FLUIDISATION

Mechanism of Fluidization








Low velocities: Packed Bed Region. No movement of particles.
Possible equations for Pressure Drop: CK, Generalized, Ergun.
Entrainment
Gas Superficial Velocity u (v gas would have in tube if there was no bed)


Graph 1: As fluctuation occurs, the Pressure drop levels off. Bubbles then begin to form in bed
centre and then pressure begins to drop.
As velocity increases, slight movement of particles is seen (especially at walls), rate of
rise of AP begins to drop off towards B. Above B, small bubbles begin to form and
burst at the top of the bed. AP moves to be a constant value with increasing u (i.e. at C).
Increasing u further increases bubble size and the number of bubbles, and the bed
resembles a boiling liquid. (Because of increased friction between gas and particles).
There will be a slight increase in AP as u increases. When at E, it is possible for
particles to be carried away at high u. [Choose u in between C and E when
designing fluidized bed.]
In decreasing the u, there is the HYSTERIS effect. As bed u decreases, bed drops
back into packed bed and may fall into a configuration of higher porosity i.e. higher . (It
falls into looser packing and AP decreases). Bed height may be slightly higher.



Minimum Fluidizing Curve







Hump in curve when increasing u, is only for the larger particles. As the gas flows up, it
tends to push the particles together to form a bridge. Bubbles form under bridge with
Minimum Fluidizing Velocity
Normal Operating Velocity = 1.5 2.5 U
o

U
o

C
pressure build up. Eventually particles pushed up a side releasing the pressure (hence the
DROP).

Types of Fluidization
a) Aggregative Fluidization (See handout #5 overside)
Normally: Gas Fluidized Beds
Bubbles characterize the bed operation. In A.F. the particles operate / move in a group /
bulk.
b) Particulate Fluidization
Normally the fluid is a liquid. There are no bubbles. The particles tend to move of their
own nature, spacing themselves evenly through the bed. Increasing the velocity simply
pushes the particles apart: VOIDAGE INCREASES. Particles operate individually.

Aggregative: Gas Fluidized Bed normally, however Particulate fluidization has been
observed. Lead shot fluidized by water.
Particulate: Liquid Fluidized normally. However light resin particles fluidized by CO
2
has been shown to exhibit PARTICULATE FLUIDIZATION.

Observation from this: difference in density between particles and fluid is the key issue:
High difference: fluidize in aggregative.
Low difference: particulate.
Determination of AP and U
o
at Incipient Fluidization









U
o

AP AP Fluidization
Pressure force must be related to the weight of
particles in fluidization region.

o
= Porosity of bed at initial fluidization.
( ) ( )
0
1
s
PA g AL c A =
2.26
Volume of particles
in bed
Incipient fluidization
conditions






To calculate u:
At the transition point between packed and fluidized bed i.e. u
o
, the pressure drop is the
same, but only at that point.
In packed region CK equation:


Put (2.20) and (2.27) together to eliminate AP:







For higher Re use Gen / Ergun, easier to use.

L
A
( ) ( ) { }
0
1
s
P g L c A =

2 27
Pressure drop at fluidization.
( )
2
2
3 2
1
1 8 0
s
U L
P
D
c

A =
(2.20)
( )
( )
2 3
0
0
2
0
180 1
s
s
D
u g
c

c
=

(2.28)
( ) ( )
( )
2
2
0
3 2
1
1 180
s
s
UL
g L
D
c

c
c

=

Equation for Minimum
Fluidizing Velocity

Behavior of Freely Bubbling Beds
How to get data on bubble sizes and bubble size development.
a) Assessment of bubble eruption diameter (difficult).
b) Wall observations on circular beds (difficult).
c) Observations of fluidization in 2 dimensional beds. Problem is influence of walls.









d) Circular bed: X ray, rays.
No wall influence.



Measurement of bubble sizes has given rise to empirical equation:



D
b
= Bubble diameter.
D
s
= Particle diameter.

s
= Solid density.
L = Depth of bed.
Results from many investigations incorporated.
Rectangular Section.
Thickness of section < Normal size of bubbles.
As bubbles comes up, you will see voids.
X rays
Collect emergent beam using
photographic techniques.
0
1.4 2.29
b s s
u
D D L
u

| |
=
|
\ .


Aspects of gas fluidized beds

Channeling and spouted beds
Channeling is the phenomenon observed when a disproportionately large amount of the
fluidizing fluid follows one or two particular parts through the bed. This is often a marked
characteristic of a bed of very fine particles, or of sticky or waxy particles which tend to
agglomerate.

A spouted bed may be seen as an extreme form channeling in which the fluidizing fluid takes
one (usually centralized) path up the bed.

Distributor plates
The general functions of the distributor plates are
1. Hold up the bed
2. Distribute the gas evenly under the bed
3. To create small bubbles (the smaller the bubbles the more efficient the transfer process
becomes)

Need to form small bubbles to start with, since we know they will increase in size.
Aim: as small bubbles as possible to improve the transfer processes (i.e. heat, mass,
catalytic processes). Large bubbles are voids (hard to get transfer activity in voids).

Distributor design
Choice of distributor Experiments by Grohse and other experiments by Zenz and Othmerhave
shown that the quality of bubbling fluidization is strongly influenced by the type of gas
distributor.

For a few air inlets the bed density fluctuates appreciably at all flow rates of 20% - 50% around
the mean value, Though more severely at high flow rates. The bed density varies with height and
gas channeling may be severe. For many inlet air openings the fluctuations in bed density is
negligible at low gas flow rates but again becomes appreciable at high gas flow rates. Bed
density is more uniform through out and , bubbles are smaller and gas solid contacting is more
intimate with less channeling of gas.

(Grohse 1955) found that the point of incipient fluidization was more reproducible with a porous
plate distributor than if the bed was supported by a BS 300 mesh screen or a multi- orifice plate.
Generally the most appropriate type of plate is the perforated plate
A sintered plate tends to becomes clogged with minute particles, it is also not very easily cleaned

The perforated plate is a flat plate with holes drilled in it, it is cheap and works well with
particles larger than the size of the holes

If there is a problem with particles passing through the holes alternative devices have to be used
to prevent flow back. Other possible methods of promoting even fluidization is to use bubble
cap, conical or porous plates. The use of baffles may also be an option to improve even
fluidization although information on its use is sparse.


Twophasetheoryoffluidization

This theory postulates that the bed is made up of (2) distinct phases
1. Dense phase contains the particles
2. Bubble phase contains no particles
It also stipulates that the gas velocity in the dense phase is at its minimum fluidizing condition
i.e. u
o
and excess gas passes through as
bubbles

Average bubble size
& average velocity =
b
b
V
u
=


From the principle of continuity
0 b
Q uA u A V q = = + (2.30)
Where
u
o
A represents the dense phase
qV
b
represents the bubble phase
q is the frequency at which bubbles pass up through the bed

Expansion of bed over the minimum fluidizing conditions
The bed undergoes expansion as bubbles appear. Increasing Q will expand the bed further since
bubble volume increases accordingly.
Bubble volume
| |
0
A L L
Lo
L
A
u
| |

0
2.31
Time for one bubble
to pass through the
bed
b
b
Volumetric
flow
L
A L L V n
u
=
Combine equations (2.30) and (2.31) and substituting for nV
b

| | | |
0 0
b
L
A L L A u u
u
=
0 0
b
b
L L u u
L u
c

= = Bubble porosity (fraction of the bed as bubbles)
The value for
( )
1
2
0.711
b b
u gD =

Where
D
b
is the bubble diameter

However gas flow patterns in fluidized beds are more complex. The difference in behavior is as a
result of the following 2 conditions
- Slow moving bubbles gas flows in the dense phases are higher than the bubble velocity
- Fast moving bubbles gas flows in the dense phase is less than the bubble velocity

(1) Slow moving bubble u
b
<u
o
because the velocity in the dense phase is high and the bubble is a
void. There is a tendency for gas to short cut through the bubble.


Gas will flow through the bed:
- Within the dense phase
Large
particles
SLOW
BUBBLE
u
b
<u
o
Bubble is stationery i.e.
the observer is situated
inside of the bubble. It
is of a kidney shape as
particles are sucked in
when passing through
the void.
u
b
>u
o
FAST
BUBBLE
- As visible flow in the form of bubbles
- As gas flow through bubbles

Unit cross-sectional area ( )

0 0
1 2.34
b b b
Bubble Bubble
Dense
Flow Through
Phase
Flow
Flow
Au Au A u Abu c c = + +

(2.34)
b is a constant which we will vary with conditions

(2) Fast moving bubbles where u
b
>u
o

The flow of gas is downwards relative to bubble. However, gas just below the base of the bubble
sees a void. It shoots up through the bubble and as it emerges and as it comes off at the top of the
bubble all of a sudden it encounters high resistance (i.e. particles). The gas gets pushed aside by
fast moving bubble eventually finding itself back at the base. It will continue to re-circulate as it
moves through the denser phase.

Application of fluidized beds
Advantages of fluidized beds
1) Smooth liquid like flow of the particles allows for ease of handling
2) Rapid mixing of particles can lead to near isothermal conditions
3) Well suited to large operations
4) Heat and mass transfer between particles and gas are high

Disadvantages
1) Difficult to describe fluid/particle contacting can give rise to inefficient contacting
2) Friable particles can be broken up and entrained
3) It is possible to get erosion of the vessel
4) There is a restricted size range of particles u
o
is increased the particles will be entrained.

There are a wide range of operations using fluidization
Physical operations
Transportation
Mixing soap powders e.g. Breeze
Heat exchange
Particle size enlargement/coatings (e.g. Urea)
Drying

Reactions
- Catalytic cracking
- Catalytic reforming
- Thermal cracking
- Calcination Al
2
O
3
.3H
2
O => Al
2
O
3
+3H
2
O
-
CaCO
3
=>CaO +CO
2

[Fluidization Engineering Kunni & Levenspiel]

Heat Transfer in fluidized beds
Cooling of Urea and Al
2
O
3


Assumptions
I. Perfect mixing of particles in vertical plane
II. No internal temperature gradients
III. Uniform distribution of gas under bed
IV. No heat loss from side of vessel

A heat balance over a differential section

( )
1 s s s g go g
Mass
flow
of
air
m C dt uWdl C t t =

Where
W is the width of the bed
Need to find a relationship for t
go
and t
s


Consider heat transfer between particles and the gas in the differential section [handout 7]

A heat balance in the differential section in the vertical plane
( )
.
sec
g g s g
volumetric Volume
flow of diff
rate tion
udLW c dt ha t t dLWdz =


Integrating between the limits
z = 0 z = z
t
g
= t
gi
t
g
= t
g0

0 0
ln
si gi
s g g
t t
hdz
t t uc
| |

=
|
|

\ .

Rewriting this equation as
( )
1 exp 2.36
go gi s gi
g
haZ
t t t t
uc
(
| |
= ( |
|
(
\ .



Insert (2.36) into (2.35)

0
exp 1 exp 2.37
s gi g g
s gi s s g
t t M c
haZ
t t M c uc
| |
(
| |

|
= ( |
|
|
(
\ .

\ .

Integrate between the limits of
l = 0 t
s
= t
s0

l = l t
s
= t
si


For the special case of where the bed depth is large and the particle size is small and there are
high values of aZ
2.37 becomes
exp 0
g
haZ
uc
| |

|
|
\ .

0
exp
s gi g g
s gi s s
t t M c
t t M c
| |
=
|

\ .

Alternatively place t
go
= t
s
into 2.35 and integrate directly