Numerical Simulation of Pressurized Spouted Fluidized Bed for Coal Semi-Gasification

Numerical simulation study is conducted for a pressurized spouted fluidized bed coal carbonizer, in which hydrodynamics of pressurized spouted fluidized bed, chemical reactions and energy balance are taken into account. The effect of operating conditions such as bed pressure, air and steam mass flow ratio, temperature on product compositions in the bed is investigated. According to the calculated results, bed pressure and bed temperature have the key effects on coal semi gasification.

Analysis of Gas-Solid Flow Characteristics in a Spouted Fluidized Bed Dryer by Means of Computational Particle Fluid Dynamics

In order to grasp the particle flow characteristics and energy consumption of industrial fluidized spouted beds,we conduct numerical simulations on the basis of a Computational Particle Fluid Dynamics(CPFD)approach.In particular,the traction model of Wen-Yu-Ergun is used and different inlet conditions are considered.Using a low-speed fluidizing gas,the flow state of the particles is better and the amount of particles accumulated at the bottom of the bed wall becomes smaller.For the same air intake,the energy loss of a circular nozzle is larger than that of a square nozzle.

Comparison of numerical simulations and experiments in conical gas–solid spouted bed

Flow behavior of gas and particles in conical spouted beds is experimentally studied and simulated using the twofluid gas-solid model with the kinetic theory of granular flow.The bed pressure drop and fountain height are measured in a conical spouted bed of 100 mm I.D.at different gas velocities.The simulation results are compared with measurements of bed pressure drop and fountain height.The comparison shows that the drag coefficient model used in cylindrical beds under-predicted bed pressure drop and fountain height in conical spouted beds due to the partial weight of particles supported by the inclined side walls.It is found that the numerical results using the drag coefficient model proposed based on the conical spouted bed in this study are in good agreement with experimental data.The present study provides a useful basis for further works on the CFD simulation of conical spouted bed.

Catalytic Partial Oxidation of Methane with Air to Syngas in a Pilot-Plant-Scale Spouted Bed Reactor

On the basis of hydrodynamic and scaling-up studies, a pilot-plant-scale thermal spouted bed reactor (50 mm in ID and 1500 mm in height) was designed and fabricated by scaling-down cold simulators. It was tested for making syngas via catalytic partial oxidation (CPO) of methane by air. The effects of various operating conditions such as operating pressure and temperature, feed composition, and gas flowrate etc. on the CPO process were investigated. CH4 conversion of 92.2% and selectivity of 92.3% and 83.3% to CO and H2, respectively, were achieved at the pressure of 2.1 MPa. It was found that when the spouted bed reactor was operated within the stable spouting flow regime, the temperature profiles along the bed axis were much more uniform than those operated within the fixed-bed regime. The CH4 conversion and syngas selectivity were found to be close to thermodynamic equilibrium limits. The results of the present investigation showed that spouted bed could be considered as a potential type of chemical reactor for the CPO process of methane.

Progress in research of process intensification of spouted beds:A comprehensive review

The development of intensification technology for spouted beds has become a current research focus,and an effective way to improve the efficiency of spouted beds is to reform their structure.Although numerous studies have been conducted on conventional beds,there are few reviews on the comprehensive application of intensification technology for spouted beds.In this paper,we comprehensively review the role of intensification technology in spouted beds for use in hydrodynamics,drying,desulfurization,pyrolysis,coating,biomass and waste gasification,and biomass drying from the perspective of experiment and simulation.Finally,potential problems and challenges in current spouted-bed research are summarized.

Experiments and Modeling of the Preparation of Ultrafine Calcium Carbonate in Spouted Beds with Inert Particles

A novel reaction-drying process was carried out in a spouted bed reactor with inert particles and used to prepare ultrafine CaCO3 particles. Effects of concentrations of CO2 and Ca(OH)2, and reaction temperature on Ca(OH)2 conversion were experimentally investigated. The particle sizes and composition of CaCO3 produced were characterized with transmission electron microscopy (TEM) and X-ray diffraction (XRD). The results indicated that ultrafine CaCO3 particles with mean size of 80 nm could be obtained with this novel process.By modifying the Arrhenius Equation and considering the Ca(OH)2 state, a kinetic model was established to describe the process in the spouted bed. The model parameters estimated from the reaction-drying experiments were found to fit well the experimental data, indicating the applicability of the proposed kinetic model.

Gas Residence Time Distributions in a Spouted Bed

In a spouted bed of 80mm in ID and 1700mm in height, the gas residence time distributions at different radial positions in both spout and annular area were measured with five different kinds of particles as spouting material, air as spouting gas, and hydrogen as tracer. The effects of superficial gas velocity, operating pressure, particle size and its category on gas residence time distribution were discussed. It was found that the gas velocity profile in spout was more uniform than that in annulus. It could be concluded that the gas flow in the spout could be treated as a plug-flow, while that in the annulus inhibited a strong non-ideal flow behavior. Increasing the superficial gas velocity and decreasing the operating pressure, the particle density and its size gave rise to spouting disturbance, thus the measured tracer concentrations vs. time curves fluctuated. The variances of residence time distribution curves could be taken as a measure of the gas fluctuation degree.

Optimization of Draft Tube Position in a Spouted Bed Reactor using Response Surface Methodology

Optimization of draft tube position in a spouted bed reactor used for treatment of wastewater containing low concentration of heavy metals is investigated in this paper. Response surface methodology is used to optimize the draft tube height, the draft tube width and the gap between the bottom of the draft tube and the inlet nozzle. It is observed that the draft tube with a height of 60 millimeter, width of 12 millimeter and the gap of 13 millimeter between its bottom and inlet nozzle, results in optimum value of minimum spouting velocity, measured 45 cubic centimeter per second (2.7 Liter per minute) .

CFD-DEM simulation of high density particles fluidization behaviors in 3D conical spouted beds

The spouted bed has been used in the coating process of high-density nuclear fuel particle.The particle fluidization behaviors in pseudo-2D and 3D spouted beds were simulated and validated.The effects of four independent variables(cone angle,particle density,inlet gas velocity,and particle loading)on particle fluidization behaviors in the 3D spouted bed were investigated systematically.The cone angle effect on fluidization mechanism was studied quantitatively first time.A new fluidization quality index was proposed based on the particle entrainment principle,and an extreme value was obtained when the cone angle was 60°,considered to be the optimum value for the 3D conical spouted bed.It was indicated the gas–solid contact efficiency can be kept up if the gas velocity was proportional to ρ_(p)^(0.65) and N_(p)^(0.78) when the particle density or loading was increased.These results will be useful for geometry and operation parameters design of the 3D conical spouted bed and helpful for developing the fluidization mechanism of high-density particles.

A new method for identifying flow pattern of spouted fluidized bed by coupling Hilbert-Huang transform characteristics of differential pressure signals in different zones

On a cold spouted fluidized bed,this study compares the characteristic differences in intrinsic mode function(IMF)energy and Hilbert–Huang spectrum between the spout zone and annulus zone under different combinations of spouted gas and fluidized gas flow rates for five typical flow patterns.The energy distribution characteristics under different flow patterns are also analyzed.The Hilbert–Huang spectrum and IMF energy of pressure difference signals exhibit distinct variations in different zones as the flow pattern changes.Moreover,there exists a correlation between the energy in the middle-frequency range and the flow pattern.Leveraging the K-means algorithm,the middle-frequency range energy of IMFs in the spout zone and annulus zone is subjected to clustering analysis,leading to the identification of partition boundaries for each flow pattern.Based on this,a flow pattern identification method of spouted fluidized bed coupled with middle-frequency range energy in spout zone and annulus zone is proposed,which has very high identification accuracy.

Minimum spouting velocity of flat-base spouted fluid bed

Experiments were performed on spout characteristics of a cylindrical spout-fluidized bed （I.D. = 10 cm） with different static heights and two materials （A1203 and high density polyethylene）. Results of minimum spouting velocity obtained in this study were compared with reported correlations for both spouted and spout-fluidized beds. Considerable discrepancies were found between the values obtained using different model equations as well as with respect to experimental results. Based on the Mathur-Gishler correlation, a new correlation is proposed for calculating the minimum spouting velocity that introduces the ratio U/Umf. It was found that the minimum spouting velocity decreases with increasing fluidizing gas velocity （U/Umf）. The pressure drop at the point of minimum spouting velocity is also correlated using this dimensionless group and is presented in this work. This investigation demonstrates that the use of correlations reported in the literature that focus primarily on conical bottom spouted beds are not applicable to fiat-bottom spouted and spout-fluidized beds.

Simulation of spray coating in a spouted bed using recurrence CFD

Although numerical models such as the computational fluid dynamics–discrete element method (CFD–DEM) have enabled the accurate simulation of laboratory-scale apparatuses, the application of these methods to large-scale apparatuses with many particles and time scales ranging from minutes to hours remains a challenge. The recently developed recurrence CFD (rCFD) method seeks to overcome these issues in pseudo-periodic processes by extrapolating globally recurring patterns in a physically meaningful way and describing the transport and interaction of passive scalars using Lagrangian tracers. Spouted beds represent an interesting target because of the associated variety of flow regimes. They can be effectively described by CFD–DEM on the time scale of tens of seconds, whereas industrially relevant processes typically take hours. In this contribution, we established the validity of applying the Lagrangian rCFD method to spouted beds by demonstrating the accurate reproduction of the particle residence time distribution in a fictitious spray zone. The deposition of spray droplets onto tracer particles was simulated for 1 h, and the particle surface coverage distribution was estimated using a statistical approach for both an unstabilized prismatic spouted bed and one stabilized by draft plates.

Flow regimes in wet conical spouted beds using glass bead mixtures

Using a high-viscosity Newtonian fluid, glycerol, an experimental investigation was carried out to evaluate the stable spouting regime in conical spouted beds using four particle mixtures： a reference （monoparticles）, a binary mixture, two ternary mixtures with flat and Gaussian distributions respectively. The mixtures were selected for particle diameters （dp） ranging from 1.09 to 4.98 mm and particle diameter ratios （dpL/dps） ranging from 1.98 to 4.0. Experimental data show that pressure fluctuation signals of the bed, as indicated by changes in their standard deviations, provide suitable information to identify the range of operational conditions for stable spouting. However, the analysis of skewness of curves of pressure fluctuation as a function of air velocity appears not sufficient to identify a particular flow regime. For glycerol in the spouting regime, the standard deviation is noted to increase with increasing glycerol concentration due to the growth of interparticle forces. The implications of these research findings on the drying of suspensions in conical spouted beds using glass bead mixtures are also discussed.

Particle shape effect on hydrodynamics and heat transfer in spouted bed:A CFD-DEM study

Spouted bed has drawn much attention due to its good heat and mass transfer efficiency in many chemical units.Investigating the flow patterns and heat and mass transfer inside a spouted bed can help optimize the spouting process.Therefore,in this study,the effects of particle shape on the hydrodynamics and heat transfer in a spouted bed are investigated.This is done by using a validated computational fluid dynamics-discrete element method(CFD-DEM)model,considering volume-equivalent spheres and oblate and prolate spheroids.The results are analysed in detail in terms of the flow pattern,microstruc-ture,and heat transfer characteristics.The numerical results show that the prolate spheroids(Ar=2.4)form the largest bubble from the beginning of the spouting process and rise the highest because the fluid drag forces can overcome the interlocking and particle-particle frictional forces.Compared with spherical particles,ellipsoidal spheroids have better mobility because of the stronger rotational kinetic energy resulting from the rough surfaces and nonuniform torques.In addition,the oblate spheroid system exhibits better heat transfer performance benefiting from the larger surface area,while prolate spheroids have poor heat transfer efficiency because of their orientation distribution.These findings can serve as a reference for optimizing the design and operation of complex spouted beds.

Spouting behaviour of binary mixtures in square-based spouted beds

From experime nts, the influe nee of the physical characteristics of different bin ary mixtures of solids on the spouting regime of a pyramidal square-based spouted bed reactor is assessed. The applied methodology permits a more precise evaluation of the effects of the tested variables (diameter, density, sphericity) on the response variables (minimum air flows at which spouting begins and at which to maintain spouting con ditions). The associated pressure drops along the bed of particles a nd the height of the formed fountai n are analysed in each case. During the initial stages of fluidisation, binary mixtures containing different density ratios show dead zones. Segregation becomes more evident at large-size and high-density ratios. The lack of sphericity was found to be the main reason leading to blocking, channelling, and start-up problems when system failures occur. Nevertheless, the extent of segregation in all cases decreases with increasing the spouting velocity. In addition, a computational fluid dynamic model based on the discrete element method, previously validated for a single solid bed, is proposed as a tool to predict and evaluate potential segregation phenomena in binary mixtures. This model reproduced with high accuracy the encountered segregation phenomena. Its use may help define the technical limts inherent in the pyramidal spouted bed reactor.

IMPROVED DEM-CFD MODEL AND VALIDATION:A CONICAL-BASE SPOUTED BED SIMULATION STUDY

An improved and efficient DEM-CFD approach is developed for spouted beds. A nonlinear Discrete Element Method （DEM）, with a concept of spring, dash-pot and friction slider, is used for tracing the movement of each individual particle. The gas flow is described by a set of reorganized governing equations. Two phases are coupled through contributions due to effects of porosity, viscosity and drag. All equations are solved with the commercial package Fluent with an implementation of User Defined Functions （UDF）. To validate the improved model, a two-dimensional conical-base spouted bed is chosen as a case study. An unstructured mesh system is adopted instead of regular grid system. The simulation also takes the Saffman force and Magnus effect into account. The calculation results show good agreement with the experimental observations which are taken from the literature.

CFD–DEM simulation of fine particles in a spouted bed apparatus with a Wurster tube

In this work, a coupled computational fluid dynamics–discrete element method (CFD–DEM) approach was employed to evaluate the spouting behavior of fine, cohesive powders in a cylindrical spouted bed with a conical base and equipped with a Wurster tube. The particle and gas dynamics inside the apparatus were simulated with 1.7 million spherical ZrO2 particles with a particle size of 100 μm. For an accurate prediction of the interactions of cohesive particles in the spouted bed, the adhesion forces according to JKR theory were included in the Hertz–Tsuji contact model. The surface energy of the particles was varied over a wide range to determine the effect of the adhesion on the spouting (the fountain shape and maximum height as well as the distribution of the concentrations and velocities of particles in different zones of the apparatus). A detailed analysis of the collision dynamics was conducted. The spouting behavior of a spouted bed with the same dimensions, particles, and processing parameters was recorded with a high-speed camera. The CFD–DEM simulations showed good agreement with the experimentally captured spouting behavior.

Numerical simulation of uranium tetrafluoride fluorination in a multistage spouted bed using the improved CFD-DEM chemical reaction model

A CFD-DEM reaction coupling model was established to simulate UF_(4) fluorination process,in which heat and mass transfer,heterogeneous chemical reaction,and particle shrinkage model were considered.The gas behavior was described by the conservation laws of mass,momentum,and energy.The solid phase is modeled with the discrete element method,considering the gas-solid interphase force,contact force,heat transfer,and chemical reaction models based on the discretized surface.Each particle can be individually tracked and associated with specific physical properties.The proposed CFD-DEM reaction coupling model based on particle shrinking reaction model with discretized surface was validated by the experimental and literature results at first.Then a multistage conical spouted bed was proposed and the process of UF_(4) fluoridation reaction in it was investigated.The fluidization characteristics and the con-centration distribution of gaseous products in the spouted bed with an extended gas velocity range were obtained and analyzed.In addition,the effects of different parameters,such as superficial gas velocity,temperature,fluorine concentration,on fluoridation rate and the fluorine conversion rate were inves-tigated based on the proposed CFD-DEM reaction coupling model.The results obtained in this work are beneficial for method development of the chemical reaction simulation research in particle scale using the CFD-DEM model,and useful for operation and equipment parameters design of the uranium tetra-fluoride fluorinate industrial process in the future.

Elutriation, attrition and segregation in a conical spouted bed with a fountain confiner

This study examined elutriation,attrition,and segregation in a conical spouted bed with a fountain confiner and incorporating an open sided draft tube.Fine silica sand with a wide particle size distribution was employed as a model material,operating in both the batch and continuous modes.The use of a fountain confiner is crucial when operating with fine particles,because otherwise the bed rapidly exhibits significant entrainment.The extent of attrition was quantified using a tracing technique based on differently-coloured sand fractions as well as monitoring size distributions by sieving.Particle breakage was found to be the primary attrition mechanism,and the fountain confiner was determined to limit the elutriation of fine particles resulting from breakage.Consequently,only a small fraction of the finest particles were entrained from the bed.The incorporation of a confiner increased operational stability while reducing segregation,especially in the upper half of the bed where the majority of segregation typically occurs.Thus,the bed was perfectly mixed apart from very minimal segregation close to the wall and at the bottom of the contactor.These results provide a basis for the design and operation of larger scale equipment for the continuous drying of materials.

CFD-DEM-VDGM method for simulation of particle fluidization behavior in multi-ring inclined-hole spouted fluidized bed

The simulation of particle fluidization behavior in a complex geometry with a large number of particles is challenging owing to the complexity of unstructured computational grids and high computational intensity.In this study,a virtual dual-grid model(VDGM)is proposed to calculate the solid volume fraction in unstructured grids and speed up the calculation.The VDGM is coupled with a computational fluid dynamics-discrete element method model to simulate particle fluidization behavior in a multi-ring inclined-hole spouted fluidized bed with 4.2 million particles under a high temperature of 1423 K.A computational fluid dynamics-discrete element method-virtual dual-grid model(CFD-DEM-VDGM)coupling model is implemented based on commercial software Fluent and EDEM.The time step settings in Fluent and EDEM and the pattern of particle data transfer in Fluent are improved to speed up the calculation.It is discovered that the VDGM can calculate the solid volume fraction in unstructured grids of complex geometry and speed up the calculation effectively.The calculation speed increased by more than 10 times compared with that of the segmentation sampling method.The new pattern of particle data transfer in Fluent can reduce data transfer time by more than 90%.The fluidization behavior of 4.2 million high-density particles in the multi-ring inclined-hole spouted fluidized bed is obtained and analyzed in detail.The CFD-DEM-VDGM coupling method is validated for the bed expansion height and spouting cycle time in a spouted fluidized bed via experimental results.