Turbulent Fluidization Research Articles

Managing Heat Transfer Intensity in a Fluidized Particle-in-Tube Solar Receiver

Particle flow structure and associated heat transfer coefficient are examined as a function of temperature in a single-tube fluidized bed solar receiver operating in upward particle flow mode. It is found that temperature has a strong effect on both fluidization regimes and wall-to-bed heat transfer coefficient that varies in the range 800-1200 W/(m2.K). Turbulent fluidization regime results in the most intense heat transfer between the irradiated wall and the fluidized particle.

Numerical Investigation into Gas-Solid Fluidized Bed Reactors for Activating the Iron-based Fischer-Tropsch Synthesis Catalyst

Abstract The present work conducted experimental and computational fluid dynamics simulation studies on the hydrodynamic characteristics of gas-solid fluidized bed reactors for activating the iron-based Fischer-Tropsch synthesis catalyst. In order to provide reliable guidance for the design and scale-up of the reactor, the present study applied experimental data from a pilot fluidized bed device to verify the accuracy of the drag force model used in the two-fluid model and further used the validated drag force model to simulate an industrial-scale fluidized bed activation reactor. It was found that the bubbling-EMMS drag model can accurately simulate the pilot-scale fluidized bed in the flow regimes ranging from bubbling to turbulent fluidization. Simulation studies on the industrial-scale fluidized bed activation reactor showed that the reactor was in a turbulent fluidization regime under the designed operating gas velocity, with high gas-solid dispersion efficiency, reasonable utilization of reactor space, and low gas-solid separation load.

The transition to turbulent fluidization in a gas-solid fluidized bed operating from ambient temperature to 1600 °C

Turbulent fluidized bed proves effective in industrial processes due to superior heat and mass transfer and chemical reaction performance. However, understanding the transition to turbulent fluidization remains limited, especially at temperatures exceeding 1000 °C, making it challenging to develop high-temperature fluidized bed applications. This paper presents an experimental investigation on the turbulent fluidization onset velocity (Uc), measured in a 30 mm diameter bed using corundum particles with average diameters from 0.68 mm to 1.58 mm in temperatures from ambient to 1600 °C. Experimental results reveal that Uc increases with temperature up to 600 °C, stabilizes within the 600–1200 °C range, and then decreases above 1200 °C, demonstrating the varying relative significance of hydrodynamic and interparticle forces at different temperatures. To help design and operate high-temperature applications of turbulent fluidization, we developed Uc correlations based on experimental data from both literature sources and this study, covering temperatures of up to 1600 °C and particles of Groups A to D.

Numerical Simulation of Hydrodynamics and Heat Transfer in a Reactor with a Fluidized Bed of Catalyst Particles in a Three-Dimensional Formulation

The hydrodynamics and heat transfer in a reactor with a fluidized bed of catalyst particles and an inert material were simulated. The particle bed (the particle density was 2350 kg/m3, and the particle diameter was 1.5 to 4 mm) was located in a distribution device which was a grid of 90 × 90 × 60 mm vertical baffles. The behavior of the liquefying medium (air) was modeled using a realizable k-ε turbulence model. The behavior of particles was modeled using the discrete element method (DEM). In order to reduce the slugging effect, the particles were divided into four separate horizontal layers. It was determined that with the velocity of the liquefying medium close to the minimum fluidization velocity (1 m/s), slugging fluidization is observed. At a velocity of the liquefying medium of 3 m/s, turbulent fluidization in the lowest particle layer and bubbling fluidization on subsequent particle layers are observed. With an increase in the velocity of the liquefying medium over 3 m/s, entrainment of particles is observed. It was shown that a decrease in the density of the liquefying medium from 1.205 kg/m3 to 0.383 kg/m3 when it is heated from 298 K to 923 K would not significantly affect the hydraulic resistance of the bed. Based on the obtained results, it can be stated that the obtained model is optimal for such problems and is suitable for the further description of experimental data.

CFD modeling of a fluidized bed with volatiles distributor for biomass chemical looping combustion

Achieving high volatiles conversion is crucial to biomass chemical looping combustion. Challenges arise from rapid devolatilization of biomass and limited biomass injection ports, resulting in volatiles with insufficient contact with oxygen carriers in fluidized beds. A concept called volatiles distributor (VD) has recently been proposed and investigated in a cold-flow fluidized bed, which shows excellent performance in achieving an even distribution of volatiles over the cross section. To deeply understand VD's impact on hydrodynamics behaviors, pioneering three-dimensional full-loop cold-flow CFD simulations were conducted using an Eulerian multiphase granular model. Three drag models, i.e., Gidaspow, Filtered, and two-step EMMS/bubbling, were evaluated against experimental data. While all models perform well in bubbling fluidization, the two-step EMMS/bubbling model excels in turbulent fluidization. Additionally, CFD simulations reveal improved mixing between volatiles and bed materials with VD, highlighting its efficiency in addressing incomplete conversion of high-volatile fuels like biomass in fluidized bed systems.

Effects of gas velocity on nonequilibrium characteristics of fluidization

The gas velocity is a key factor of the macroscale operating conditions, affecting the nonequilibrium behavior and regime transitions of fluidization, but the mechanism of its effects remains unclear, resulting in a deterioration of the accuracy of the two-fluid model (TFM) simulation with the increase of the gas velocity. To seek its underlying mechanism, we performed time-resolved, particle-tracking velocimetry (PTV) measurements of a fluidized bed operated under bubbling to turbulent states, thereon the analysis of the probability density distribution of particle velocity, and hydrodynamic parameters. It is found that a stronger nonequilibrium exists with the increase of the gas velocity, in the sense that the bimodal distribution of particle velocity is more significant at turbulent fluidization. The total fluctuating energy and stress show a scale separation, suggesting that a reasonable continuum modeling should take into account the whole range of fluctuation.

Influence of Temperature on Properties and Dynamics of Gas-Solid Flow in Fluidized-Particle Tubular Solar Receiver

A fluidized particle single-tube solar receiver has been tested for investigating the gas-particle characteristics that enable the best operating conditions in a commercial-scale plant. The principle of the solar receiver is to fluidize the particles in a vessel – the dispenser – in which the receiver tube is plunged. The particles are flowing upward in the tube, irradiated over 1-meter height, by applying an overpressure in the dispenser. Experiments with a concentrated solar flux varying between 188 and 358 kW/m² are carried out, and the particle mass flux varied from 0 to 72 kg/(m²s). The mean particles and external tube wall temperatures in the irradiated zone are heated from the ambient to respectively 700°C and 940°C. It is shown that the temperature rise leads to a decrease of the particle volume fraction. Furthermore, a self-regulation of the system is evidenced with a short transient regime. This characteristic is essential from the operational viewpoint. The thermal efficiency of the receiver increases with the particle flow rate, reaching between 60 and 75% above 30 kg/(m²s). Several fluidization regimes are identified thanks to pressure signal analyses, like slugging, turbulent and fast fluidization, showing that regimes transitions are strongly affected by the temperature.

Pressure fluctuations in a fluidized bed of binary particles with significant differences in particle size

Pressure fluctuation signals are investigated in a binary particle fluidized bed in which two types of particles have similar physical properties but significant differences in particle size (90 μm Vs. 1800 μm). The relationship of the measured pressure drop to gas velocity exhibits a distinct ‘‘step’’ profile, indicating that the incipient fluidization of binary particle bed can be characterized by different stages, i.e. the fixed bed, the fine particle fluidization, the coarse particle partial fluidization and the binary particle complete fluidization. And then the statistical method and scale decomposition method are used to quantify pressure fluctuation amplitude and frequency in each stage. The result shows that when binary particles are completely fluidized, the bubble size and frequency in binary particle systems are larger than that in sole fine particle systems. Additionally, binary particle systems need higher gas velocity to achieve turbulent fluidization. Furthermore, the local solids holdup measured with optical fiber probes is also employed to verify the result of pressure fluctuation analysis.

Heat transfer in a fluidized bed tubular solar receiver. On-sun experimental investigation

Using particles as heat transfer fluid in a solar receiver is an attractive way to increase the global efficiency of solar power plants. In the case of the particle-in-tube solar receiver concept, the fluidized particles circulate vertically in tubes thanks to a controlled pressure gradient and an additional air injection. Experiments are conducted with olivine particles in a one-tube mock-up at the 1 MW CNRS solar furnace (France). The tube of high aspect ratio (more than 3 m height over 48 mm internal diameter) is irradiated along a 1-m height with several solar flux configurations that correspond to realistic operation conditions of a solar thermal power plant. The novelties of this paper lie in extending the operating parameters compared to earlier studies and in linking the fluidization regimes to wall heat transfer. Slugging, turbulent fluidization and fast fluidization regimes are detected within the receiver tube. It is shown that the system can tolerate high solar flux densities, up to 800 kW/m2. The system proves to be highly controllable and flexible with respect to particle mass flux variation and transient operations. Particle temperature increase ranges from 100 to 650 °C depending on the particle mass flux. Maximum thermal efficiency and particle outlet temperature of respectively ∼ 60 % and 680 °C are obtained, proving that this technology can be combined with highly efficient thermodynamic cycles. Global wall-to-particle heat transfer coefficient varies strongly with particle mass flux. It reaches a quasi-plateau above 15 kg/(m2s) with a mean value of 1000 ± 200 W/(m2K) and peaks data up to 1500 W/(m2K). A dimensionless heat transfer index is derived to account for the effects of the particle mass flux on the experimental results. It highlights that both increasing the temperature and working in the turbulent fluidization regime result in the increase of the heat transfer between the tube walls and the particles.

Micro-flow structure at regime transition from bubbling to turbulent fluidization in a fluidized bed

Gas-solid fluidized beds have found extensive utilization in frontline manufacturing, in particular as low-velocity beds. The fluidization status, the bubbling or turbulent flow regime and the transition in between, determine the system performance in practical applications. Though the convoluted hydrodynamics are quantitively evaluated through numerous data-processing methodologies, none of them alone can reflect all the critical information to identify the transition from the bubbling to the turbulent regime. Accordingly, this study was to exploit a coupling data processing methodology, in the combination of standard deviation, power spectrum density, probability density function, wavelet transform, and wavelet multiresolution method, to jointly explain the micro-flow structure at the regime transition from bubbling to turbulent fluidization. The transient differential pressure fluctuation was measured for the evaluation in a fluidized bed (0.267 m i.d. × 2.5 m height) with FCC catalysts (d¯p=65μm, ρp=1780kg/m3) at different superficial gas velocities (0.02–1.4 m/s). The results show that the onset of turbulent fluidization starts earlier in the top section of the bed than in the bottom section. The wavelet decomposition displays that the fluctuation of differential pressure mainly concentrates on the sub-signals with an intermediate frequency band. These sub-signals could be synthesized into three types of scales (micro-scale, meso-scale, and macro-scale), representing the multi-scale hydrodynamics in the fluidized bed. The micro-scale signal has the characteristic information of bubbling fluidization, and the characteristic information of turbulent fluidization is mainly represented by the meso-scale signal. This work provides a systematic comprehension of fluidization status assessment and serves as an impetus for more coupling analysis in this sector.

Effect of temperature on the hydrodynamics of a fluidized bed circulating in a long tube for a solar energy harvesting application

The particle-in-tube solar receiver concept for solar towers uses fluidized particles as heat transfer fluids. The experiments are conducted with a single tube of aspect ratio H/D = 67 irradiated over a 1-m height using concentrated solar energy. Olivine particles of Geldart’s Group A are used. Fluidization regimes are identified thanks to pressure signal analyses, and regime maps are plotted depending on the temperature in the range 150–700 °C. Both the local slip Reynolds number and the particle temperature govern the regime transitions. The limits and size of the turbulent fluidization regime domain decrease with temperature. The particle volume fraction also decreases with temperature. Finally, the intensity of the wall-to-particle heat transfer is discussed as a function of the fluidization regimes. As an indicator of the heat transfer intensity, a dimensionless coefficient is derived. This coefficient increases with temperature and exhibits the highest values for the turbulent fluidization regime.

Turbulent fluidization and transition velocity of Geldart B granules in a spout–fluidized bed reactor

Turbulent fluidization and transition velocity of Geldart B granules in a spout–fluidized bed reactor

Dimensioning Air Reactor and Fuel Reactor of a Pressurized Chemical Looping Combustor to Be Coupled to a Gas Turbine: Part 1, the Air Reactor

This paper provides a simple methodology for the design of the air reactor of a chemical looping combustor to optimize its characteristics when it is employed connected to a turbo expander to produce power. The design process, given a certain objective (e.g., electric power) defines the reactor specifics, namely height and diameter, taking into account the following aspects: solids inventory of the air reactor; gas velocity; air reactor transport disengaging height (TDH); solids concentration profile along the reactor height, dense bed height; freeboard height; pressure drop depending on air reactor injectors design and configuration. The total air reactor height was about 9.5 m, while the diameter was about 1.8 m. The total inventory was about 10,880 kg; while the circulation rate in the air reactor was about 110 kg/s. The operating pressure and temperature were, respectively, 12 bar and 1200 °C. The average velocity of the gases inside the reactor was about 4 m/s. The fluidization regime resulted to be comprised between turbulent and fast fluidization. Further work must be directed into the estimate of the pressure drop of the reactor, which will affect the plant efficiency in a considerable way.

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.

Experimental Study of an upflow Fluidized Bed: Identification of Fluidization Regimes

The concept of solar receiver using fluidized particles as heat transfer fluid is attractive from the point of view of its performance but also of the material used. In this concept, the receiver is composed of tubes subjected to concentrated solar radiation in which the fluidized particles circulate vertically. Circulation in the tubes, immersed in a “nurse” fluidized bed, is ensured thanks to a controlled pressure difference imposed on the latter and secondary aeration. This ventilation located at the bottom of the absorber tubes makes it possible to control the fluidization regimes. The latter strongly influence the parietal heat transfers and therefore the performance of the receiver. In order to better understand the conditions of appearance of these regimes and to better identify them, a study at room temperature was carried out with a tube 45 mm in internal diameter and 3.63 m in height. The tube is instrumented with several pressure sensors distributed over its height. More than 170 experiments have been performed exploring wide ranges of particle and aeration flow rates, with and without particle circulation. Signal processing methods, classically used in the scientific literature of fluidized beds, are applied. Combined together, these methods have enabled the identification of bubbling, pistoning (of the wall and axisymmetric), turbulent fluidization and rapid fluidization regimes. The pooling of all this information allows the establishment of a diagram of the fluidization regimes and their transition, showing that the local slip velocity is the key parameter governing the structure of the flow.

Research on abrasive pool machining method based on gas–solid two-phase flow

For complex curved difficult-to-machine parts, a new method based on pneumatic suspension abrasive pool bright finishing processing is proposed, using the mixing of pneumatic suspension abrasive, the workpiece surface, and fluidized abrasive to produce relative motion velocity, so that the solid particles and workpiece surface microscopic two-body abrasive wear to achieve the effect of precision machining. The experimental test material is the widely used Q235 steel plate. The experimental parameters include workpiece shape (round tube, square tube, cylindrical), abrasive particle size (24, 80, 120 mesh count), gas–solid two-phase flow pattern (dispersion fluidization state, turbulent fluidization state, spurting fluidization state), abrasive particle shape (sphere, irregular), and spindle speed (600, 900, 1200 rpm). An orthogonal test was designed according to the experimental parameters, and the degree of influence of each parameter on the processing of the abrasive cell was evaluated by the roughness of the workpiece surface together with the scanning electron microscope (SEM) micrograph of the workpiece surface, and the optimal combination of parameters was judged using the extreme difference method as well as the factor trend diagram. The results show that under the present experimental conditions, the workpiece surface roughness (Ra) can reach a minimum value of 0.4 μm. The feasibility of gas–solid two-phase flow processing is demonstrated from an experimental point of view, and the advantages of abrasive cell processing are explored.

Catalyst-scale investigation of polydispersity effect on thermophysical properties in a commercial-scale catalytic MTO fluidized bed reactor

The methanol-to-olefin (MTO) process is commercialized worldwide, yet the understanding of in-furnace phenomena is still lacking. Accordingly, this work explores the multiphase flow and thermochemical characteristics in a commercial-scale MTO fluidized bed reactor using a three-dimensional multiphase particle-in-cell model. After model validations, the intrinsic relationship of solid transportation and thermochemical properties is elucidated together with the study of the polydispersity effect on reactor performance. The non-uniform gas-solid distribution in the reactor demonstrates the turbulent fluidization regime. Heat transfer coefficients (HTCs) of about 300 and 200 W/(m2·K) are observed in the medium and upper regions, respectively. The small velocity, particle Reynolds number, temperature, and HTC correspond to those large-size catalysts in the dense region where particles are nearly close packing with a large solid volume fraction. Increasing particle size distribution (PSD) width increases the catalyst HTCs and the mass fraction of C2H4, promoting reactor performance. Besides, increasing the PSD width enlarges gas viscosity, gas specific heat capacity, and gas thermal conductivity but decreases gas density.

Anisotropy characterization of turbulent fluidization

The turbulence anisotropy in moderately dense turbulent fluidization is characterized with the aid of the barycentric anisotropy map (BAM). Therein, the phase-filtered anisotropy Reynolds stress tensor is considered to classify the possible states of turbulence into: 1C (one-dimensional), 2C (two-dimensional isotropic) and 3C (three-dimensional isotropic). The turbulence trajectories on the gas phase, as highlighted in the side Figure, have revealed a prevalent 2-D ellipse-like turbulence in the dilute regions, changing to 1-D turbulence in transition areas, and tend towards 3-D turbulence in elongated pancake-like at the interface and inside the clusters.

Computational simulations of hydrodynamics of supercritical methanol fluid fluidized beds using a low density ratio-based kinetic theory of granular flow

Hydrodynamics of fluid and particles were simulated using a low density ratio-based kinetic theory of granular flow (KTGF) in supercritical methanol (ScM) fluidized beds (FB). Results indicated that the fluidization state of the methanol fluid and particle mixtures change progressively from particulate to aggregative fluidization. A transition exists with wavy-like flows near the bottom and churn-like flows at the upper part along bed height, unlike the homogeneous fluidization in atmospheric methanol fluid FB and turbulent fluidization regime with particle strands in ScM FB. The threshold to identify the occurrence of strands was proposed in terms of mean value and standard deviation of solid volume fractions. The frequencies of particle strands increased with increasing methanol fluid temperatures and pressures. The computed fluid volume fractions agreed with experimental data in a supercritical carbon dioxide fluid fluidized bed.

Using wavelet analysis to characterize the transition from bubbling to turbulent fluidization

Turbulent fluidized bed (TFB) regime has demonstrated many advantages such as a combination of enhanced gas-solids contact and increased gas throughput, making it an optimal reactor in many industrial chemical and metallurgical processes. While the transition from bubbling to turbulent bed has been extensively investigated, some details still remain unclear such as the local transition velocity and the corresponding flow characteristics during the transition process. In this work, experiments were conducted in a conventional fluidized column with 0.267 m in diameter and 2.46 m in height and solids holdup was measured using an optical fiber probe in a superficial velocity range of 0.1–1.0 m/s. A discrete wavelet analysis method was proposed to extract quantitative information of bubbles/voids including the count and the lasting time. The local transition details and the onset velocity to the TFB regime in the fluidized bed were more clearly identified based on the extracted bubble/void information.