Professional Documents
Culture Documents
Fluidized Bed Dryers
Fluidized Bed Dryers
CONTENTS
TABLE 8.1
Comparison of Fluidized Bed Dryers (Conventional Types and Modified Types) with Other Competing Dryers
for Particulate Solids
Particle size Large range Fine particles 500 mm–10 mm 100–2000 mm 10 mm–10 mm
Particle size distribution Flexible Limited size distribution Flexible Limited size distribution Wide distribution
Drying time (approx.) Up to 60 min 10–30 s Up to 120 min Up to 60 min Up to 60 min
Floor area Large Large length Large Small Small
Turndown ratio Large Small Small Small Small
Attrition High High Low High High
Power consumption High Low Low Medium Medium
Maintenance High Medium Medium Medium Medium
Energy efficiency Medium Medium High High High
Ease of control Low Medium High High High
Capacity High Medium Medium Medium High
a
Flash dryer is used only for removing surface moisture from smaller particles at relatively short drying times typically in the range of 10–30 s.
FIGURE 8.2 Various fluidization regimes exhibited by different classes of particles with increasing gas velocity.
be chosen carefully in order to achieve the appropri- across the distributor must be high enough to ensure
ate product cut size. Cut size refers to the critical size good and uniform fluidization.
that separates the fine (elutriated) and coarse (remain As a rule of thumb, for upwardly and laterally
in bed) particles. directed flow, pressure drop across the distributor
To ensure uniform and stable fluidization, the must exceed 30% of the pressure drop across the bed
type of distributor has to be chosen carefully. This is [4]. Whereas for downwardly directed flow, the pres-
to prevent poor fluidization quality of solids in certain sure across the distributor must be greater than 10%
regions in the fluidized bed, to prevent plugging of of the pressure drop across the bed. Upwardly direc-
distributor-perforated holes, and to avoid solids from ted flow is normally found in ordinary perforated
dropping into windbox or gas plenum located be- plates (Figure 8.3, lower right image-i). Sandwich-
neath the fluidized bed. There are many types of type distributor is used if reinforcement of the
distributors available. Figure 8.3 (lower right image) distributor is needed due to heavy load of bed of
shows four common types of distributors, namely, particles (Figure 8.3 lower right image-ii). Laterally
ordinary (i), sandwiched (ii), bubble cap tuyere (iii), directed flow is normally obtained with bubble caps
and sparger (iv). It should be noted that pressure drop and nozzle types of distributors (Figure 8.3, lower
Solids hold up
Windbox
Gas feed
Distributor plate
Heater Blower
FIGURE 8.3 Typical fluidized bed drying setup. Zones in a fluidized bed with its corresponding solids hold-up are shown in
upper right side image. Types of perforated distributor plates that can be used are shown in lower right side image.
Particle
Diameter, dp For fine particles, h is higher; for coarse particles, h is lower 9
Shape Higher for rounded and smooth surface particles 10,11
Specific heat, cp h /cpn, where 0.25 < n < 0.8 12,13
Thermal conductivity, kp No influence for small Biot number 14,15
Gas
Velocity, ug Increases above umf to a maximum value at an 9
optimum velocity, uopt and decreases thereafter
Density, rg Increases with increasing, rg 10,11
Viscosity, mg Increases with decreasing, mg
Specific heat, cg At moderate pressure and velocity, no information available 16,17
At high pressure, increases with increasing cg
Thermal conductivity, kg h / kgn, where 0.5 < n < 0.66 14,18
h Increases as bed temperature increases, due to increasing of kg
Fluidized bed
Bed height, Hb No influence 12,19
Bed diameter, db No information available
Bed temperature, Tb Gas-convective: increases for small particles; decreases for coarse particles 20
Bed pressure, Pb No influence on particle-convective heat transfer 21
Gas-convective heat transfer increases
Heat transfer surface
Length, L No influence 22
Tube diameter, dtube Increases with decreasing dtube 17
where X is the free moisture content, i.e., that in 8.4.2 EMPIRICAL MODEL
excess of the equilibrium value, D is the diffusivity
(m2/s), and r is radial dimension (m). In this model, the drying process is divided into dif-
If diffusivity is variable and dependent on the ferent periods where drying mechanisms in each dry-
radial distance of drying boundary from the center ing period are different.
of the solids, the following diffusion equation is used The general solution of Fick’s diffusion expresses
instead: the moisture content in terms of the drying time in
exponential function. The solution for spherical solids
2 is given in the folowing the equation [26–28]:
@X @ X 2 @X @D @X 2
¼D þ þ (8:9) Sphere:
@t @ r2 r @r @X @r
where Ms is the mass hold-up of dry solid in bed (kg), dYbb Vgbb
X is the average moisture content (kg/kg), Gg is the rg «bb þ rg (Ybb Yin )
dt Vb t
mass flow rate of dry air (kg/s), and Y is the air
6Kc rg «bb
humidity (kg(water vapor)/kg(dry air)). ¼ (Yd Ybb ) (8:24)
Energy Balance: dbb
Solid particles
ms, Ts, cs
Dense phase Gas crossflow Dilute phase
particulate solids bubbles
The above equation expresses the change of particle 8.6 TYPES OF FLUIDIZED BED DRYERS:
temperature in the dense phase in terms of average
moisture content, X , which can be determined from
CLASSIFICATION AND SELECTION
any one equation from Equation 8.8 through Equa- Various types of fluidized bed dryers have been studied,
tion 8.21 depending on the operating conditions and developed, and operated in many industrial processes
the drying model, humidity of dense and bubble according to the respective process, product, oper-
phases, Yd, Ybb, enthalpy of evaporation, DHevap, ational safety, and environmental requirements. It is
bubble diameter, dbb, and mass transfer coefficient important to become familiar with the specific charac-
of bubble boundary. Solving Equation 8.27 yields teristics of different fluidized bed types in order to make
the solids temperature at different drying times. a logical and cost-effective selection. It should be noted
that in many instances several different types may pro-
8.5 EFFECT OF OPERATING PARAMETERS vide similar performance at the same cost.
Some novel fluidized bed dryers, which have not
ON FLUIDIZED BED DRYING
found application in industrial drying, are used to
8.5.1 EFFECT OF BED HEIGHT overcome disadvantages and difficulties that may
occur in conventional fluidized bed dryers. It should
For materials with high mobility of internal moisture be noted that not all modified fluidized bed dryers
such as iron ore, ion-exchange resins, silica gel, most are necessarily better than the conventional dryers
drying takes place close to the distributor plate. Bed in terms of product quality, or energy efficiency, or
height has no effect on its drying rate that increasing drying performance.
lot air or
Dry solids
flue gas
Fluidized
bed
FIGURE 8.6 Batch fluidized bed dryer. FIGURE 8.8 Well-mixed fluidized bed dryers.
Hot air
Hot air
Partition plate/
internal baffle
Perforated
distributor Dry solid
Perforated
Dry solid distributor
(a) (b)
FIGURE 8.9 Plug flow fluidized bed dryers. (a) Straight path; (b) reversing path.
cyclone fluidized bed dryer [39]. Wet solids are first It was found that the roto-fluidized dryer performs
charged into the cyclone dryer by exiting fluidizing better than the conventional rotary dryer.
gas from fluidized bed dryer. Surface moisture
content of solids is quickly removed with the gas 8.8.3 PULSATING FLUIDIZED BED DRYERS
in the cyclone dryer. Solids and gas are separated in
the cyclone. Partially dried solids are then pneuma- Pulsating fluidized bed dryers are used to overcome the
tically conveyed into the fluidized bed for second- problems of restricted particle size and size distribu-
stage drying. Other types of hybrid fluidized bed tion, as well as aggregative fluidization and channeling
dryers include flash-fluidized bed dryer, filter-fluidized that occur in a conventional fluidized bed dryer when
bed dryer [41]. processing certain types of powders. By pulsating the
A multistage spray fluidized bed dryer consists of fluidizing gas stream, the fluidized bed either the whole
a spray chamber followed by first-stage fluidized bed bed or part of the bed is subjected to variable fluidizing
drying and second-stage fluidized bed cooling (Fig- gas velocity (Figure 8.14) [43–46]. This contributes to
ure 8.13). When solid powders are formed in the spray effective energy costs saving and enhanced drying per-
dryer, these powders still contain some internal mois- formance without affecting the fluidization quality and
ture. It is costly to use a spray dryer to remove all of process performance or added extra capital costs. For
the internal moisture. Instead, using a second-stage larger particles (group D particles), intermittent spout-
fluidized bed dryer is more cost-effective. Lisboa et al. ing of the bed with a rotating spouting jet has been
[42] applied fluidization technique in a conventional shown to reduce energy consumption with only a mar-
rotary. The dryer is known as roto-fluidized dryer. ginal increase in drying time for batch drying.
Inlet solids
Exhaust air
Lower
stage
(a) (b)
FIGURE 8.11 Two-stage fluidized bed dryers. (a) Upper stage well-mixed fluidized bed followed by lower stage plug flow
fluidized bed; (b) first-stage dryer followed second-stage cooler.
Pneumatic
8.8.5 MECHANICALLY ASSISTED FLUIDIZED
conveyor Air BED DRYERS
Dry Fluidization quality of fine and large particles can be
solid Hot gas enhanced by the assistance of external means such as
vibration or agitation. Moreover, these particles can
FIGURE 8.12 Hybrid cyclone fluidized bed dryer. be immersed in a bed of fluidizable inert particles to
improve their fluidization quality [47].
8.8.4 FLUIDIZED BED DRYERS WITH IMMERSED 8.8.6 VIBRATED FLUIDIZED BED DRYERS
HEAT EXCHANGERS
Vibration combined with upward flow of air in an
Fluidized beds equipped with internal heaters or im- aerated bed enables particles to pseudofluidize
mersed tubes transfer heat indirectly to the drying smoothly. The gas velocity required for minimum
material. Horizontal tube bundles (Figure 8.15) are fluidization is considerably lower than the mini-
used extensively compared to vertical type. Tube mum fluidization velocity in conventional fluidized
pitch is an important design parameter. Fluidizing bed dryer. Attrition due to vigorous actions between
gas stream fluidizes the material and carries over the particle–particle and particle–wall is thus minimized
evaporated moisture. As a result, total sensible heat appreciably. Hence, application of fluidized bed can
of gas and thus quantity of gas required are reduced. be extended to fragile, abrasive, and heat-sensitive
Immersed tubes or internally heated fluidized bed materials. The problem of fine particle entrainment
dryers are used to dry smaller size or fine powders. is also avoided. For polydisperse powders, low gas
This is because heat transfer coefficient decreases with velocity fluidizes the fine particles gently whereas
increasing particle size. Instead of tubes, vertical vibration keeps the coarse particles in a mobile state.
plates are also used as immersed heaters. Vibrating fluidized beds are generally plug flow
Heat transfer is highly dependent on the particle type (Figure 8.16). Vibrating fluidized beds are rela-
heat capacity and mixing. Vigorous bubble action tively shallow as the effect of vibration imparted by
gives better particle circulation and mixing, and thus the vibrating grid decays with distance from the grid.
Liquid
Exhaust gas Exhaust gas
Feed
Heated air
Aglomeration
chamber
Cyclone
Vibro-fluidizer
Particles
Sieve
Wet Product
feed
Perforated
distributor
Hot air
FIGURE 8.14 Pulsating fluidized bed. Parts of the bed are fluidized periodically.
There are some acoustic noise issues associated with bed is formed without channeling or formation of
such devices. These units can operate in batch as well large bubbles. Moreover, agitated fluidized bed dryers
as continuous modes. are useful for drying pastes or cakes consisting of fine
particles [48]. In this case, agitation helps to disinte-
8.8.7 AGITATED FLUIDIZED BED DRYERS/SWIRL grate and disperse the pasty feed. The agitator serves
FLUIDIZERS as a mixer in the dryer [49]. Moreover, deeper bed
depth is possible if the bed is agitated whereas its
Another way to improve fluidization quality of fine fluidization quality is maintained.
particles is to impart mechanical agitation to the bed
(Figure 8.17). By agitation, a homogeneous fluidized
8.8.8 FLUIDIZED BED DRYERS OF INERT PARTICLES
In recent years, the application of fluidized bed drying
Exhaust gas has been extended to drying of fine powders, pastes,
slurries, suspensions, pulp, and enzymes-containing
aqueous medium [50–55]. This is accomplished by
using inert particles of high heat capacity (Figure
8.18) [56]. Inert particles must be able to fluidize
Solids well in a fluidized bed. By mixing the inert particles
inlet
whose fluidization quality is generally good with the
materials mentioned above, the fluidization quality of
the materials is improved appreciably [57,58]. In add-
ition, the inert particles with high heat capacity serve
as energy carriers that enhance heat transfer [59,60].
Drying on inert particles can be performed in a var-
Solids flow iety of fluidized beds namely ordinary fluidized bed,
Heating
fluid spouted bed, spouted fluidized bed, jetting-spouted
Gas flow
bed, as well as vibrated fluidized bed [61].
Immersed tube The liquid to be dried is sprayed into the fluidized
bed; it coats the inert particle surfaces. The coated
Solids out layer dries as a result of combined convective heat
Hot gas transfer from hot air and contact heat transfer due to
FIGURE 8.15 Immersed tubes fluidized bed dryer. sensible heat of the particles. When the thin layer is
Wet solids
Dry solids
Hot air
Vibrator
FIGURE 8.16 Vibrating fluidized bed.
dry, it becomes brittle, cracks, and is peeled off transports the particles to the bed surface. Energetic
due to attrition by particle–particle and particle–wall spouting at the bed surface thrusts the particles
collisions. As a result, a fine powder is formed and is into the freeboard region at the center of the bed
carried over by the exhaust gas to be collected (Figure 8.19). After losing their momentum, these
and separated in suitable gas-cleaning devices such particles fall back onto the bed surface. Through
as cyclones or bag filters. this fountain-like action, good solid mixing is in-
duced. A cyclical flow of particles is thus created.
8.8.9 SPOUTED BED DRYERS Details of spouted bed drying are discussed elsewhere
in this handbook.
Spouted bed dryers are useful for drying of large The spout bed has been applied to drying, granu-
(Geldart’s group D) particles (>5 mm), which exhibit lation, coating as well as to drying of pastes, solu-
slugging under normal fluidization. In a spouted bed, tions, slurries, and suspensions. Mujumdar [62] has
a high gas velocity jet of gas penetrates through an classified spouted beds into at least 30 different vari-
opening at the bottom of the bed of particles and ants, each with a specific set of advantages and limi-
tations. Periodically spouted beds, multiple spouted
Exhaust
air
Exhaust gas
Solids inlet
Liquid
Rotation
Agitator
Heated air
Bed surface
Draft tube Solids out
Downcomer
Solids flow
Gas and
solid feed
Conical
base FIGURE 8.20 Recirculating fluidized bed dryer.
Solids in
Bubbles
Horizontal
baffles
Gas distributor
Solids out
Gas in Gas
in
(a) (b)
FIGURE 8.22 (a) Horizontal baffled fluidized bed dryer; (b) vertical baffled fluidized bed dryer.
External Receiver
condenser
Compressor Expansion valve
Dry solids
Evaporator
Condenser Condensation
constant rate and the other for the falling rate. Table 8.9.1.4 Mass Balance, Continuous
8.4 shows the equations for calculating residence time Drying, Well-Mixed Bed
at different operating conditions.
Sizing of bed is based on simple hold-up mass bal- In this equation, Fs is the solids flow rate (kg/s), X is
ance. Cross-sectional area of the fluidized bed can be the moisture content (kg/kg), Gg is the gas flow rate
determined from the following equation after solids (kg/s), and Y is the absolute humidity (kg/kg).
flow rate (dry basis), Fs, bed density, rb, and bed
height, Hb, are specified, and particle residence time,
8.9.1.5 Heat Balance, Continuous
tR, is determined:
Drying, Well-Mixed
Fs tR Heat balance for the single-phase model gives the
A¼ (8:28)
r b Hb following energy balance:
Batch Drying
(Xo X)Ms l
1. Constant rate period Only surface moisture present tR ¼
Gg cpg (Tin Tout )
X Xeq 6 X 1
1 [(np)2 Dt=R2 ]
2. Falling rate period (i) From diffusion model ¼ 2 e
Xo Xeq p n¼1 n2
tR is obtained by trial and error
Ms cps Tp Tin
(ii) Simplified equation tR ¼ ln
Gg cpg Tpo Tin
Xcr1 Xeq
(iii) Empirical formulation tR ¼ k1 ln
X Xeq
Continuous drying
Ð1
(a) Well-mixed Design curve: X ¼ 0 X (t)E(t)dt [79]
Xo X
1. Constant rate period Only surface moisture tR ¼
k
1 Xin Xeq
2. Falling rate period tR ¼ 1 [80]
k Xout Xeq
3. Batch drying curve (1) Obtain a record of the changing bed temperature Tb during constant inlet air temperature run
(2) Divide the constant inlet air temperature batch drying curve X(t) into increments of length, DX. For each
increment note the time DtT1 required to accomplish that amount of drying at constant bed
temperature of T1
(3) Calculate the time DtT2 required to accomplish the same increment of drying at constant bed temperature,
T2 by the use of the following equation:
DtT1 [(psat pin )(X Xe )]T1
¼ [81,82]
DtT2 [(psat pin )(X Xe )]T2
(4) Build up the constant bed temperature batch drying curve by increments
(5) Obtain drying equation for each curve
(6) Obtain residence time from design curve
SA Xin Xout
tR ¼ [83,84]
f *Gb Xout Xeq
where S is the bed loading, A is the bed area, f* is ratio of bed loading (S) and flux of gas flow rate (G/A)
at constant be temperature, T1
(b) Plug flow " #
1 (1 t=tm )2
1. Batch drying curve Residence time distribution function is E(t) ¼ pffiffiffiffiffiffiffi exp
2 pB 4B
where
4
Dtm 3:71 10 (u umf )
B ¼ 2 and D ¼ 1=3
[82];
L u mf
For a gas–vapor system, Hgin and Hgout can be Hgout ¼ (cpg þ Yout c1 )Tgout þ Yout l (8:35)
obtained from Mollier diagram and for organic vapor–
inert gas systems, Hgin and Hgout can be obtained A summary of steps for fluidized bed dryer design is
from the following equations: given in Figure 8.25, whereas a simple guide for
selecting suitable fluidized bed dryers (FBD) based
Hgin ¼ (cpg þ Yin c1 )Tgin þ Yin l (8:34) on material properties is given in Figure 8.26.
Change A, Gg
Determine outlet gas humidity, Yout
Change Gg
and dew point
Yes
8.9.2 A SAMPLE DESIGN CALCULATION between drying rate and moisture content is given by
the following equation:
Wet particulate solids (6000 kg/h) with an initial
moisture content of 20% (db) at 208C are to be dried dX
to final moisture content of 4% (db). Inlet air at ¼ 0:005X
dt
1258C with humidity of 0.005 kg/kg is used. Bed
depth is 20 cm. Calculate
Under these conditions, bed density is 500 kg/m3
and equilibrium moisture content is zero. Specific (a) Mean particle residence time
heat of the dry solids and liquid water are 1.0 and (b) Bed area
4.2 kJ/kg8C, respectively. Figure 8.27 gives the sum- (c) Mass flow rate of air
mary of all available data on this problem. Heat loss (d) Absolute humidity of exhaust air
at the wall of the dryer is estimated as 5% of the heat (e) Temperature of exhaust air
content of inlet air. Batch drying curve was obtained (f) Check whether condensation will occur in
at the conditions mentioned above; the relationship cyclone
• V-FBD
WM-FBD Well-mixed FBD SBD Spouted bed P-FBD Pulsating FBD H-FBD Hybrid FBD
PF-FBD Plug flow FBD M-FBD Multistage FBD IT-FBD Immersed tubes FBD IS-FBD Inert Solids FBD
V-FBD Vibrated FBD A-FBD Agitated FBD B-FBD Baffled FBD SD Spray drying
tR ¼ 800 s 1:389
Yout ¼ (0:20 0:04) þ 0:005
7:777
Dry solid mass flow rate is calculated from wet solid Yout ¼ 0:0336 kg H2 O=kg dry air
mass flow rate, wet solid has initial moisture content
of 20%, Outlet air temperature can be obtained from the
equation
kg wet solid 1 kg dry solid 1h
F ¼ 6000 Fs Hsin þ Gg Hgin þ Qh ¼ Fs Hsout þ Gg Hgout þ Qw
h 1:20 kg wet solid 3600 s