Virtual experimentation through 3D full-loop simulation of a circulating fluidized bed

Eulerian granular multiphase model with a drag coefficient correction based on the energy-minimization multi-male (EMMS) model was used to simulate a semi-industry scale circulating fiuidized bed (CFB).Three-dimensional(3D), time-dependent simulation of a full-loop CFB revealed that the axial profiles of cross-sectionally averaged solid volume fraction,and the radial profiles of solid axial velocity and solid volume fraction were in reasonable agreement with experimental data.Based on this agreement,database derived from experiments not yet accomplished was replenished with such simulations, and fluid regime diagrams and pressure balance around the CFB loop were derived accordingly. This work presents an integrated viewpoint on CFB and unfolds a fresh paradigm fur CFB modeling, which can be expected to help resolve certain issues long in dispute but hard for experiments.     

Non-uniform distribution of gas–solid flow through six parallel cyclones in a CFB system: An experimental study

In large-scale circulating fluidized bed (CFB) boilers, it is common to use multiple cyclones in parallel for the capture of solids, assuming that gas–solid flow to be the same in the cyclones. This article presents a study investigating gas–solid flow through six parallel cyclones in a CFB cold test rig. The six cyclones were located asymmetrically on the left and right walls of the riser. Solid volume fraction and particle velocity profiles at the riser outlets and in the horizontal ducts were measured using a fiber optical probe. Cyclone pressure drop and solid circulating rate were measured for each individual cyclone. Measurements showed good agreement as to the non-uniform distribution of the gas–solid flow, which occurred mainly across the three cyclones on one side: the middle cyclones on both sides had higher particle velocities. Conversely, the solid volume fractions, solid fluxes and solid circulating rates of the middle cyclones were lower than those of the other four cyclones. The apparent reason for the flow non-uniformity among the cyclones is the significant flow non-uniformity at the riser outlets. Under typical operating conditions, the solid volume fractions at the riser outlets had a deviation of up to 26% whereas the solid circulating rates at the stand pipes, 7%. These results are consistent with most other studies in the literature.     

3D full-loop simulation and experimental verification of gas-solid flow hydrodynamics in a dense circulating fluidized bed

Because of their advantages of high efficiency and low cost, numerical research methods for large-scale circulating fluidized bed （CFB） apparatus are gaining ever more importance. This article presents a numer- ical study of gas-solid flow dynamics using the Eulerian granular multiphase model with a drag coefficient correction based on the energy-minimization multi-scale （EMMS） model. A three-dimensional, full-loop, time-dependent simulation of the hydrodynamics of a dense CFB apparatus is performed. The process parameters （e.g., operating and initial conditions） are provided in accordance with the real experiment to enhance the accuracy of the simulation. The axial profiles of the averaged solid volume fractions and the solids flux at the outlet of the cyclone are in reasonable agreement with experimental data, thereby verifying the applicability of the mathematical and physical models. As a result, the streamline in the riser and standpipe as well as the solids distribution contours at the cross sections is analyzed. Computational fluid dynamics （CFD） serves as a basis for CFB modeling to help resolve certain issues long in dispute but difficult to address experimentally. The results of this study provide the basis of a general approach to describing dynamic simulations of gas-solid flows.     

Particle size distribution in CPFD modeling of gas–solid flows in a CFB riser

A computational particle fluid dynamics (CPFD) numerical method to model gas–solid flows in a circulating fluidized bed (CFB) riser was used to assess the effects of particle size distribution (PSD) on solids distribution and flow. We investigated a binary PSD and a polydisperse PSD case. Our simulations were compared with measured solids concentrations and velocity profiles from experiments, as well as with a published Eulerian-Eulerian simulation. Overall flow patterns were similar for both simulation cases, as confirmed by experimental measurements. However, our fine-mesh CPFD simulations failed to predict a dense bottom region in the riser, as seen in other numerical studies. Above this bottom region, distributions of particle volume fraction and particle vertical velocity were consistent with our experiments, and the simulated average particle diameter decreased as a power function with riser height. Interactions between particles and walls also were successfully modeled, with accurate predictions for the lateral profiles of particle vertical velocity. It was easy to implement PSD into the CPFD numerical model, and it required fewer computational resources compared with other models, especially when particles with a polydisperse PSD were present in the heterogeneous flow.     

Particle size distribution in CPFD modeling of gas-solid flows in a CFB riser

A computational particle fluid dynamics(CPFD) numerical method to model gas-solid flows in a circulating fluidized bed(CFB) riser was used to assess the effects of particle size distribution(PSD) on solids distribution and flow.We investigated a binary PSD and a polydisperse PSD case.Our simulations were compared with measured solids concentrations and velocity profiles from experiments,as well as with a published Eulerian-Eulerian simulation.Overall flow patterns were similar for both simulation cases,as confirmed by experimental measurements.However,our fine-mesh CPFD simulations failed to predict a dense bottom region in the riser,as seen in other numerical studies.Above this bottom region,distributions of particle volume fraction and particle vertical velocity were consistent with our experiments,and the simulated average particle diameter decreased as a power function with riser height.Interactions between particles and walls also were successfully modeled,with accurate predictions for the lateral profiles of particle vertical velocity.It was easy to implement PSD into the CPFD numerical model,and it required fewer computational resources compared with other models,especially when particles with a polydisperse PSD were present in the heterogeneous flow.     

稠密气固两相湍流流动的实验和数值模拟

基于气固两相流动模型计算循环流化床内稠密气固两相流湍流动,颗粒动理学方法模拟颗粒相湍动能,ＳＧＳ模型模拟气相湍流,采用γ－射线密度计和非等速取样管测量局部颗粒浓度和流率,利用ＦＦＴ方法计算颗粒浓度功率谱密度。模拟计算得到上升管内气相和固相速度和浓度分布等。同时数值模拟与Ｔｓｕｊｉ等和Ｋｎｏｗｌｔｏｎ等试验结果进行了比较,结果表明数值模拟计算与实验结果相吻合。     

Quantitative measurement of solids distribution in gas–solid riser flows using electrical impedance tomography and gamma densitometry tomography

An electrical impedance tomography (EIT) system has been developed to non-invasively measure particle distributions in the riser of a pilot-scale circulating fluidized bed (CFB). Although EIT systems have often been applied to yield qualitative information about gas–solid flows, the present EIT system yields quantitative information that is validated by comparison to a gamma densitometry tomography (GDT) system. EIT and GDT were applied to the CFB riser (14-cm inner diameter, 5.77-m height) containing fluid catalytic cracking particles in air. The flows examined were annular with a dilute core and had average and near-wall solids volume fractions up to 0.25 and 0.66, respectively. For all cases, the average and near-wall solids volume fractions from EIT and GDT agreed to within 0.03 and 0.07, respectively. This good agreement suggests that, where feasible, EIT can be used in place of GDT, which is advantageous since EIT systems are often safer, less expensive, and faster than GDT systems.     

Characterization of countercurrent liquid-upward and solid-downward fluidized system

Acting as an operating mode of fluidization, the flow characteristics of a countercurrent liquid–solid fluidized bed (CCLSFB) were experimentally investigated using a Plexiglas column of 1.5 m in height. Countercurrent liquid-upward and solid-downward fluidization was achieved under a limited solid flowrate before flooding occurred.The “flooding” phenomena and the flooding velocity were identified by measuring the variations in pressure drop in the axial direction of the column. Two different methods were used to quantify the flooding point that led to the instability of the system. Axial solids holdup profiles were also obtained from the pressure drop data along the column and the influences of device structure and operating conditions on the solids holdup were also studied. Seven types of particles with different diameters and densities were used. An agreement was found between the experimental results and the mathematic prediction derived from the Richardson–Zaki equation on the data of the solids holdup.     

Numerical simulation and experimental validation of gas–solid flow in the riser of a dense fluidized bed reactor

Gas–solid flow in the riser of a dense fluidized bed using Geldart B particles (sand), at high gas velocity (7.6–15.5 m/s) and with comparatively high solid flux (140–333.8 kg/m² s), was investigated experimentally and simulated by computational fluid dynamics (CFD), both two- and three-dimensional and using the Gidaspow, O’Brien-Syamlal, Koch-Hill-Ladd and EMMS drag models. The results predicted by EMMS drag model showed the best agreement with experimental results. Calculated axial solids hold-up profiles, in particular, are well consistent with experimental data. The flow structure in the riser was well represented by the CFD results, which also indicated the cause of cluster formation. Complex hydrodynamical behaviors of particle cluster were observed. The relative motion between gas and solid phases and axial heterogeneity in the three subzones of the riser were also investigated, and were found to be consistent with predicted flow structure. The model could well depict the difference between the two exit configurations used, viz., semi-bend smooth exit and T-shaped abrupt exit. The numerical results indicate that the proposed EMMS method gives better agreement with the experimental results as compared with the Gidaspow, O’Brien-Syamlal, Koch-Hill-Ladd models. As a result, the proposed drag force model can be used as an efficient approach for the dense gas–solid two-phase flow.     

Numerical investigations on gas–solid flow in circulating fluidized bed risers using a new cluster-based drag model

A cluster-based drag model is proposed for the gas–solid circulating fluidized bed (CFB) riser by including the cluster information collected from image processing and wavelet analysis into the calculation of system drag. The performance of the proposed drag model is compared with some commonly used drag models. A good agreement with the experimental data is achieved by the proposed cluster-based drag model. Error analysis of the proposed cluster-based drag model based on the local distributions of solids holdup and particle velocity is conducted. The clustering phenomenon in the low-density and high-density CFB risers and the effect of the cluster size on the simulation accuracy are also numerically studied by the proposed drag model.     

THERMAL BOUNDARY LAYER IN CFB BOILER RISER

Measurement of temperature profiles of gas-solid two-phase flow at different heights in commercial-scale circulating fluidized bed (CFB) boilers was carried out. Experimental results showed that the thickness of thermal boundary layer was generally independent of the distance from the air distributor, except when close to the riser outlet. Through analysis of flow and combustion characteristics in the riser, it was found that the main reasons for the phenomena were: 1) the hydrodynamic boundary layer was thinner than the thermal layer and hardly changed along the CFB boiler height, and 2) both radial and axial mass and heat exchanges were strong in the CFB boiler. Numerical simulation of gas flow in the outlet zone confirmed that the distribution of the thermal boundary layer was dominated by the flow field characteristics.     

Viscosity of concentrated noncolloidal bidisperse suspensions

At the same solid volume fraction (Φ) the relative viscosity (η _r ) of a concentrated noncolloidal bidisperse suspension of hard spherical particles is lower than that of a monodisperse suspension. In this paper a semi-analytical viscosity model of noncolloidal bidisperse suspensions is derived using an integration method. In this model the random loose packing density obtained by computer simulation is taken as the limit of solid volume fraction Φ _m which depends upon both the diameter ratio (λ) of large to small particles and the volume fraction of large particles (ξ=Φ _l /Φ). This model shows that at high solid volume fraction, Φ > 0.40, both λ and ξ significantly influence η _r . For example, at Φ=0.5, it predicts that for monodisperse suspensions η _r =70, while for bidisperse suspensions (λ=2 and ξ=0.7) η _r =40. Comparison shows that, at high solid volume fraction (0.4–0.5), the relative viscosity predicted by this model is in good agreement with that predicted by the work of Shapiro and Probstein (1992) and of Patlazhan (1993), but is higher than that predicted by the work of others. Received: 27 February 2001 Accepted: 25 April 2001     

Heterogeneous nucleation in CFD simulation of flashing flows in converging–diverging nozzles

Flashing flow is an important phenomenon in many industrial contexts; however simulation of these flows remains difficult. CFD simulations are able to describe the distribution and evolution of 3D structures in the flow but are dependent on good closure relations for interphase transfer. Nucleation during flashing flow is often neglected in CFD simulation where a minimum starting vapour fraction and a constant bubble number density are given. Models that include nucleation have used wall nucleation terms from 1D system code models, averaged over the domain. In this work, three models for wall nucleation are tested and compared with experimental data from a converging–diverging nozzle. Nucleation is applied at the walls of the domain, and various models are investigated. Good agreement with the critical flow rate and axial profiles are found, but agreement with the radial void fraction data is not satisfactory. Methods of addressing this are explored, and it is found that including a small bulk heterogeneous nucleation term gives the best agreement with the radial profiles, with negligible impact on the axial average properties.     

Lateral migrations of solid spheres in tube flow

Cross-flow displacements of neutrally buoyant solid spheres under Poiseuille-type flow conditions in narrow channels, at low volume fraction, are described by a phenomenological model within the framework of the Fokker-Planck equation. In this model, the effects of particle-particle and particle-wall interactions are taken into account. In addition to the classical wall effect (depleted layer near the wall), numerical solutions of the derived equations display two opposite lateral migrations towards the wall and the tube axis, and an alignment of the particles in adjacent layers parallel to the flow. These numerical results are then compared with experimental results obtained by Goldsmith and Marlow [18] for erythrocyte suspensions. A good qualitative agreement is observed.     

Local liquid velocity measurements in air-water bubbly flow

Local measurements of axial liquid velocity were performed for vertical upward air-water bubbly flow in a 101.6-mm inner-diameter round pipe by using a laser Doppler anemometer (LDA) and a hot-film anemometer (HFA). The data reduction approaches for both the LDA and HFA are discussed in detail. A threshold scheme with the information of local void fraction and velocity distribution in single-phase flow was applied to the LDA to approximately discriminate liquid velocity signals from those of the bubble interface velocity. Furthermore, a formulation was given to account for the effect of the bubble relative velocity on the liquid in the front and wake regions of the bubbles. For the HFA, an amplitude threshold scheme and a slope criterion were used to extract liquid velocity information. To reduce the measurement uncertainty, the experiments were performed in flow conditions where the area-averaged void fraction was less than 20%. The experimental results showed satisfactory agreement between the liquid volumetric flow rates calculated by area integration of the local liquid velocity and void fraction measurements, and the measured value by a magnetic flow meter. Also, the area-averaged relative velocity between the gas and liquid phases obtained from the current measurements agreed well with previous research.     

Multi-fluid modeling of density segregation in a dense binary fluidized bed

This paper presents simulation results of the density segregation in a dense binary gas fluidized bed using a multi-fluid model from Chao et al. (2011). The segregation behavior of two types of particles with approximately same particle diameters and different particle densities was studied and validated using the experimental data from Formisani et al. (2008). Some detailed information regarding the gas, particle velocity profiles, the distributions of the particle volume fractions and the flotsam-to-total particle volume fraction ratios is presented. The simulation results show that the simulated axial average flotsam-to-total particle volume fraction ratio distribution agrees reasonably with the experimental data of Formisani et al. (2008). The binary particle velocities are closely coupled though the segregation exists. The segregation behavior and the particle velocity profiles are superficial gas velocity dependent. The number and distribution of particle velocity vortices change dramatically with superficial gas velocity: at a comparatively low superficial gas velocity, the particles mainly segregate axially, and at a comparatively high superficial gas velocity, the particles segregate both axially and radially.     

Mixing and segregation of solid particles in a conical spouted bed: Effect of particle size and density

In this work, the mixing and segregation of binary mixtures of particles with different sizes and densities in a pseudo-2D spouted bed were studied experimentally. A binary mixture of solid particles including sand, gypsum, and polyurethane was used. To determine the particles mass fraction, and their mixing and segregation in the bed, an image-processing technique was developed and used. Important hydrodynamic parameters, such as the axial and radial segregation profiles of the solid particles, were measured. The effects of air velocity, particle size, and particle mass fraction were also evaluated. The flow regime in the spouted bed and the time required for reaching the equilibrium state of the solid particles were discussed. The results showed that the segregation of solid particles and the time to equilibrium both decreased when the air velocity increased to much larger than the minimum spouting velocity. The axial segregation increased with the diameter ratio of the particles. Upon completion of the test, coarse particles were concentrated mainly in the spout region, while fine particles were aggregated in the annulus region. Examination of the flow pattern in the spouted bed showed that the particles near the wall had longer flow paths, while those near the spout region had shorter flow paths.     

Modeling and simulation of circulating fluidized bed reactors applied to a carbonation/calcination loop

A fluid dynamic model for a gas-solid circulating fluidized bed （CFB） designed using two coupled riser reactors is developed and implemented numerically with code programmed in Matlab. The fluid dynamic model contains heat and species mass balances to calculate temperatures and compositions for a carbonation/calcination loop process. Because of the high computational costs required to resolve the three-dimensional phenomena, a model representing a trade-offbetween computational time requirements and accuracy is developed. For dynamic processes with a solid flux between the two reactor units that depends on the fluid dynamics of both risers, a dynamic one-dimensional two-fluid model is sufficient. A two-fluid model using the constant particle viscosity closure for the stress term is used for the solid phase, and an algebraic turbulence model is applied to the gas phase. The numerical model implementa- tion is based on the finite volume method with a staggered grid scheme. The exchange of solids between the reactor units constituting the circulating fluidized bed （solid flux） is implemented through additional mass source/sink terms in the continuity equations of the two phases, For model validation, a relevant experimental analysis provided in the literature is reproduced by the numerical simulations, The numerical analysis indicates that sufficient heat integration between the two reactor units is important for the performance of the circulating fluidized bed system, The two-fluid model performs fairly well for this chemical process operated in a CFB designed as two coupled riser reactors. Further analysis and optimization of the solution algorithms and the reactor coupling strategy is warranted.     

Experimental characterization and CFD simulation of gas maldistribution in turbulent fluidization of Group A particles

The study presented hereby investigates experimentally and with CFD simulations the gas distribution effect on the hydrodynamic of a Geldart Group A turbulent fluidized bed. Experiments were carried out on a cold flow fluidized bed column with an even and uneven gas distribution. Local solid volume fraction profiles were measured using optical probes at different bed heights and along two radial directions. Optical probe measurements allow catching a clear hydrodynamic difference between both even and uneven gas distributions. These results were then used to assess CFD simulations with the code Barracuda™ (MP-PIC approach). It is noteworthy that the choice of drag correlation and boundary conditions strongly influences the agreement between the experimental and CFD results. Once the correct parameters are chosen, CFD simulations captured the effect of gas distribution changes.     

Modeling and simulation of circulating fluidized bed reactors applied to a carbonation/calcination loop

A fluid dynamic model for a gas-solid circulating fluidized bed (CFB) designed using two coupled riser reactors is developed and implemented numerically with code programmed in Matlab. The fluid dynamic model contains heat and species mass balances to calculate temperatures and compositions for a carbonation/calcination loop process.Because of the high computational costs required to resolve the three-dimensional phenomena, a model representing a trade-off between computational time requirements and accuracy is developed. For dynamic processes with a solid flux between the two reactor units that depends on the fluid dynamics of both risers, a dynamic one-dimensional two-fluid model is sufficient.A two-fluid model using the constant particle viscosity closure for the stress term is used for the solid phase, and an algebraic turbulence model is applied to the gas phase. The numerical model implementation is based on the finite volume method with a staggered grid scheme. The exchange of solids between the reactor units constituting the circulating fluidized bed (solid flux) is implemented through additional mass source/sink terms in the continuity equations of the two phases.For model validation, a relevant experimental analysis provided in the literature is reproduced by the numerical simulations. The numerical analysis indicates that sufficient heat integration between the two reactor units is important for the performance of the circulating fluidized bed system.The two-fluid model performs fairly well for this chemical process operated in a CFB designed as two coupled riser reactors. Further analysis and optimization of the solution algorithms and the reactor coupling strategy is warranted.