A new framework for population balance modeling of spray fluidized bed agglomeration

Previous work (Hussain et al. (2013). Chemical Engineering Science, 101, 35) has pointed out that the conventional, one-dimensional population balance equation for aggregation can be expanded to accurately reproduce the results of discrete simulations of spray fluidized bed agglomeration. However, some parameters had to be imported from the discrete simulation (Monte-Carlo). The present paper shows how the expanded population balance can be run without importing parameters from the Monte-Carlo simulation. The expanded population balance still reproduces the results of Monte-Carlo simulations accurately, taking into account key micro-scale phenomena (sessile droplet drying, efficiency of collisions), but with much lower computational cost. Required input parameters are just the drying time of sessile droplets (calculated in advance), and the pre-factor of an equation that correlates particle collision frequency with fluidized bed expansion. In this way, the expanded population balance is, apart from autonomous, also (nearly) predictive. Its performance is demonstrated by comparisons with both Monte-Carlo results and experimental data for various operating conditions (binder mass flow rate, gas temperature). Despite formally being a one-dimensional expression, the expanded population balance captures additional properties, such as the number of wet particles and the number of droplets in the system, which are even difficult to measure in experiments.     

CFD–DEM study of effect of bed thickness for bubbling fluidized beds

The effect of bed thickness in rectangular fluidized beds is investigated through the CFD–DEM simulations of small-scale systems. Numerical results are compared for bubbling fluidized beds of various bed thicknesses with respect to particle packing, bed expansion, bubble behavior, solids velocities, and particle kinetic energy. Good two-dimensional (2D) flow behavior is observed in the bed having a thickness of up to 20 particle diameters. However, a strong three-dimensional (3D) flow behavior is observed in beds with a thickness of 40 particle diameters, indicating the transition from 2D flow to 3D flow within the range of 20–40 particle diameters. Comparison of velocity profiles near the walls and at the center of the bed shows significant impact of the front and back walls on the flow hydrodynamics of pseudo-2D fluidized beds. Hence, for quantitative comparison with experiments in pseudo-2D columns, the effect of walls has to be accounted for in numerical simulations.     

Onset velocity of circulating fluidization and particle residence time distribution: A CFD–DEM study

Until now, the onset velocity of circulating fluidization in liquid–solid fluidized beds has been defined by the turning point of the time required to empty a bed of particles as a function of the superficial liquid velocity, and is reported to be only dependent on the liquid and particle properties. This study presents a new approach to calculate the onset velocity using CFD–DEM simulation of the particle residence time distribution (RTD). The onset velocity is identified from the intersection of the fitted lines of the particle mean residence time as a function of superficial liquid velocity. Our results are in reasonable agreement with experimental data. The simulation indicates that the onset velocity is influenced by the density and size of particles and weakly affected by riser height and diameter. A power-law function is proposed to correlate the mean particle residence time with the superficial liquid velocity. The collisional parameters have a minor effect on the mean residence time of particles and the onset velocity, but influence the particle RTD, showing some humps and trailing. The particle RTD is found to be related to the particle trajectories, which may indicate the complex flow structure and underlying mechanisms of the particle RTD.     

Scale-up of bubbling fluidized beds with continuous particle flow based on particle-residence-time distribution

Few studies have investigated scale-up of the residence-time distribution (RTD) of particles in bubbling fluidized beds (BFBs) with continuous particle flow. Two approaches were investigated in this study: first, using well-known scaling laws that require changes in particle properties and gas velocity; second, using a simple approach keeping the same particles and gas velocity for different beds. Our theoretical analysis indicates it is possible to obtain similar RTDs in different BFBs with scaling laws if the plug-flow residence time (t_plug) is changed as m^0.5, where m is the scaling ratio of the bed; however, neither approach can ensure similar RTDs if t_plug is kept invariant. To investigate RTD variations using two approaches without changing t_plug, we performed experiments in three BFBs. The derivatives dE(θ)/dθ (where E(θ) is the dimensionless RTD density function and θ is the dimensionless time) in the early stage of the RTDs always varied with m⁻¹, which was attributed to the fact that the particle movement in the early stage were mainly subject to dispersion. Using the simple approach, we obtained similar RTDs by separately treating the RTDs in the early and post-stages. This approach guarantees RTD similarity and provides basic rules for designing BFBs.     

Effect of Gaussian size distribution width on minimum fluidization velocity in tapered gas–solid fluidized beds

This paper investigated the effect of Gaussian distribution width, average particle diameter, particle loading, and the tapered angle on minimum fluidization velocity (U_mf) by conducting extensive experiments in tapered fluidized beds. Three powders with Gaussian size distribution and different distribution widths were used in the experiments. An increase in U_mf with increasing the average particle diameter, particle loading, and the tapered angle was observed. There was also a nonmonotonic behavior of U_mf as the Gaussian distribution width increased. An empirical correlation including dimensionless groups for predicting U_mf in tapered beds was developed in which the effect of distribution width was considered. The proposed correlation predictions were in good agreement with the experimental data, with a maximum deviation of 16.5% and average and standard deviations of, respectively, 6.4% and 7.4%. The proposed correlation was also compared with three earlier models, and their accuracy was discussed.     

Effects of grid size on predictions of bed expansion in bubbling fluidized beds of Geldart B particles: A generalized rule for a grid-independent solution of TFM simulations

Numerical simulations of gas–solid fluidized beds based on the kinetic theory of granular flow exhibit a significant dependence on domain discretization. Bubble formation, bubble size and shape all vary greatly with the discretization, and the use of an inappropriate scale resolution leads to inaccurate predictions of fluidization hydrodynamics. In this study, grid-independent solutions of the two fluid model were examined by comparing the bed expansions obtained from numerical simulations with experimental results and empirical predictions, based on bubbling fluidized beds of Geldart B particles. Grid independence was achieved with a grid resolution equal to 18 times the particle diameter. The simulation results were compared with previously published data for verification purposes. The results of this work should provide a guideline for choosing the appropriate grid size and thereby minimize the time and expense associated with large simulations.     

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.     

Application of CFD-DEM to the study of solid exchange in a dual-leg fluidized bed

The CFD-DEM model was developed to simulate solid exchange behavior between two half beds in a bench-scale two-dimensional dual-leg fluidized bed （DL-FB）. Power spectrum density （PSD） analysis was applied to obtain the dominant frequency （F） of the simulated differential particle number （APLR） between the two half beds. Effects of fluidization velocity （u） and bed material inventory （H） on the solid exchange behavior were studied using the CFD-DEM model. Not only snapshots of the simulated particle flow patterns using the OpenGL code but also the dominant frequency of APLR was similar to the experimental results. The simulation results show that higher fluidization velocity assists the exchange of more particles between the two half beds, but the dispersion of clusters on the bed surface into single particles decreases the cluster exchange frequency. A greater bed material inventory results in more intense cluster exchange. The cluster exchange frequency decreases with an increase of the bed material inventory.     

Onset velocity of circulating fluidization and particle residence time distribution:A CFD-DEM study

Until now,the onset velocity of circulating fluidization in liquid-solid fluidized beds has been defined by the turning point of the time required to empty a bed of particles as a function of the superficial liquid velocity,and is reported to be only dependent on the liquid and particle properties.This study presents a new approach to calculate the onset velocity using CFD-DEM simulation of the particle residence time distribution(RTD).The onset velocity is identified from the intersection of the fitted lines of the particle mean residence time as a function of superficial liquid velocity.Our results are in reasonable agreement with experimental data.The simulation indicates that the onset velocity is influenced by the density and size of particles and weakly affected by riser height and diameter.A power-law function is proposed to correlate the mean particle residence time with the superficial liquid velocity.The collisional parameters have a minor effect on the mean residence time of particles and the onset velocity,but influence the particle RTD,showing some humps and trailing.The particle RTD is found to be related to the particle trajectories,which may indicate the complex flow structure and underlying mechanisms of the particle RTD.     

鼓泡流化床中流动特性的多尺度数值模拟

鼓泡流化床因其较高的传热特性以及较好的相间接触已经被广泛应用于工业生产中,而对鼓泡流态化气固流动特性的充分认知是鼓泡流化床设计的关键.在鼓泡流化床中,气泡相和乳化相的同时存在使得床中呈现非均匀流动结构,而这种非均匀结构给鼓泡流化床的数值模拟造成了很大的误差.基于此,以气泡作为介尺度结构,建立了多尺度曳力消耗能量最小的稳定性条件,构建了适用于鼓泡流化床的多尺度气固相间曳力模型.结合双流体模型,对A类和B类颗粒的鼓泡流化床中气固流动特性进行了模拟研究,分析了气泡速度、气泡直径等参数的变化规律.研究表明,与传统的曳力模型相比,考虑气泡影响的多尺度气固相间曳力模型给出的曳力系数与颗粒浓度的关系是一条分布带,建立了控制体内曳力系数与局部结构参数之间的关系.通过模拟得到的颗粒浓度和速度与实验的比较可以发现,考虑气泡影响的多尺度曳力模型可以更好地再现实验结果.通过A类和B类颗粒的鼓泡床模拟研究发现,A类颗粒的鼓泡床模拟受多尺度曳力模型的影响更为显著.      

Experimental analysis of volatile liquid injection into a fluidized bed

Experiments were conducted on a lab-scale fluidized bed to study the distribution of liquid ethanol injected into fluidized catalyst particles. Electrical capacitance measurements were used to study the liquid distribution inside the bed, and a new method was developed to determine the liquid content inside fluidized beds of fluid catalytic cracking particles. The results shed light on the complex liquid injection region and reveal the strong effect of superficial gas velocity on liquid distribution inside the fluidized bed, which is also affected by the imbibition of liquid inside particle pores. Particle internal porosity was found to play a major role when the changing mass of liquid in the bed was monitored. The results also showed that the duration of liquid injection affected liquid–solid contact inside the bed and that liquid–solid mixing was not homogeneous during the limited liquid injection time.     

Modeling of aggregation kernels for fluidized beds using discrete particle model simulations

Aggregation is one of the many important processes in chemical and process engineering. Several researchers have attempted to understand this complex process in fluidized beds using the macro-model of population balance equations （PBEs）. The aggregation kernel is an effective parameter in PBEs, and is defined as the product of the aggregation efficiency and collision frequency functions. Attempts to derive this kernel have taken different approaches, including theoretical, experimental, and empirical techniques. The present paper calculates the aggregation kernel using micro-model computer simulations, i.e., a discrete particle model. We simulate the micro-model without aggregation for various initial conditions, and observe that the collision frequency function is in good agreement with the shear kernel. We then simulate the micro-model with aggregation and calculate the aggregation efficiency rate.     

Influence of rolling friction on single spout fluidized bed simulation

In this paper we study the effect of rolling friction on the dynamics in a single spout fluidized bed using Discrete Element Method (DEM) coupled to Computational Fluid Dynamics (CFD). In a first step we neglect rolling friction and show that the results delivered by the open source CFD–DEM framework applied in this study agree with previous simulations documented in literature. In a second step we include a rolling friction sub-model in order to investigate the effect of particle non-sphericity. The influence of particle–particle as well as particle–wall rolling friction on the flow in single spout fluidized bed is studied separately. Adequate rolling friction model parameters are obtained using first principle DEM simulations and data from literature. Finally, we demonstrate the importance of correct modelling of rolling friction for coupled CFD–DEM simulations of spout fluidized beds. We show that simulation results can be improved significantly when applying a rolling friction model, and that experimental data from literature obtained with Positron Emission Particle Tracking (PEPT) technique can be satisfactorily reproduced.     

Comparison of the standard Euler-Euler and hybrid Euler-Lagrange approaches for modeling particle transport in a pilot-scale circulating fluidized bed

Particle transport phenomena in small-scale circulating fiuidized beds （CFB） can be simulated using the Euler-Euler, discrete element method, and Euler-Lagrange approaches. In this work, a hybrid Euler-Lagrange model known as the dense discrete phase model （DDPM）, which has common roots with the multiphase particle-in-cell model, was applied in simulating particle transport within a mid-sized experimental CFB facility. Implementation of the DDPM into the commercial ANSYS Fluent CFD package is relatively young in comparison with the granular Eulerian model. For that reason, validation of the DDPM approach against experimental data is still required and is addressed in this paper. Additional difficulties encountered in modeling fluidization processes are connected with long calculation times. To reduce times, the complete boiler models are simplified to include just the combustion chamber. Such simplifications introduce errors in the predicted solid distribution in the boiler. To investigate the conse- quences of model reduction, simulations were made using the simplified and complete pilot geometries and compared with experimental data. All simulations were performed using the ANSYSFLUENT 14.0 package. A set of user defined functions were used in the hybrid DDPM and Euler-Euler approaches to recirculate solid particles.     

Discrete particle simulations of bubble-to-emulsion phase mass transfer in single-bubble fluidized beds

A classical Euler–Lagrangian model for gas–solid flows was extended with gas component mass conservation equations and used to obtain fundamental insights into bubble-to-emulsion phase mass transfer in bubbling gas–solid fluidized beds. Simulations of injected single rising bubbles under incipient fluidization conditions were carried out, using Geldart-A and -B particles. Phenomena observed in the simulations and those of various theoretical models used to derive phenomenological models were compared to challenge the assumptions underlying the phenomenological models. The bubble-to-emulsion phase mass transfer coefficients calculated for the simulations using Geldart-B particles were in a good agreement with predictions made using the Davidson and Harrison (1963) model. The bubble-to-emulsion phase mass transfer coefficients for Geldart-A particles were, however, much smaller than the predictions obtained from theoretical models (e.g. Chiba and Kobayashi (1970)). The newly developed model allows a detailed analysis of various hydrodynamic aspects and their effects on the mass transfer characteristics in and around rising bubbles in fluidized beds.     

A novel dual-material probe for in situ measurement of particle charge densities in gas–solid fluidized beds

Particle charge density is vitally important for monitoring electrostatic charges and understanding particle charging behavior in fluidized beds. In this paper, a dual-material probe was tested in a gas–solid fluidized bed for measuring the charge density of fluidized particles. The experiments were conducted in a two-dimensional fluidized bed with both single bubble injection and freely bubbling, at various particle charge densities and superficial gas velocities. Uniformly sized glass beads were used to eliminate complicating factors at this early stage of probe development. Peak currents, extracted from dynamic signals, were decoupled to determine charge densities of bed particles, which were found to be qualitatively and quantitatively consistent with charge densities directly measured by Faraday cup from the freely bubbling fluidized bed. The current signals were also decoupled to estimate bubble rise velocities, which were found to be in reasonable agreement with those obtained directly by analyzing video images.     

A novel dual-material probe for in situ measurement of particle charge densities in gas-solid fluidized beds

Particle charge density is vitally important for monitoring electrostatic charges and understanding particle charging behavior in fluidized beds.In this paper,a dual-material probe was tested in a gas-solid fluidized bed for measuring the charge density of fluidized particles.The experiments were conducted in a two-dimensional fluidized bed with both single bubble injection and freely bubbling,at various particle charge densities and superficial gas velocities.Uniformly sized glass beads were used to eliminate complicating factors at this early stage of probe development.Peak currents,extracted from dynamic signals,were decoupled to determine charge densities of bed particles,which were found to be qualitatively and quantitatively consistent with charge densities directly measured by Faraday cup from the freely bubbling fluidized bed.The current signals were also decoupled to estimate bubble rise velocities,which were found to be in reasonable agreement with those obtained directly by analyzing video images.     

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.     

A model for expansion ratio in liquid-solid fluidized beds

Liquid-solid fluidized beds are used in mineral processing industries to separate particles based on parti- cle size, density, and shape. Understanding the expanded fluidized bed is vital for accurately assessing its performance. Expansion characteristics of the fluidized bed were studied by performing several experi- ments with iron ore, chromite, quartz, and coal samples. Using water as liquid medium, experiments were conducted to study the effects of particle size, particle density, and superficial velocity on fluidized bed expansion. The experimental data were utilized to develop an empirical mathematical model based on dimensional analysis to estimate the expansion ratio of the fluidized bed in terms of particle character- istics, operating and design parameters. The predicted expansion ratio obtained from the mathematical model is in good agreement with the experimental data.     

Study of fluid cell coarsening for CFD-DEM simulations of polydisperse gas–solid flows

Particle polydispersity is ubiquitous in industrial fluidized beds, which possesses a significant impact on hydrodynamics of gas–solid flow. Computational fluid dynamics-discrete element method (CFD-DEM) is promising to adequately simulate gas–solid flows with continuous particle size distribution (PSD) while it still suffers from high computational cost. Corresponding coarsening models are thereby desired. This work extends the coarse-grid model to polydisperse systems. Well-resolved simulations with different PSDs are processed through a filtering procedure to modify the gas–particle drag force in coarse-grid simulations. We reveal that the drag correction of individual particle exhibits a dependence on filtered solid volume fraction and filtered slip velocity for both monodisperse and polydisperse systems. Subsequently, the effect of particle size and surrounding PSD is quantified by the ratio of particle size to Sauter mean diameter. Drag correction models for systems with monodisperse and continuous PSD are developed. A priori analysis demonstrates that the developed models exhibit reliable prediction accuracy.