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Cold Flow Model of Dual Fluidized Bedshrestha2016
Cold Flow Model of Dual Fluidized Bedshrestha2016
art ic l e i nf o
a b s t r a c t
Article history:
Received 16 September 2014
Received in revised form
24 May 2015
Accepted 17 September 2015
Available online 10 November 2015
Gasication in dual uidized bed gasier (DFBGs) has proven itself as a promising technology. Apart from
gasication, dual uidized bed (DFB) technology has also been utilized for CO2 capture-chemical looping
combustion (CLC), calcium looping (CaL) and adsorption enhanced reforming (AER). Although pilot
plants applying these technologies are available, still need improvement to be commercially viable.
Fundamentally, the performance of the reactor depends upon the uid dynamics within the reactor. So
cold ow models (CFMs) are widely used in order to study the process fundamentals such as: pressure
drop, solid fraction and solid circulation rate, to improve the operation and tackle the problem by
troubleshooting. This paper outlines the application of scaling relationships to realize the hydrodynamic
similarity among the industrial scale plant, the laboratory scale and CFMs of dual uidized bed (DFB).
Moreover, the occurring uidization regimes and the stable operating regions in the cold model of DFB
have been explored by reviewing the existing data in the literature. The pressure proles, solid fraction
proles and the solid circulation rate obtained from the existing studies are presented and discussed
together with the effect of the parameters inuencing their behavior.
& 2015 Elsevier Ltd. All rights reserved.
Keywords:
Dual uidized bed gasiers
Dual uidized bed
Calcium looping combustion
Chemical looping combustion
Adsorption enhanced reforming
Cold ow models
Contents
1.
2.
3.
4.
5.
6.
7.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application of scaling laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluidization regimes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid fraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid circulation rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.
Effect of gas velocity in riser, inventory and particle property . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.
Effect of air staging in riser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.
Effect of gas velocity in loop-seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.
Effect of gas velocity in BFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction
The energy demand has been growing gradually due to the
increase of population and the rapid development of the advanced
technology. In response, contemporary world is looking for a
n
sustainable alternative resources to fulll the energy demandsupply cycle [1,2]. A few decades ago, the world was solely
dependent on fossil fuels. However, rising problems like global
warming and dearth of the natural energy resources have aroused
scientists attention to realize the incorporation of some accrual
http://dx.doi.org/10.1016/j.rser.2015.09.034
1364-0321/& 2015 Elsevier Ltd. All rights reserved.
1529
1531
1537
1538
1539
1541
1542
1543
1543
1544
1545
1545
1546
1546
1546
1530
Notations
A
Ar
Cs
Cv
D
dp
dp
De
Fl
Fr, FrD
g
G
H
h/l
Iv
Le
M
_
m
P
Q
Re
S/T
t
T
U
u*
V
V*
w
z
area (m2)
Archimedes number (dimensionless)
dimensionless solid loading (dimensionless)
volume concentration of circulating solids (dimensionless)
diameter (m)
dimensionless particle size (dimensionless)
particle diameter (m)
ratios of solid to uid densities (dimensionless)
ow number (dimensionless)
Froude number (dimensionless)
acceleration of gravity (m/s2)
solid circulation rate (kg/(m2 s))
height (m)
height/base line ratio (dimensionless)
total inventory, total particle mass load (kg)
length ratio (dimensionless)
dimensionless mass turnover (dimensionless)
mass ow, (kg/s)
pressure, (Pa)
volumetric ow rate, (m3/h)
Reynolds number (dimensionless)
ratio of secondary to total air ow (dimensionless)
time (s)
temperature (C)
velocity (m/s)
dimensionless gas velocity (dimensionless)
Volume ow rate (m3/h)
dimensionless volumetric ow rate (dimensionless)
opening width of the riser exit (m)
height of accumulated material (m)
Greek letter
P x
s;core
Subscripts
AR
b
bot
con
cyc
dc
FR
g
gas
ILS
LLS/lls
ls
mf
p
pri
t
T
s
sc
sec
r, ris
rc
th
top
tr
ULS
v
air reactor
bulk
bottom
connection
cyclone
down-comer
fuel reactor
gas
gasier
internal loop-seal
lower loop-seal
loop-seal
minimum uidization
particle
primary gas injection
terminal (applied to velocity),
total
solids
supply chamber
secondary gas injection
riser
recycle chamber
thermal
top
transport (applied to velocity)
upper loop-seal
vertical
Abbreviations
AER
AR
ASR
BFB
CaL
CFB
CFMs
CHP
CLC
DCFB
DFB
DFBG
FCC
FR
ICFB
PSD
SER
CO H2 O2CO2 H2
1531
1532
1
Table 1
Typical sets of dimensionless scaling groups [56].
[55]
Gs U g
p U g ; U t ;
Gs U g
p U g ; U t ;
Gs U g
p U g ; U t ;
[52,48]
Full set
[54,49]
Simplied set
[53,50]
Gs U g
p U g ; U t ;
Viscous-limit set
Gs
p U g ;
Gs
p U g ;
U2
FrD gDg ; p ;
g
U 2g
g U g dp
g
FrD
p g gdp dp
;D
2g
U2
or
Ug
U mf ;
FrD gDg ; g
or
Ug
U mf ;
FrD gDg
U2
p U g dp
Gs
p U g ; g D
U 2g
gD
FrD gDg ; g ; Ar
g D
m D
:
Iv U t
FrD gD; pg
2
p U g dp
Ref.
Gs
U U t p
U2
the gassolid ow in the fully developed zone of the risers. Conclusions made were based on ambient conditions with air as the
uidization medium and it was emphasized that, the scaling
parameter should be conrmed under both high temperature and
pressure conditions with different gases.
Although research have been carried out to modify the scaling
parameters as discussed above, the scaling laws shown in Table 1
Table 2
Previous studies in cold model of DFB.
Ref.
ConFig.uration: CFB/BFB
CFB: H 2.2 m, D 0.175 m
Hpri 0.175 m, Hsec 0.250 m
BFB: H 1.3 m, D 0.55 m
Connection:
Upper: loop-seal
Lower: chute
ConFig.uration: CFB/BFB
Capacity: 30 kWth
CFB: H 6 m, D 0.075 m
BFB: H 2.1 m, D 0.2 m
Connection: 2 loop-seal
Hls 0.2 m Dls 0.12 m
Karmakar and
Datta [80]
ConFig.uration: CFB/BFB
CFB: D 0.07 H 5.18
BFB: 0.2 m wide 0.2 m
depth 2.95 m high
Typeb: 1. Below the bottom of the
gasier and distributor installed on
a slat wall.
2. On the side of the gasier which
is upper than the distributor is
installed on a slat wall.
ConFig.uration: CFB/BFB
ConFig.uration: CFB/BFB
Scaling criteria
Ratioa
Gas leakage
Bronze
dp 180 m
p 8900 kg/m3
Glicksman [52]
N/A
Bronze
Glicksman [52]
N/A
Glicksman [52]
Deviation:
Rep 1
Frp 1
p/g 0.83
Re 0.95
H/dp 0.99
D/dp 0.79
N/A
N/A
N/A
N/A
Medium: air
Qr,pri 35 m3/h
N/A
N/A
N/A
N/A
N/A
N/A
dp 119 m
p 8750 kg/m3
Bronze
Range 40280 m
dp 125 m
p 8730 kg/m3
b 5370 kg/m3
Ut 0.38 m/s
1
Silica sand
dp 260 m
p 2500 kg/m3
b 130 kg/m3
Umf 0.052 m/s
Ut 1.57 m/s
Utr 3.07 m/s
Silica sand
Group: B
dp 376.1 m
Medium: air
g 1.05 kg/m3
g 19.9 10 6 Pa s
QT 450 N m3/h
U 6.25 m/s
Gs 120 kg/m2 s
Ur 2.754 m/s
Ubfb 0.0520.156 m/s (13
Umf)
Uls 0.1350.362 m/s
(1.54 Umf)
b 1220 kg/m3
Ur 3.54.25 m/s
Ubfb 00.27 m/s
1533
Operating conditions
DFBGs
Kehlenbeck et al. ConFig.uration: CFB/BFB
[46]
CFB: H 0.054 m
BFB: D 0.18 m
Standpipe: D 0.024 m
Connection:
Upper: loop-seal
Lower: chute
Kaiser et. al. [44] ConFig.uration: CFB/BFB
CFB: H 2 m, D 0.17 m
BFB: Dbot 0.25 m, Dtop 0.55 m
Connection:
Upper: loop-seal
Lower: chute
Particle properties
1534
Table 2 (continued )
Ref.
Scaling criteria
Ratioa
Gas leakage
N/A
N/A
N/A
Farrell [105]
g/p 1.08
Ar 0.92
Fl 1.14
Cs 0.22
N/A
N/A
N/A
N/A
N/A
N/A
N/A
dp 250 m
p 2466 kg/m3
b 1281 kg/m3
Umf 0.06 m/s
Ut 1.403 m/s
0.48
Medium
Compressed air
g 1.229 kg/m3
g 1.7 10 5 kg/m s
Ur 3.5/4 m/s
Ubfb 0.14 m/s
Uls,rc 00.18 m/s
Uls,sc 0.06 m/s
Uls,v 0.06 m/s
Iv 35 kg
Glass beads
T 25 C
Glicksman [52]
Mass 0.17
Particle properties
3
Nguyen et al.
[91]
Manchasing
et al. [71]
Silica sand
Range: 4080 m
dp 67 m
p 2550 kg/m3
1
Bronze
Medium: He/N2
Iv 1.12.2 kg
Ur,sec 410 Ut
Ur,pri 1.23 Ut
Ubfb 515 Umf
Uls 1.24 Umf
g 1.25 kg/m3
g 1.79 10 5 Pa s
UAR 4.25
UFR 1.21
QAR 30.3 N m3/h
QFR 10.1 N m3/h
Length 0.55
Area 0.552
Velocity 0.74
Volume ow 0.22
Solids ux 0.23
Glicksman [52]
Deviation (AR/FR)
Rep 0.50/0.52
Ar 0.36/0.43
Fr 1/1 p/g 1.39/
1.53
D/dp 1.01/0.99
N/A
dp 250 m
p 2466 kg/m3
b 1281 kg/m3
Operating conditions
dp 54 m
QLLS 1.5 N m3/h
p 8730 kg/m3
QULS 1.0 N m3/h
1
QFR,ILS 0.15 N m3/h
FeSi alloy (rounded irregular shape) Medium: air
dp 34 m
U 2.2 m/s
p 7000 kg/m3
Group A
Silica sand
Markstrm and
Lyngfelt [107]
CFB(FR)
AR: H 5 m, D 0.23
FR: H 5 m, D 0.144 m
Connection
Upper: loop-seals
Lower: bottom extraction lift and
dp 34 m
p 7000 kg/m3
g 1.188 kg/m3
g 1.82 10 5 Ns/m2
UAR 2.4 m/s
UFR 2.4 m/s
Concept: CLC
ConFig.uration: CFB (AR)/CFB (FR)
with a Circulation Riser (CR) , Carbon Stripper (CS) and 4 loop-seals
T 20 C
g 19.72 10 6 Pa s
UAR 600 (Ln/min)
0.75
CaL
Charitos et al.
[45]
Lisbona et al.
[81]
ConFig.uration: CFB(carbonator)/
BFB(calciner)
CFB: H 5.3 m, D 0.030 m
BFB D 0.049
Connection: upper double exit
loop seal and cone vale
Lower: loop-seal
N/A
Glicksman [54]
ZrO2
g 1.188 kg/m3
Glicksman [52]
dp 142/230 m
p 5700 kg/m3
g 18 10 6 Pa s
and
dp 200 m
U 5 m/s
N/A
p 2000 kg/m3
N/A
Ur 2.35/2.17/2.68/2.04 m/s
Glicksman [108]
P x
p gD
[48]
N/A
N/A
N/A
Iv 7.18/8.18/4.192/3.972
Uls 0.087/0.088/0.067/
0.09 m/s
1535
ConFig.uration: CFB(Carbonator)/
CFB(Calciner)
H 35 m D 15.95 m
ConFig.uration: CFB (carbonator)/
CFB(calciner)
CFB: H 4 m, D1 0.17 m
D2 0.16 m
Standpipe: H 1.447 m D 0.08 m
Loop-seal: H 0.3 m, D 0.177 m
dp 150 m
p 2600 kg/m3
T 20 C
g 1.188 kg/m3
g 1.82 10 6 Pa s
UAR 0.751.15 m/s
UFR 0.090.31 m/s
Uls 0.0650.097 m/s
Gs 26.062.5 kg/m2 s
Iv 9 kg
T 20 C
N/A
1536
Table 2 (continued )
Ref.
Particle properties
ConFig.uration: CFB/BFB
CFB: H 6 m, D 0.041 m
BFB: H 2.0 m, D 0.13 m
Lower loopseal, D 0.041 m
Ratioa
Gas leakage
Glicksman [54]
(Carbonator/Calciner)
Deviation (Carbonator/Calcinier)
Re 0.31/0.23
Ar 0.1/0.07
FR 2/2.7
De 2.1/3.5
D/dp 1/1
Glicksman [53]
N/A
T 20 C
Ragne 100200 m
dp 166 m
p 5170 kg/m3
g 1.18 kg/m3
Regenerator, medium Air/
CO2
g 1.26 kg/m3
Ur 2.54 m/s
Gs 1045 kg/m2 s
Iv 5.59 kg
Limestone
Range 2121180 m
dp 438 m
p 2870 kg/m3
b 1364 kg/m3
Umfg 0.15, 0.14, 0.11 m/s
Uth 2.52, 1.94, 1.02 m/s
Glicksman [52]
N/A
T 20 C
CFB
Medium air
g 1.18 kg/m3
U 5.64 m/s
Gs 1320i kg/m2 s
BFB, medium Air He
g 0.9 kg/m3
U 0.260.52 m/s
Iv 813 kg
Glicksman [54]
SER/AER
Ramirez [85]
Scaling criteria
Operating conditions
are widely accepted and used to scale and design the uidized
beds. Similarly, these scaling laws are also seemingly popular and
applied in the case of DFB. Table 2 lists several studies conducted
in the DFB, followed by their design and dimensions, particle
properties, operating conditions, scaling criteria, ratio and gas
leakage between the reactors. It can be seen that the scaling
relationships by Glicksman is popular and widely used. In Table 2,
along with the designed setups using the scaling relationships,
works with suit designs used to investigate the uidization performance in DFB are also shown, which are also equally valuable
and provide insights to the researchers. The particle and their
properties used in these two different setups are not alike, mostly
1537
bronze, glass beads, copper, ZrO2 and Fe3O4 have been used in the
scaled models whereas sand, dolomite dominates in the suit
designs. This difference arises since scaled models tend to match
the scaling parameters, and while fullling the dimensionless set,
the particles are chosen to meet the scaling ratio. For example, Lim
et al. [26] selected copper particles in his experiments. According
to the scaling relationship, Density ratio (De) in hot and cold
model should be same. As gas density of 0.3 kg/m3 is common in
an industrial gasier and sand has a density of 2500 kg/m3. Thus,
Dehot 0.00012. In order to maintain the same De for the cold
model operated at ambient temperature (with air density of
1.18 kg/m3), copper particles with the density of 8940 kg/m3 were
selected yielding Decold 0.00013. Hence Dehot EDecold. However,
in real-world it is not easy to match all the parameters in the
scaling relationships [58] and deviation is always observed. The
observed deviation in matching the dimensionless parameters
obtained from the studies reviewed in this paper is shown in
Table 2 (scaling criteria). One of the ways to minimize the deviation is to construct CFMs of similar size with hot rig and utilize the
particles with same properties [41,43]. In general, proper ratio of
reactor geometry, gas solid mixture and the operating conditions
are selected to fulll the scaling criteria.
Briey, the scaling laws are applied to achieve similar ow
behaviors in a laboratory scale cold model that is observed in the
hot plant; which is of great importance to perceive the uidization
regime encountered in the actual operating conditions.
3. Fluidization regimes
Fluidization is an operation in which ne solids are transformed into a uid like state through contact with gas or liquid
[59]. Fluidization occurs when the supplied gas or liquid exerts
sufcient force on the particles that exactly counter their weight.
Fluidization process involves the suspension of a very large
Fig. 4. Regime map (a) idealized ow regime map for gassolids transport [104] and (b) general ow regime diagram for vertical pneumatic conveying and uidized bed
systems [66].
1538
Cv
1 1 C v
8
4. Operational map
Fluidization process is inherently a complex process and its
operation is relatively complicated. DFB technology utilizes two
uidized bed simultaneously making it more difcult in its
operation. Taking these into consideration, accordingly, numerous
researches in DFB have been conducted to report the operational
stability under various operating conditions. Charitos et al. [45]
used a 10 kWth DFB system for CaL, with a riser carbonator and a
BFB regenerator to present the operational regions of the cold
model. They dened the operating behavior of the riser with
respect to the gas velocity, riser pressure drop and total solid
inventory. A region of stable operation bordering with the maximum and minimum velocity was identied. At a given total solid
inventory, slugging occurred below the minimum riser velocity,
while unstable operation was observed above the maximum
velocity resulting from the variation of the riser pressure drop and
solid looping rate with respect to different periods of time.
Recently loop-seals have been incorporated as a non-mechanical
valve and widely used in the uidized bed systems since they tend
to provide effective control of solids ow [75]. These loop-seals
build necessary pressure drop in a solid circulation loop to convey
particles from low pressure zone to high pressure zone without
undesirable inverse gas ow [76,77]. With the application of the
loop-seal to improve solid transfer, to prevent gas mixing and
obtain gas seal, the operation of DFB becomes further intricate and
needs better operational understanding. Sung et al. [78] presented
a map of possible operation condition of the lower loop seal and
riser for DFB. A boundary of stable region for a set of velocities in
the riser and loop-seal was obtained. Moreover, three unstable
regions were observed:1. Due to low velocity in the lower loop-seal, no smooth solid
circulation and sluggish motion in gasier.
2. Due to high riser velocity, low solid holdup exists in the riser.
3. Due to low riser velocity, low solid is transferred from the riser
to the cyclone.
To minimize the unstable region 1, loop-seal velocity can be
adjusted to achieve smooth solid circulation rate whereas unstable
region 2 and 3 need a proper handling of riser velocity. The total
gas velocity in the riser should be such that the solid would be
carried out from the riser to ensure the proper gassolid mixing
but cannot be so high that the solid elutriated could be accumulated in the standpipe but not recirculated, which results in the
drop of solid density in the riser. Consequently, the failure of the
system either by overloading of the loop-seal or by the uctuation
of pressure drop could occur leading to unsteady solid ow. In
addition, the loop-seal airow should also not be too high to
deplete solid from the loop seal resulting in the bypass of gas from
the BFB. Lim et al. [25] developed an operational map on a cold
model of a circulating uidized bed based on ow visualizations
using solid mass ow rate and pressure drop measurements to
differentiate between uidization regimes. A stable operating
region F where solid moved freely up and out of the riser, down
through the cyclone into the standpipe and back into the riser via
the loop-seal bounded by six unstable regions was developed as
shown in Fig. 6. Likewise, maximum operating limits for primary
air, secondary air and inventory were obtained. Furthermore, Lim
[26] presented an operational boundaries for the steady state
operation of the DFB as a function of the primary airow rate in
the CFB riser and the BFB airow rate. A stable and an unstable
operating region were identied as shown in Fig. 7. Moreover, he
determined that chute pressure drop must be sufciently high to
prevent chute airow bypass from CFB to the BFB. Likewise, BFB
airow and chute airow should also be sufciently high so that
chute becomes adequately lled with solid for stable operation.
Region F in Figs. 5 and 6 is also suggested to be a stable region, but
due to experimental limitations, it was dened as hypothetical
stable region. The operational maps discussed above hold true for
any DFB process to be utilized with the conguration used to
determine the operational map. But to improve the operation and
achieve the required performance, various designs have been put
forward (refer Table 2). The operational maps might not be
applicable to the congurations which employ double exit loopseal, cone valves, riser with wider bottom, etc., and setups
operated under different operational conditions like dissimilar
particle properties, uidization velocities, inventory, etc. Nevertheless, the results showed that it might be helpful in determining
the operational map or region of the stability in any setup
listed in Table 2 with some improvement mainly for the CFB
which is common regardless of the process DFB is operated.
Moreover operational stability was achieved when the global solid
1539
Fig. 7. Operational Map for dual uidized bed (Qsec 324 m3/h, Qls 5 m3/h,
Qch 5 m3/h) [26].
ow rate1 was steady and the total pressure drop in both the
reactors remained constant over the operating-period [79]. While
operating the DFB, after achieving the dynamic balance, it is
essential to know its hydrodynamic characteristics like pressure
drop, solid fraction and solid circulation rate and their variation
under different operational conditions.
5. Pressure prole
In an atmospheric DFB as shown in Fig. 2, two pressure balance
loops exist, Eqs. (9) and (10) [44]. Eq. (9) shows the overall pressure
balance loop of the DFB whereas Eq. (10) represents the pressure
balance loop along the cyclone, down-comer and loop-seal.
P Out;ris P Out;gas P gas P con P ris P cyc
P Out;ris P Out;gas P dc P ls
9
10
Eqs. (9) and (10) are not valid for all the congurations of DFB
listed in Table 2 and it depends upon the loop implemented for the
process. However, in DFB mostly two pressure loops exist within
the system, one representing the overall balance which includes
both reactors and the lower connection between them and the
other also representing the connection between the two reactors
at the upper section which includes CFB (combustor) pressure
drop for DFBG, AR for CLC and regenerator for CaL along with
cyclones pressure drop. Pressure balance is also used while
empirical modeling of DFB as boundary conditions [44,45,8082].
Likewise, the obtained pressure drops are used to interpret other
hydrodynamic properties such as solid holdup, inventory, etc.
[45,58,79]. Furthermore, pressure proles helps to evaluate modications done in cold model and conrm their usability [83].
Overall pressure proles observed in previous studies on DFB for
various purposes are shown in Fig. 8.,2 In the closed loop-system,
increasing the solid circulation rate in the riser pushes the solids to
the BFB, consequently increases the solid inventory in BFB, thereby
pressure drop and results in a decrease in riser pressure drop
which can also be understood from Eq. (8) [44]. Goo et al. [84]
observed pressure prole to be nearly same except in the lower
region of the riser and lower seal-pot when solid circulation rate
was varied in the range of 30.543.5 kg/m2 s by aeration rate into
the lower loop-seal (Fig. 8a). Similarly, Ramirez [85] observed
higher pressure drop across the riser, especially at the bottom
when the solid circulation ux was increased while pressure drop
across the riser declined progressively, with riser velocity
1
Global solid ow rate: solid circulation rate between the two reactors.
Not all datas has been presented and reader are urged to see the references if
needed.
2
1540
Fig. 8. (a) Pressure prole for DFBGs. (b) Pressure prole for CLC. (c) Pressure prole for CaL. (d) Pressure prole for AER/SER.
increasing (Fig. 8d3). Similar effect of riser velocity has also been
observed by Seo et al. [86] (Fig. 8a) and Charitos et al. [45].
Increase in riser velocity decreases pressure drop in the riser as
solid entrainment is increased. Similarly, increase in primary air in
the riser decreases the pressure drop in dense zone as solids are
transported to transport zone. This leads to an increase in pressure
drop in transport zone as solids get redistributed, resulting in
frictional losses from the inter-particle and particle-wall interactions [25]. Apart from the solid circulation rate and riser velocity,
other parameters like inventory, BFB freeboard absolute pressure
drop, and double exit loop-seal aeration have been found to
increase pressure drop in the riser, since the increase in all these
3
(PPref) The pressure at every section of the loop is plotted against the height
from riser distributor, with the pressure at the outlet of secondary cyclone as the
reference pressure (Pref).
1541
Fig. 9. (a) Solid fraction prole for riser in case of ASR. (b) Solid fraction prole for riser with varying riser velocity. (c) Solid fraction prole for riser with varying solid
circulation rate.
6. Solid fraction
The solid fraction is the measure of fraction of volume occupied
by the solid in a gassolid suspension and also termed as solid
holdups. In uidized bed reactors solid holdups are generally
determined with the measurement of differential pressure drop in
the reactors and using the properties of gas and solid phases in
accordance to Eq. (11) [75]. Differential pressure drop is
1542
11
s z 1
1 dP
g p dz
12
U
z
m
b Adc and Gs
Ar
t
13
1543
Fig. 11. Specic solids circulation rate design chart of conFig.uration A. Parameters:
total solid inventory (TSI) and bed mass distribution, riser velocity, air/fuel ratio. Gs,
min gives the required solid ow from mass and energy balance [47].
Fig. 12. Effect of riser velocity for varying particle size and inventory.
14
15
2
Gs entrainment 2:65P 0:87
exit region ; R 0:82
16
1544
Fig. 14. Effect of primary air for different inventory and secondary air ow rates
[25].
Fig. 15. Effect of primary air percentage and secondary air ratio to total
uidization air.
cyclone, it thus reduces the required primary airow. The secondary air is placed at some height above the distributor and
usually above the transport velocity. With two airow inlet, it is
obvious that solid circulation rate is inuenced to a certain extent.
Lim et al. [25] observed that solid circulation increases with the
increase of the primary air and the secondary air ow rates and
solid inventory of the plant in a cold model of a CFB as shown in
Fig. 14. Based on the geometry of the outlet and solids inertia, a
semi-empirical model including aerodynamic factor (d) was
developed to estimate the ratio of solid exiting the CFB riser to
solid recirculating back as shown in Eqs. (17) and (18). Moreover,
they identied primary and secondary air as key operational
variables.
w
17
m
ms d
D core
D
1 exp as;core 1
18
d
w
The coefcient a took at a value of 3668 which gives R2 a value
of 0.8327.
Although primary air and secondary air both signicantly
inuence the solid circulation rate, studies suggested uidization
air at bottom or primary level should be more effective
[42,58,79,97]. The solid mass ux per area decreases while the
ratio of secondary air in the total uidization air is increasing;
meanwhile, an increase in the bottom air ow as well as primary
air would increase the circulation rate. However, primary air ow
must be limited as high primary air may lead to gas leakage and
pressure uctuations leading to unstable operation. Fig. 15 shows
the effect of primary air percentage on left y-axis, whereas effect of
secondary air to the total uidization air ratio for different bottom
air is given on right y-axis.
7.3. Effect of gas velocity in loop-seal
Accompanied by riser gas velocity, the loop-seal in DFB plays a vital
role in governing the solid circulation rate. Moreover, solid circulation
rate is controlled by gas velocities of the riser and non-mechanical
valve [84,98,99]. The available literature data on the effect of gas
velocity on the loop-seal in DFB are presented in Fig. 16 (left-axis). Goo
et al. [84] designed and constructed a cold model of DFB gasier to
determine hydrodynamic properties. They reported that solid circulation rate could be controlled by gas velocities to the lower loop-seal
Fig. 16. Effect of gas velocity to the loo-seal for different riser velocities.
and the riser. Maximum Gs (90 kg/m2 s) was obtained at riser velocity
of 4 m/s and loop-seal aeration at 4 Umf. The amount of circulating ux
increased sharply with the increase of Uls up to 2.53 Umf to reach the
maximum capacity of the loop-seal as a function of gas velocities to the
loop-seal and the riser. Also, Gs values were correlated with dimensionless terms initially proposed by Kehlenbeck et al. [46] and Monazam et al. [99] as shown in Eq. (19).
ms D
U 2r
8:88 X 10 5
Iv U t
gD
!0:529
U ls 0:459
Ut
19
1545
The increase in solid circulation rate with the riser velocity and
loop-seal aeration increasing was also reported by Ramirez [85].
Moreover, solid circulation rate depends on the amount and the
location of the aeration supplied to the loop-seal. Yang et al. [100]
concluded that aeration location inuenced the threshold aeration
rate in loop-seal and air injection to the supply chamber was more
effective for adjustment of solid circulation rate as shown in Fig. 17.
Moreover, solid circulation rate increases with the aeration rate, total
solid inventory and uidizing gas velocity in the riser increasing. An
empirical equation was proposed to correlate solid circulating rate
with the operating parameters as presented in Eq. (20).
Gs 9:6877 U 0:575
Q 1:020
Iv0:543
sc
r
20
8. Recommendations
4
For, Nguyen et al. hydraulic diameter used to calculate the volumetric ow
rate of recycle chamber (4A/P).
5
For, Seo et al. hydraulic diameter used to calculate the volumetric ow rate of
BFB (4A/P).
1546
9. Conclusion
DFB technology is developing for processes like gasication,
CLC, CaL and AER which primarily involve to remove CO2. Generally, CFMs are employed to study the hydrodynamics which aid
toward the optimization of the industrial scale plant. Mostly, the
scaling laws consisting a set of dimensionless parameters are used
to construct the CFMs to govern the dynamic similarity between
CFMs and industrial scale plant. Moreover, the regime maps
developed aid designers in selecting the uidization regime for the
applied conditions. In DFB, the CFB riser operates in fast uidization regime whereas gasier in bubbling regime. Smooth solid
circulation rate is difcult to achieve. Fluidization velocities are
found to be the key operational variables governing the stability of
the system. To achieve the stability in the system, the loop-seal
must be sufciently uidized. Operational map can assist in the
identication of the stable and unstable regions in the system.
Pressure balance, solid fraction and solid circulation rate are the
three important hydrodynamic parameters.
Pressure balance in the DFB helps in empirical modeling,
identifying suitability and modications needed to be done in
CFMs. Increasing the solid circulation rate increases the pressure at
the bottom region of the riser and then progressively declines
along the height whereas increasing riser velocity subsequently
decreases the pressure drop. The non-mechanical valves and
connection applied are operated under higher pressure drop to
acquire better gas-seal as well as to avoid inverse gas ow. Besides,
pressure balance, solid fraction in riser is another vital hydrodynamic parameter. Solid fraction prole of the riser indicates a
dense zone followed by a core-annulus zone and an exit zone for
riser with a constricted exit. Solid fraction was found to increase
with increase of solid circulation rate whereas to decrease with the
riser velocity increasing.
Gas velocity in the riser and the loop-seal are two primary
variables inuencing the solid circulation rate. Solid circulation
rate increases while increasing the gas velocity and the total solid
inventory in the riser. The aeration required in the loop-seal
increases with the solid circulation rate and particle size increasing. Further increment in the aeration enhances the solid circulation until it reaches optimum capacity of loop-seal. Moreover,
aeration in the recycle chamber of the loop-seal plays a key role in
regulating the solid circulation rate. Although, the gas velocity to
the BFB has negligible inuence in the solid circulation rate,
proper uidization is required for smooth solid circulation.
Acknowledgment
This research is nancially supported by University of Malaya,
Ministry of Higher Education High Impact Research (UM.C/HIR/
MOHE/ENG/30).
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