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Fluidized Bed Reactor

Fluidized Bed Reactor

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Table of content :
Introduction

to Fluidized Bed Reactor.


Description and Flow Regimes.
Advantages and disadvantages.
Industrial Current Applications.
Working of (FBR) at molecular level.
Designing of (FBR).

Judging a Person Does not


define who they were ..
Actually !
It defines who you are .

What Is Fluidization .
The Operation by which Fine
Solids are Transformed into
Fluid-Like State, through
Contact with the Gas or
Liquid.

Some Size Reduction Processes used in

Attrition
Compression
Impact
Shear

Why is size Reduction process important in (FBR)?

Smaller

the size of the particles greater is its


surface area and greater will be its efficiency.
In this case smaller the size the solid catalyst
greater is the number of active sides that are
available for reactions.

How Fluidization Occurs??

When the flow of gas is introduced from the


bottom of the reactor.
The gas exerts drag force on the solid particles.
The solid exerts gravitational force due to its
natural weight.
A time comes when the drag force (Fd) becomes
equal to the gravitational force (Fg).
And the Bed of solid particles become suspended
the process is known as fluidization.

A simplified every-day-life example of a gas-solid


fluidized bed would be a hot-air popcorn popper.
Because of the intense mixing of the particles, a
uniform temperature of the kernels throughout the
chamber is maintained, minimizing the amount of
burnt popcorn.
After popping, the larger popcorn particles
encounter increased aerodynamic drag because of
there low density which pushes them out of the
chamber and into a bowl.

Flow Regimes Observed in (FBR):

Fixed

Bed Condition.
Fluidized Bed Condition.
Aggregative Bubbling.
Slugging Process.
Pneumatic Conveying.

Fixed Bed Operation:

When the drag force exerted by the


fluid on the solid particles is less then
the gravitational force exerted by the
solid particles in the downward
direction the fluid passes through void
and this is known as fixed bed
operation

Fluidized Operation
A time comes when the
drag force exerted by the
fluid become equal to the
gravitational force (due to
weight of particles) the
condition is known as
fluidization.

Aggregative bubbling:

On further increasing the


gas velocity bubbles of
gases
are
formed
a
turbulent mixing starts of
fluid and catalyst.

Slugging Operation

As the superficial velocity


of air is further increased
slugs are formed and the
gas phases escapes
through the channels

Further
increasing
the
fluidization velocity pneumatic
transport starts and it is used
only for transportation not for
fluidization
reactions
other
wise catalyst will come out the
reactor tube.

Fluidized bed reactor

(FBR) is a type of reactor


that can be used to carry
out a variety of multiphase
chemical reactions. In this
type of reactor, a fluid (gas
or liquid) is passed
through a granular solid
material (usually a catalyst
possibly shaped as tiny
spheres) at high enough
velocity to suspend the
solid.

larger processing
capacity then
other type of
reactors

gives a larger
production

Easier in catalyst Replacement:

One

of the advantages of fluidized bed reactor is


that the catalyst can easily be replaced.
And the exhausted Catalyst can be regenerated.

Due

to the intrinsic fluid-like behavior of the solid


material.
fluidized beds do not experience poor mixing as
in packed beds.
The complete mixing allows for a uniform product
that can often be hard to achieve in other reactor
designs.

Many chemical reactions produce or require the


addition of heat.
Local hot or cold spots within the reaction bed,
often a problem in packed beds, are avoided in a
fluidized situation such as a FBR.
In other reactor types, these local temperature
differences, especially hotspots, can result in
product degradation. Thus FBR are well suited to
exothermic reactions.
Researchers have also learned that the bed-tosurface heat transfer coefficients for FBR are high.

Increased Reactor Vessel Size

Because

of the expansion of the bed materials in


the reactor, a larger vessel is often required than
that for a packed bed reactor.
This larger vessel means that more must be
spent on initial startup costs.

Pumping Requirements and Pressure Drop

The

requirement for the fluid to suspend the solid


material necessitates that a higher fluid velocity
is attained in the reactor.
In order to achieve this, more pumping power is
required
Higher energy costs are needed. In addition, the
pressure drop associated with deep beds also
requires additional pumping power.

Erosion of Internal Compone


The fluid-like behavior of
the fine solid particles
within the bed eventually
results in the wear of the
reactor vessel. This can
require expensive
maintenance and upkeep
for the reaction vessel
and pipes.

Current

understanding of the actual behavior of


the materials in a fluidized bed is rather limited.
It is very difficult to predict and calculate the
complex mass and heat flows within the bed.
Due to this lack of understanding, a pilot plant
for new processes is required.
Even with pilot plants, the scale-up can be very
difficult and may not reflect what was
experienced in the pilot trial.

The high gas velocities present in this


style of reactor often result in fine
particles becoming entrained in the fluid.
These captured particles are then carried
out of the reactor with the fluid, where
they must be separated. This can be a
very difficult and expensive problem to
address depending on the design and
function of the reactor.
This may often continue to be a problem
even with other entrainment reducing
technologies.

Current Applications for Fluidized Bed Reacto

FBRs are everywhere in the Process Industries.


They find broad use in the petroleum and
petrochemical industries, as well as numerous
chemical industries.

Acetone Recovery
Aniline
Aniline from Nitrobenzene
Ethanol from Butadiene
Polyethylene
Hydrogen from Steam
Coal Gasification
Styrenes from Hydrocarbons
Cracking of Methylcyclohexane
Maleic Anhydride
Maleic Anhydride from Benzene and Butylenes
Vinyl Chloride
Vulcanization of Rubber

Here are some other applications

Fertilizers from Coal


Oil Decontamination of
Sand.
Industrial and Municipal
Waste Treatment.
Radioactive Waste
Solidification.

Kunni and Levenspeil Model


Gas

flows up in bubble.
Mass transfer takes place in and out bubble,
Reactions takes place on the active sides of the
solid catalyst.
E.g.: Any reaction A
B
Mass Transfer of the products takes place through
the bubble.
All bubble are of same sizes.
Gas void fraction is nearly equal to void fraction
at minimum fluidization velocity.
In Wakes concentration of solid is maximum.

Factors:
Mass

transfer
Bubble residence time which is a function of
superficial velocity.
Rate of Reaction.

Parameters Needed in the


Designing of Fluidized bed
Reactor:
Porosity

of the bed (Emf).


Velocity of the Bubble rising through the column.
Minimum and maximum fluidization velocity for
different cases.
Diameter of Bubbles and Various others.

. Fluidization Technology, vol. I and II.


Washington, D.C.: Hemisphere Publishing Co. in
association with McGraw-Hill I(1975), II(1976). 7.
Kunii, D.,
O. Levenspiel, Ind. Eng. Chem. Process Design
Devel., 7, 481 (1968). 8. Kunii, D., and O.
Levenspiel, Fluidization Engineering, 2nd Ed.,
(Boston: Butterworth, 1991).
Coulson and Richardson volume 2,Chp:6
Fluidization.

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