Flow regime diagrams for gas-solid fluidization and upward transport

Flow regime maps are presented for gas-solids fluidized beds and gas-solids upward transport lines. For conventional gas solids fluidization, the flow regimes include the fixed bed, bubbling fluidization, slugging fluidization and turbulent fluidization. For gas solids vertical transport operation, solids flux must be incorporated in the flow regime diagrams. The flow regimes then include dilute-phase transport, fast fluidization or turbulent flow, slug/bubbly flow, bubble-free dense-phase flow and packed bed flow. In practical circulating fluidized beds and transport risers, operation below the fast fluidization regime is commonly impossible due to equipment limitations. Practical flow regime maps are proposed with the flow regimes, including homogeneous dilute-phase flow, core-annular dilute-phase flow (where there are appreciable lateral gradients but small axial gradients) and fast fluidization (where there are both lateral and axial gradients). The boundary between fast fluidization and dilute-phase pneumatic transport is set by the type A choking velocity, at which the uniform suspension collapses and particles start to accumulate in the bottom region of the transport line, while the mechanism of transition from fast fluidization to dense-phase flow depends on the column and particle diameters.     

Numerical comparison of two modes of gas-solid riser operation: Fluid catalytic cracking vs CFB combustor

Two modes of gas-solid riser operation, i.e., fluid catalytic cracking (FCC) and circulating fluidized bed combustor (CFBC), have been recognized in literature; particularly in the understanding of choking phenomena. This work compares these two modes of operation through computational fluid dynamics (CFD) simulation. In CFD simulations, the different operations are represented by fixing appropriate boundary conditions: solids flux or solids inventory. It is found that the FCC and CFBC modes generally have the same dependence of solids flux on the mean solids volume fraction or solids inventory. However, during the choking transition, the FCC mode of operation needs more time to reach a steady state; thus the FCC system may have insufficient time to respond to valve adjustments or flow state change, leading to the choking. The difference between FCC and CFBC systems is more pronounced for the systems with longer risers. A more detailed investigation of these two modes of riser operation may require a three-dimensional full loop simulation with dynamic valve adjustment.     

关于颗粒悬浮机理和悬浮动的讨论

从分析气体分子的悬浮和静水中Ｂｒｏｗｎ微粒的悬浮之机理出发,论述了重力场中粒子（分子、微粒等）的悬浮不一定需要其它外力,粒子本身的任何形式的无规则运动,达到一定强度后都能使粒子弥散悬浮．河流中的泥沙颗粒和气（水）力输送管道中的颗粒的悬浮也主要靠颗粒物的无规则运动．作用于颗粒的升力和其它力可改变颗粒悬浮沿高度的分布,但仅用这些力（若无任何无规则运动）无法解释颗粒的弥散悬浮状态．讨论了颗粒对流动阻力的双重作用：支持颗粒悬浮的湍流脉动因引入颗粒而削弱,这是颗粒的减阻作用;颗粒增阻的一个主要机制是,流体给予颗粒的水平动量在颗粒一壁面碰撞中不断地损失．用悬浮动概念解释颗粒引起的增阻是不正确的．     

Continuous segregation of binary heterogeneous solids in a fast-fluidized bed

Continuous segregation of binary heterogeneous solids (different density mixtures) is carried out in a gas–solid fluidized bed to study the effects of gas velocity, solids feed rate, feed composition and density difference of solids on the separation factor (recovery of flotsam at top outlet) and the quality of the product (purity of flotsam at top outlet) in a continuous fast-fluidized bed. The holdup of the bed material is obtained in each experimental run. It is observed that the separation factor decreases with increase in solids feed rate or density difference of solids, and increases with gas velocity or proportion of flotsam in the feed. The quality of the product decreases with increase in gas velocity or solids flow rate, and increases with feed composition or density difference of solids. The experimental results show that the separation factor and the quality of the product are more sensitive to gas velocity than to other operating parameters. Empirical correlations for predicting the separation factor and quality of the product are proposed based on the Richards model for individual flotsam mass fraction in the feed, and the predictions agree satisfactorily with the present experimental data.     

Resistant effect of non-equilibrium inter-particle collisions on dense solids transport

There exist big gaps between measurements and modeling predictions on solids holdup and pressure drop in dense solids transport, such as those occuring in the bottom sections of gas-solids risers. The inability of closing this gap by common modeling approaches indicates certain missing and/or misrepresentation of some controlling mechanisms in modeling the transport. Previous research efforts show that the gap can not be effectively narrowed by simply modifying the drag force formulations without inclusion of the collision effect. This paper explores the origin of some controlling mechanisms that might have been overlooked in previous modeling approaches, and recommends how to make the model dense solids transport better. Our analysis shows the presence of a resistant force arising from inter-particle collision when the solids are accelerated in dense-phase transport. This may be caused by non-equilibrium collision during solids acceleration, which differs from local-equilibrium assumptions on which the current kinetic theory modeling of granular particles is based. A complete modeling of this collision-induced resistance calls for a total revision of the kinetic theory, with the inclusion of non-equilibrium collisions and offcenter collisions in dense solids transport.     

关于颗粒悬浮机理和悬浮动的讨论

从分析气体分子的悬浮和静水中Ｂｒｏｗｎ微粒的悬浮之机理出发，论述了重力场中粒子（分子、微粒等）的悬浮不一定需要其它外力，粒子本身的任何形式的无规则运动，达到一定强度后都能使粒子弥散悬浮．河流中的泥沙颗粒和气（水）力输送管道中的颗粒的悬浮也主要靠颗粒物的无规则运动．作用于颗粒的升力和其它力可改变颗粒悬浮沿高度的分布，但仅用这些力（若无任何无规则运动）无法解释颗粒的弥散悬浮状态．讨论了颗粒对流动阻力的双重作用：支持颗粒悬浮的湍流脉动因引入颗粒而削弱，这是颗粒的减阻作用；颗粒增阻的一个主要机制是，流体给予颗粒的水平动量在颗粒一壁面碰撞中不断地损失．用悬浮动概念解释颗粒引起的增阻是不正确的．     

Continuous segregation of binary heterogeneous solids in fluidized beds

Continuous segregation of a binary mixture of heterogeneous (different density) solids is carried out in a gas–solid fluidized bed. We investigate how gas velocity, solids feed rate, flotsam feed composition, bottom discharge pipe diameter, and minimum fluidization velocity ratio of the flotsam to jetsam particles influence the solids holdup, separation factor, and product quality (flotsam purity at the top outlet). The results are interpreted in terms of solids holdup information. The results indicate that the separation factor decreases when the gas velocity, bottom discharge pipe diameter, flotsam feed composition, or the minimum fluidization velocity ratio increase, while the separation factor increases as the solids feed rate increases. The product quality decreases when the gas velocity, solids feed rate, or minimum fluidization velocity ratio increase, while the product quality increases as the bottom discharge pipe diameter or flotsam feed composition increase. Correlations for predicting the separation factor and product quality are proposed using a logistic model for individual flotsam feed compositions, which satisfactorily compares with the present experimental data.     

Gas turbulence modulation in the pneumatic conveying of massive particles in vertical tubes

The present work is concerned with the interaction between large particles and gas phase turbulence. Gas turbulence modulation in these systems is considered to be dominated by a generation mechanism which arises due to the presence of wakes behind particles. Following a recent proposal, a closure for gas turbulence modulation accounting for the effect of wakes is employed within the context of a mathematical model for particle-laden, turbulent flows. The model accounts for particle particle and particle-wall interactions associated with larger particles based on concepts from gas kinetic theory. It is shown that due to the significant flattening of the mean gas velocity profile with the addition of particles, and the corresponding decrease in turbulent energy production, a generation mechanism must be present in order to produce gas velocity fluctuation predictions which are consistent with the experimental measurements, even in the case where the experimental results indicate a net suppression of gas phase turbulence in the presence of particles.     

Reactive gas-solids flows in large volumes--3D modeling of industrial circulating fluidized bed combustors

A model is presented for the simulation of reactive gas-solids flows in large industrial reactors. Circulating fluidized bed （CFB） combustors with several thousands of cubic meters reaction volume are probably the largest reactors of this type. A semi-empirical modeling approach has been chosen to model the three-dimensional concentration distributions of gas and solids components and temperatures inside the combustion chamber of such boilers. Two industrial CFB boilers are investigated in detail： the 105 MWe Duisburg combustor in Germany and the 235 MWe Turow combustor in Poland. The semi-empirical model approach is described first. Then the model is used to show how the three-dimensional concentration and temperature fields are formed by the interaction of several local phenomena. Good agreement between simulation and measurements has been achieved.     

The elimination of severe slugging-experiments and modeling

Severe slugging can occur in a pipeline-riser system operating at low liquid and gas rates. The flow of gas into the riser can be blocked by liquid accumulation at the base of the riser. This can cause formation of liquid slugs of a length equal to or longer than the height of the riser. A cyclic process results in which a period of no liquid production into the separator occurs, followed by a period of very high liquid production. This study is an experimental and theoretical investigation of two methods for eliminating this undesirable phenomenon, using choking and gas lift. Choking was found to effectively eliminate or reduce the severity of the slugging. However, the system pressure might increase to some extent. Gas lift can also eliminate severe slugging. While choking reduces the velocities in the riser, gas lift increases the velocities, approaching annular flow. It was found that a relatively large amount of gas was needed before gas injection would completely stabilize the flow through the riser. However, gas injection reduces the slug length and cycle time, causing a more continuous production and a lower system pressure. Theoretical models for the elimination of severe slugging by gas lift and choking have been developed. The models enable the prediction of the flow behavior in the riser. One model is capable of predicting the unstable flow conditions for severe slugging based on a static force balance. The second method is a simplified transient model based on the assumption of a quasi-equilibrium force balance. This model can be used to estimate the characteristics of the flow, such as slug length and cycle time. The models were tested against new severe slugging data acquired in this study. An excellent agreement between the experimental data and the theoretical models was found.     

An equation set for non-equilibrium two phase flow,and an analysis of some aspects of choking,acoustic propagation,and losses in low pressure wet steam

An equation set for multidimensional, time variant, inviscid flow of a condensing vapour is presented. The equations include the effects of relative motion between the primary gas phase and the suspended liquid droplets. They have been formulated with steam turbine applications in mind but are also relevant to problems of gas-particle and liquid bubble flow.It is shown that the critical velocity in one dimensional choking of low pressure wet steam is identical with the “frozen” speed of acoustic propagation, and the variation of choking mass flow with respect to equilibrium based calculations is described. Results obtained with two different models of droplet growth are compared, and simple formulae for calculating limiting values of choking flow are given. A generalised loss coefficient including the effects of thermodynamic and kinematic non-equilibrium is introduced.     

Coupling between countercurrent gas and solid flows in a moving granular bed: The role of shear bands at the walls

We extended the standard approach to countercurrent gas–solid flow in vertical vessels by explicitly coupling the gas flow and the rheology of the moving bed of granular solids, modelled as a continuum, pseudo-fluid. The method aims at quantitatively accounting for the presence of shear in the granular material that induces changes in local porosity, affecting the gas flow pattern through the solids. Results are presented for the vertical channel configuration, discussing the gas maldistribution both through global and specific indexes, highlighting the effect of the relevant parameters such as solids and gas flowrate, channel width, and wall friction. Non-uniform gas flow distribution resulting from uneven bed porosity is also discussed in terms of gas residence time distribution (RTD). The theoretical RTD in a vessel of constant porosity and Literature data obtained in actual moving beds are qualitatively compared to our results, supporting the relevance under given circumstances of the coupling between gas and solids flow.     

Technical note A simple shock tunnel driver gas detector

A device has been developed to detect the arrival of the driver gas in a shock tunnel. The detector is small enough to be used in conjunction with other experiments. It works by choking a duct when the specific heat ratio is increased past a critical value. Times are given for the onset of a 7.5% contamination level in flows with freestream enthalpies ranging from 3–9 MJ/kg. These results are compared with and are shown to be in agreement with measurements made with a mass spectrometer. Results displaying the rate at which the test gas is contaminated are also given.     

Eulerian–Lagrangian simulation of distinct clustering phenomena and RTDs in riser and downer

Numerical simulation of fully developed hydrodynamics of a riser and a downer was carried out using an Eulerian–Lagrangian model, where the particles are modeled by the discrete element method (DEM) and the gas by the Navier–Stokes equations. Periodic flow domain with two side walls was adopted to simulate the fully developed dynamics in a 2D channel of 10 cm in width. All the simulations were carried out under the same superficial gas velocity and solids holdup in the domain, starting with a homogenous state for both gas and solids, and followed by the evolution of the dynamics to the heterogeneous state with distinct clustering in the riser and the downer. In the riser, particle clusters move slowly, tending to suspend along the wall or to flow downwards, which causes wide residence time distribution of the particles. In the downer, clusters still exist, but they have faster velocities than the discrete particles. Loosely collected particles in the clusters move in the same direction as the bulk flow, resulting in plug flow in the downer. The residence time distribution (RTD) of solids was computed by tracking the displacements of all particles in the flow direction. The results show a rather wide RTD for the solids in the riser but a sharp peak RTD in the downer, much in agreement with the experimental findings in the literature. The ensemble average of transient dynamics also shows reasonable profiles of solids volume fraction and solids velocity, and their dependence on particle density.     

Solids flow diagram of a CFB riser using Geldart B-type powders

Riser operating modes are vital to designing a circulating fluidized bed (CFB) reactor for a required process of either a gas-solid or a gas-catalytic nature. Different operating modes provide different solids’ residence times and mixing behaviors, which define the reactions’ efficiency and yield. The literature demonstrates distinct operating modes resulting from observed differences in slip factors and the range of particle velocities and their associated residence time distribution. The present research uses positron emission particle tracking (PEPT) in a riser of B-type bed material to determine the different operating modes by measuring (i) particle velocities and residence time distribution, (ii) population densities of these particles in the cross-sectional area of the riser, and (iii) solids flow pattern at the bottom of the riser. Data treatment defines four distinct solids hold-up regimes in the riser and proposes a "phase diagram" depicting the existence of the different operating modes (dilute, dense, core-annulus and combined) as a function of the superficial gas velocity and solids circulation flux in the riser. The delineated regimes have good agreement with available literature data and known industrial operations. Comparison with literature data for risers using A-type powders is also fair. The diagram enables CFB designers to better delineate operating characteristics.     

Numerical modelling of shocks in solids with elastic-plastic conditions

Results are presented for a range of one- and two-dimensional shock-wave problems in elastic-plastic and hydrodynamic metals. These problems were solved numerically using the Flux-Corrected Transport (FCT) technique which achieves high resolution without non-physical oscillations, especially at shock fronts, and has not been used before in elastic-plastic solids. The two-dimensional problems were solved using both operator- and non-operator-split techniques to highlight the significant differences between these techniques when solving shock-wave problems in elastic-plastic solids. Comparisons of the elastic-plastic solutions with the hydrodynamic solutions are made and illustrate the importance of including elastic-plastic conditions when modelling the behaviour of solids. Also, the errors in these solutions that are due to the initial conditions are discussed in detail.This article was processed using Springer-Verlag T_EX Shock Waves macro package 1.0 and the AMS fonts, developed by the American Mathematical Society.     

Anti-wear beam effects on gas–solid hydrodynamics in a circulating fluidized bed

Anti-wear beams installed on water walls of circulating fluidized bed (CFB) boilers are one of the most effective ways to protect against water-wall erosion. Beam effects from, for example, beam size and superficial gas velocity were investigated on gas–solid hydrodynamics in a CFB test rig using CFD simulations and experimental methods. The downward flow of the wall layer solids is observed to be disrupted by the beam but is then restored some distance further downstream. When falling solids from the wall layer hit the anti-wear beam, the velocity of the falling solids decreases rapidly. A fraction of the solids accumulates on the beam. Below the beams, the falling solids have reduced velocities but upward-moving solids were observed on the wall. The effect of the beam increases with width and superficial gas velocity. Wear occurs mainly above the beam and its variation with width is different above to below the beam. There is an optimum width that, when combined with beam height, results in less erosion.     

Numerical simulation of gas–solid flow with two fluid model in a spouted-fluid bed

The flow characteristics in a spouted-fluid bed differ from those in spouted or fluidized beds because of the injection of the spouting gas and the introduction of a fluidizing gas. The flow behavior of gas–solid phases was predicted using the Eulerian–Eulerian two-fluid model (TFM) approach with kinetic theory for granular flow to obtain the flow patterns in spouted-fluid beds. The gas flux and gas incident angle have a significant influence on the porosity and particle concentration in gas–solid spouted-fluid beds. The fluidizing gas flux affects the flow behavior of particles in the fountain. In the spouted-fluid bed, the solids volume fraction is low in the spout and high in the annulus. However, the solids volume fraction is reduced near the wall.     

Flow dynamics and contact efficiency in a novel fast-turbulent fluidized bed with ring-feeder internals

The flow dynamics in a novel fast-turbulent fluidized bed (FTFB) with middle-upper expanding structure and two different ring-feeder internals (mixed and vortex ring-feeder) were studied to achieve a reduction in gasoline olefin production. Compared with a conventional circulating fluidized bed, the novel FTFB displayed unique characteristics and advantages. A higher solids holdup and more uniform solids holdup distribution existed in the diameter-expanding region, especially for the FTFB with vortex ring-feeder structure. A probability density distribution analysis indicated that the novel fluidized bed could reduce gas–solids segregation and enhance gas–solids interaction. A constant carbon dioxide tracer system was used to simulate the reactant gas distribution. The gas–solids contact efficiency was defined according to the solid dispersibility and the amount of gas covering the solid surface. Novel FTFB risers, especially those with vortex ring-feeders, have a much higher gas–solids contact efficiency than that of traditional risers.     

Numerical simulation of gas-solid flow with two fluid model in a spouted-fluid bed

The flow characteristics in a spouted-fluid bed differ from those in spouted or fluidized beds because of the injection of the spouting gas and the introduction of a fluidizing gas. The flow behavior of gas-solid phases was predicted using the Eulerian-Eulerian two-fluid model （TFM） approach with kinetic theory for granular flow to obtain the flow patterns in spouted-fluid beds. The gas flux and gas incident angle have a significant influence on the porosity and particle concentration in gas-solid spouted-fluid beds. The fluidizing gas flux affects the flow behavior of particles in the fountain. In the spouted-fluid bed, the solids volume fraction is low in the spout and high in the annulus. However, the solids volume fraction is reduced near the wall.