41

Test case F: three-stage cyclone separation

first stage: ∆pc = 1600 Pa, uc,in = 17.5 m/s


second stage: ∆pc = 3800 Pa, uc,in = 25 m/s
third stage: ∆pc = 3800 Pa, uc,in = 25 m/s
1.0
0.9
0.8 0.01
t=0 t = 600 h, 2-stage standard
0.7
conversion X, -

0.6

loss, kg/s
0.5 1E-3
0.4 t = 600 h, standard 2-stage
0.3 3-stage
1E-4
0.2
t = 600 h, 3-stage
0.1
0.0 1E-5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 0 100 200 300 400 500 600
height h, m time, h

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
42 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
42

Test case H: long term run (3-stage separation)

first stage: ∆pc = 1600 Pa, uc,in = 17.5 m/s


second stage: ∆pc = 3800 Pa, uc,in = 25 m/s
third stage: ∆pc = 3800 Pa, uc,in = 25 m/s
80
1.0

60 0.9
Sauter diameter, µm

conversion X, -
0.8
40 0.7

0.6
20
0.5

0 0.4
0 2000 4000 6000 8000 0 2000 4000 6000 8000
time, h time, h

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 43

Longterm chemical performance of different 43

reactor configurations

0.8
conversion after 1 year, -

0.6

0.4

0.2

0.0 e
d

c.

p.

p.

ed
fle

n
ar

cy

se

se
lo

iz
nd

af

tim
yc
f.

e
b
a

ef

ag

ag
tic
st

op
w.

gh

st

st
ul
m
hi

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
44 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
44

Catalyst losses with different reactor configurations


cumulated loss during 1 year, kg 8000
7000
6000
5000
4000
3000
2000
1000
0
s
rd

ed
ne
c.

p.

p.
fle

cy

se

se
da

lo

iz
af

tim
yc
an

f.

e
.b

ef

ag

ag
tic
st

op
w

gh

st

st
ul
m
hi

Technische Universität Hamburg-Harburg


Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 45
45

Influence of mean particle dia. on conversion

1.0
3 stage separation
2 stage separation
high efficiency cyclone
3 stage separation
multi-cyclone
conversion, -

0.8 with multi-cyclone

standard cyclone
0.6

50 60 70 80 90
Sauter diameter min bed, µm
Technische Universität Hamburg-Harburg
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003
46 International Journal of Chemical Reactor Engineering Vol. 1 [2003], Presentation P1
46

Influence of the fines content in the bed material


100

99
propylene conversion XA [%]

98

97

reaction:
96
propylene  acrylonitrile
95

reactor dt = 0.5 m
94
u = 0.38 m/s
93
Ref.: M. Pell (1987)
20 25 30 35 40 45
wt.-%initial
wt.-% < 44fines
µm (<
fresh catalyst
44 µm)
Technische Universität Hamburg-Harburg
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
http://www.bepress.com/ijcre/vol1/P1
Werther and Hartge: Modelling of Fluidized Bed Reactors 47
47

Summary and Conclusions

- Modelling of industrial fluidized bed reactors requires in


cases where
- fine particles of Geldart A type are involved and
- mass transfer between bubbles and suspension
phase is limiting
a careful consideration of the influence of the bed particle
size distribution on the conversion.
- The bed particle size distribution develops under the
combined influences of attrition and solids recovery.
- It may take months until an equilibrium particle size
distribution has been established.

- Fluidized bed reactor modelling which takes proper account


of these effects may help to solve practical questions.
Technische Universität Hamburg-Harburg
Verfahrenstechnik I Chemical Reaction Engineering IX, June 29 – July 4, 2003, Quebec City, Canada
Published by The Berkeley Electronic Press, 2003

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