CFD SIMULATION OF FLOW REGIME MAPS IN A SLOT-RECTANGULAR SPOUTED BED Seyed Alireza Tabatabaei,’ Nader Mahinpey,"* Ehsan Esmaili’ and C. Jim Lim? 1. Department of Chemical and Petroleum Engineering, Schulch School of Engineering, University of Calgary, 2500 Univesity Drive NW, Calgary, AB, Canada, T2N 1N4 2, Department of Chemical and Bio-Resources Engineering, University of Bish Columbia, Vancouver, BC, Canada, V6T 123 ‘The recognition of low regimes i very important inthe application of spouted beds. In this paper, two-dimensional computer simulations of slo rectangular spouted bed using FLUENT commercial software were utlsed to constructflow regime maps. Two-phase gas-sold flows inthe bed were Simulated with computational ud dynamics (CFD) using the two-phase Elerian-Euleran granlar model. The numerical simulations were applied to predict diferent fw regimes. The constructed flow regime map for a bed containing solid particles with a diameter of 1.4mm was in good Sgreement with the experimental map previously reported elsewhere With this ucessul numerical mapping flow regime mapfor particles with 3 siameter of 3.77 mm was constructed for various supericial gas velocities and static bed heights. The map was composed a sxlitinc flow patterns, ‘thats fixed bed, internal je, jetin-uidized-bed, spouting, incoherent spouting and slugging. The slgging flow regime occurred at large value for the static bed height and aint velocity while the spouting regime arose by increasing the ar inlet velocity atlow values of staicbed height Unie the spouting regime, large pressure drop fuctuations were observed inthe incoherent spouting regime, Keywords: spouted bed, slot rectangular spout INTRODUCTION pouted beds have been successfully applied to various coating.) gasincation,") combustion, *") chemical vapour deposition"! and pyrolysis of different wastes, such as tres,” biomass” and plastics") In order to improve the design of spouted beds for optimal performance, a better understanding of the flow field and recognition ofthe low regimes are required, Some experimental, studies on the hydrodynamics, stability, scale-up and flow regimes of slotrectangular spouted beds have been reported"! ‘One of the advantages of two-dimensional (2D) spouted beds is, the capability of achieving different flow regimes with small variations inthe ar velocity or the orifice width ofthe air inlet. The regimes and stability of flow for a slotrectangular spouted bed have been obtained experimentally for different slot widths and vwidth-to-thickness ratios.) The reported detailed regime maps have contained eight identified flow regimes, including two types of spouting regimes. Flow regime maps for half slotrectangular spouted beds with different widths of air entrance and basal angles for 4mm polyethylene particles were reported by Dogan et al."! The authors reported five different flow regimes consisting of fixed bed, Internal jet, jetin-luidsed-bed, spouting and slugging. Freitas, et a2! analysed absolute pressure fluctuations ina slot rectangular spouted bed to investigate their applicability for flow regime identification without visual observation. Their results suggested that measured pressure fluctuations can be applied to recognise flow regime transitions in spouted beds. ‘The aforementioned identifications of flow regimes reported in the literature were based on experimental observations. However, {he literature concerning numerical simulations ofslot-rectangular beds is scarce, *~! and no previous work has been reported in which the preparation of low regime maps of slotrectangular [se] He cANADIAN JOURNAL OF CHEMICAL ENGINEERING | bea, flow regimes, multiphase flow, two-dimensional, CFD spouted beds have been performed using computational fluid ‘dynamics (CFD) simulations. Im the present study, a CFD technique based on a two-phase Bulerian-Eulerian granular model was employed to simulate gas— solid lows in a slot-rectangular spouted bed, The bed configuration ‘was based on the experimental setup of Dogan et al.” The Adjusted Di Felice model"! was used to describe the interfacial 4dragiorce. A two-dimensional analysis (2D) was performed, due to the large column width-to-thickness ratio in the slot rectangular spouted bed, with the 2D simulation conducted using FLUENT software. The validation of the model was accomplished by comparing the numerical results on the fountain height with ‘experimental data from Dogan et a." for various superficial gas velocities. {As the experimental data inthe literature were not comprehen- sive enough to cover the whole range of flow regimesin the spouted beds, the current numerical simulation was designed to predict the behaviour of rectangular spouted beds during operation. The flow regimes and hydrodynamic behaviour of the slot-rectangular spouted beds were studied for different superficial gas velocities and bed heights. Visual observation of the contours of the solid ‘volume fraction was used to identify the different flow regimes. ‘The regime maps were prepared based on various superficial gas velocities and bed heights fortwo different solid particle sizes. The numerical results for solid particles with a diameter of 1.4mm were compared withthe experimental data from Dogan et al."”! “Author to whom correspondence may be addressed. ‘Email addres: nader mahinpey@ucelgary.ca can, J. Chem. Eng. 91:1856-1864, 2013 {© 2013 Canadian Society for Chemical Enginecring Dot 10.1002/ejee21905 Published online § August 2013 in Wiley Online Library (ileyonlinelirary.com) [ vowume 91, NoveNtseR 2015 |DESCRIPTION OF THE MODEL The structure of the bed used in the current study is shown in Figure 1. The model had a 2D rectangular configuration that attempted to replicate that of the experimental work of Dogan etal"?! The height of the column (5) was 70 em; and, the widths of the column at the upper (a) and lower (y) sections were 15 and 4.em, respectively. The internal angle ofthe lower section (6) was 30°. An air entry slot width (3) of 6mm and various static bed heights (Hf) up to 30cm were considered in the simulations. ‘The particles used in the simulation had a sphericity of 1 and density (p,) of 2520kg/m’. The regime maps were prepared for particle diameters (d,) of 1.44 and 3.77 mm. For the simulations, a ‘maximum solid particle packing limit of 0.63 was chosen, due to the assumption of mono-dispersed spheres. The solid in the bed ‘was assumed to be at its maximum packing limit atthe beginning of the simulations. The density and viscosity of the inlet air were 1.225kg/m? and 1.7894 10 *kg/m-s, respectively, at a bed temperature of 20°C. ‘A restitution coefficient of 0.95 between particles was assumed. A sensitivity analysis on restitution coefficient was performed by Esmaili and Mahinpey"*! on three-dimensional CFD simulations of a gas-solid bubbling fluidised bed. The value of 0.95 showed the a Figure 1, Schematic ofthe slotrectangular spouted bed configuration. Lvotume 91, NovemueR 2015 | best agreement between the experimental flow regimes and the predicted values. GOVERNING EQUATIONS In this study, the Eulerian—Eulerian two-fluid model, which treats the gas and solid phases as fully interpenetrating continua, was used to simulate the hydrodynamics of a 2D spouted bed. The sum ‘of the volume fractions of all contributing phases was equal to one. ‘The balance in the volume fraction is: Yank a where sand g denote the solid and gas phases, respectively. “The continuity equation for phase sas follows a) ; Jeo) +¥- (eed =9 @) in which q uses both s and g indices to conserve the mass in the solid and gas phases ‘The conservation of momentum in the solid and gas phases are ‘given in Equations (3a) and (3b), respectively: 2 aogF + V (tet Fe) a aa) VF eaVP and tKel ane ao (apa) +9: (e050 04) Jonet)+¥- (n.d 0s) a) =V-% VP, aVP + oad +s The equations for the stress tensor are governed by Equations 0): Fea ~ tele +7) @ Fem ndPPe VON) Fad V0 e 6 > (90 4) —2ud 0-0, Zend © Fa (VO e+ (7 0)) Fad 0-0, egogtd © Ha anlOVs HOP +a (mz )T Fa @ 4 ca dugy (1+ ef Sy SVT EVE [4 1 ede (1 +e) 4 RE I Fatt] 6) 4 ate 6) 15 Fepsdagoll +2)= 6) ‘The granular temperature is described by Equations (10)-(14) woth Ge)" “ [THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING [16575]3[a “ 3 Fiano + vente] an Be VW = Vay 70 — 3K, a, = ke, VO, (2) _ Soden 6, et. +en(= fe, OEE Lh Sena] Bayo eo SE 3) =e a fay Yo, ae yes ay The interphase momentum exchange is computed using Equations (15)-(20): 36,9, Tite) ) Rug = 0 FEI, - 7 Nl) as) Fle) = (16) x= P-0-e9| OS a7 B= log(Re,) (a8) Where P and Q are adjusted to satsy the following relations a9) Ke . Samay pe)6 = Eugen (20) NUMERICAL SIMULATION FLUENT, a commercial CFD software package, was used to run the numerical simulations. The finite volume method was utilited to discretise the set of governing equations. Phase-coupled semi- implicit method for pressure-linked equations (PC-SIMPLE) provided the pressure-velocity coupling, The quadratic upstream {interpolation for convective kinematics (QUICK) and second-order upwind discretisation schemes were used to discretise the partial differential equations of volume fraction and momentum. ‘The two-fluid Eulerian-Eulerian approach was applied. In this approach, two interpenetrating phases are considered, and the properties of the solid phase are obtained by granular kineties theory. This technique considers separate sets of the conservation fof mass and momentum for each continuous and incompressible phase. In order to include the momentum transfer between the phases, the interfacial drag force was implemented using the adjusted Di Felice model of Esmaili and Mahinpey..* ‘The 2D computational meshed domain was composed of unstructured triangular cells in the cone base and structured square cells in the fest of the domain. Gambit meshing software ‘was utilised to generate the computational grids. The grid used in [Esse] THe CANADIAN JOURNAL OF CHEMICAL ENGINEERING | Swractured square ell on oos! Unstructured oo teangula cells obs Figure 2. Computational mesh, the domain discretisation is shown in Figure 2. The generated grids had node spacing larger than the particle diameter, that is 0.0025m. The mesh independency of the results was checked ‘with variation of the number of mesh elements [A fixed time step size of 1 10-*s was applied. A maximum of 50 iterations were used for each time step, and the convergence criteria of the solutions were assumed to be at scaled residuals of smaller than 10. A value of 0.2 forall under-relaxation factors was chosen, Two seconds of flow time simulation were necessary Experimental data Dogan etal. (17D [Numeritl simulation ute) Figure 3. A comparison between this studys numerical suits and the ‘experimental data of Dogan etal" on the fountain height for diferent values of superficial ar veloc. L vowuMe 91, NoveMBeR 2015 |os i os 02 on @ ) © @ © 0 @) Figure 4. Contours of the slid volume faction for different lw regimes for 2. 6mm and dy ~ 1.44 mm: (a fed bed, (b) internal je, ()jecinfudised- bed, (8) spouting, () transition, () incoherent spouting, (9) slugging (My to ensure a statistically steady-state condition, For large values of the bed height, up to 4 of flow time were considered. In order to reduce computational times, the symmetry boundary condition was assumed along the axis of symmetry; therefore, the required simulations were carried out in half of the 2D domain. The boundary condition at the entrance was considered as a velocity inlet with a uniform velocity profile. A pressure outlet boundary condition was applied at the outlet of the system. On the walls of the spouted bed, a no-slip boundary condition was considered, which assumes a zero velocity forthe flow and the partiles at the walls RESULTS AND DISCUSSION ‘The verification of the current model was checked through the comparison of the results of the fountain height in a slot rectangular spouted bed with the experimental data reported by Dogan et al." The results ofthe fountain height are presented in Figure 3 for the case ofl — 11cm, d, -0.86mm and 3. - 6mm for Gifferent superficial air velocities. This figure shows that the results of the 2D model did agree with the previously reported experimental results ‘The simulations of the gas-solid flows in the bed were conducted for various values of the effective parameters. The numerical results were analysed, and the model was validated by comparing the regimes predicted by the current model with the regimes that were observed experimentally by Dogan et al”! and Freitas ct al” The flow regimes were distinguished by visual observar tions of the contours of the solid volume fraction, Various flow patterns were identified at different operating conditions, as shown in Figure 4 for the case of =6mm and 4,—1.44mm. The flow regimes in Figure 4 for cases a-g were fdentified as fixed bed, internal jet, jetin-luidised-bed, spouting, transition, incoherent spouting and slugging flow, respectively For very low airflow rates, the flow stayed ata fixed bed regime. In the interna jt regime, a submerged cavity or jet was formed at the air inlet. The jetin-luidised-bed regime occurred when bubbles separated from the internal jet and fluiisation appeared {nthe upper part of the bed. With the increase in the ar flow rate, Lvotume 91, NovemueR 2015 | Temand and 4rmis for (¢ and), respectively, Hy = 30cm and u= Bris for (@) 0.5, 0.8, 1.05 and 2m/sfor (ad), respectively; Hy=21 cm and the internal jet grew and the particles formed 2 stable and non- ppulsating spout. The fountain above the bed surface in the incoherent spouting regime contained a pulsating variable height. ‘The transition regime demonstrated mixed characteristics of the jet-in‘luidised-bed and incoherent spouting flow regimes. In the slugging regime, slugs originated at the top of the submerged jets, causing the top Surface to rise and fall ‘The detailed descriptions of these flow regimes are presented elsewhere !""!"" all cases ofthe different flow characteristics, ‘good agreement with the previously reported experimental data ‘was found, revealing the capability of the proposed 2D model ‘The normalised fluctuations of bed pressure drop (the bed pressure drop divided by the mean value of the bed pressure drop) corresponding to the case presented in Figure 4 were plotted against time in Figure 5. The presented pressure fluctuations were in agreement withthe experimental data from Freitas etal.""' The differences between the flow regimes can be seen by comparing the normalised bed pressure drop fluctuations, For example, the particles had a relatively stable configuration in the spouting regime shown in Figure 4d. Therefore, based on Figure Sd, the bed pressure drop fluctuations were small with no periodicity. In the slugging flow regime (Figure 4g), the particle configuration dramatically changed due to the slugs. In Figure 5g, the large ‘bed pressure drop fluctuations are evident. ‘Based on the aforementioned validations, a full ow regime map for the case of 6mm and d,~ 1.44 mm was constructed and is. shown in Figure 6. The static bed height was varied from 4 to ‘30cm. The various superficial air velocities were examined to ‘obtain the transitions in the map. The transitions were distin- ‘guished by analysing the distributions ofthe solid volume fraction, In Figure 6, the new numerical map is plotted beside the ‘experimental map reported by Dogan etal." ‘Although the analysis partly failed to distinguish the regimes, for the lowest static bed height examined (Je. Hy=dem), the ‘numerical simulation was successfully applied inthe determination ‘of the mapping boundaries. It can be observed that the numerical simulation provided close agreement to the experimental data for transition lines around the jetin-luidised-bed (JF) regime. However, deviation between the predicted and experimental values [THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING [18595]@ Ann » © BRAN ARAVA AIA i) © 0 ® Figure 5. Normalised fluctuations of bed pressure drop versus flow time {or liferent flow regimes for »—6mm and ,—1-44rmm (2) fixed bed, (@) internal jel, (0) eLin-ucised-bed, (8) spouting, () transition, () incoherent spouting, (9) slugging (Hy = 11 em and y= 0.5, 08, 1-05 and 2mjstor (ed), respectively; thy=21 em and u=2 and 4s for (eand 0 respectively, H =30¢em and «= 3 mis for (Q) Jn transition from fixed bed (FB) to internal jet (U) is evident in Figure 6, The uncertainties in experimental data in the lower velocity range and the difficulties in observing the exact transition point may have been partially responsible for this deviation Examples of the detection of the map boundaries are presented in Figures 7-12. Although the examples are shown with an accuracy ‘0f 0.025 m/s for more resolution in displaying the transitions, the ‘mapping was constructed with an aceuracy of +0.0125 m/s, except for the transitions between internal jet and jet-in-fluidised-bed flows, which were detected with an accuracy of 0.025 m/s ‘A transition between fixed bed and internal jet regimes is shown in Figure 7 for H,=7 em, when smooth contour lines for the solid volume fraction can be seen in the cate of fixed bed flow. This transition can also be detected from Figure 8, in which contours of the solid velocity magnitude are presented. A comparison of the contours presented in Figure 8a and b reveals that a transition [Litseo] THe CANADIAN JOURNAL OF CHEMICAL ENGINEERING | os (Dogan ea 17) Figure 6. The regime maps obtained by current numerical simulations and ‘experimentation reported by Dogan eal!" for i= 61mm and 4,~1.44mm.F3, fixed bed flow I, internal jet flow, F, jetinluldised-bed flow SL, sigging low I, incoherent spouting flow; T, vanstional flow, ‘occurred by increasing the air velocity from 0.55 to 0.60m/s: at 0.5Sm/s, the particles around the air entrance were relatively stagnant ‘A transition from internal jet into jet-insluidised-bed flows is ‘shown in Figure 9, which presents the contours ofthe solid volume fraction for Hy—2Sem, This transition can be detected from Figure 10, in which the distributions of the solid volume fraction on. the symmetry line are presented. In tis figure, it can be seen that increasing the gas velocity above the value of 1.30m/s resulted in fluctuations on the gas-solid surface, which led to a decrease of more than em in the area without solids ‘A transition from jetin-luidised-bed to spouting flows is shown. in Figure 11 for Ff, ~7 em, which presents the contours ofthe solid volume fraction for the air velocities of 0.80 and 0.85 m/s. Figure 12 presents an example of the formation of incoherent spouting, in ‘which the contours ofthe solid volume fraction for Hy — 21 em atair velocities of 2,30™m/s and 2.35 m/s are presented, The incoherent spouting occurred just after the slug vanished above the fountain. ‘The difference between the spouting, incoherent spouting and slugging regimes could be detected if the larger ar velocities were ‘maintained. Different spout types for cases of Hy = 7 and 21 em can be observed in Figure 13a and b, in which the contours ofthe solid ‘volume fraction are shown at an air velocity of 3 m/s, Ifthe slug above the central jet did not vanish and instabilities were seen, the ‘slugging flow regime appeared. This case is presented in Figure 13¢ for the case of Fi, = 25m ata superticial air velocity of 3m/s. The normalised bed pressure drop fluctuations corresponding to these ‘eases ae plotted against time in Figure 14. As discussed by Freitas etal, different behaviours can be distinguished in bed pressure drop fluctuations for these different flow regimes. ‘The successful numerical predictions forthe solid particles with ‘a diameter of 1.44 mm allowed for the extension of the analysis to ‘other configurations. A similar procedure was applied to construct, 4 regime map for solid particles with a diameter 3.7mm. The ‘transition line between internal et and jet-in-fluidised-bed regimes was drawn with an accuracy of +0.025 m/s, For other transition | voLuMe 91, NoveMBeR 2013 |@ o) Figure 7. Contours of solid volume fraction in the transition from fixed bed to internal jet for Hy =7 em: (a) a fied bed at = 0.55 m/s (b) an internal jt at 02 18 on 0.08 ° @ CO) u=0.60mis, Figure 8, Contours of sold velocity magnitude_in the transition from fixed bed internal efor Hy at u=0.600mis. Doundaries, the mappings were prepared with an accuracy of £0.0125 m/s, The constructed regime map forthe case of .— 6mm. and d, = 3.77 mms presented in Figure 15. Itcan be seen that there are six different flow patterns in this case, thats fixed bed, internal jet, jetin-fluidised-bed, spouting. incoherent spouting and slug- ging flows. In this low regime map, the flow pattern of transition was not detectable. CONCLUSIONS ‘The gas-solid flows in a slotrectangular spouted bed were simulated using 2D computer simulations. The CFD technique 3 a y, os o4 os 02 on @ ) Figure 9. Contours of solid volume fraction inthe transi ietintojecinsucised-bedtor Hy ~ 25 em: (a) an internat atu (@) a jevinfludsed-bed at v= 1.35 mis 1 from internal 1.30mi, Lvotume 91, NovemueR 2015 | Tem: (a)afixed bed at 0.55 ms, (0) an internal jet with the two-phase Eulerian-Eulerian approach was applied using FLUENT software. The effects of variations in the superficial air velocity and static bed height on the flow regimes and hydrody- namic behaviour of the bed were investigated. The model verification was accomplished by comparing the predicted ‘numerical results of the fountain height with earlier experimental data, Good agreement was achieved “The 2D model was applied to assess its capability in predicting the flow regimes, which had been experimentally observed elsewhere, for a slot-rectangular spouted bed. The constructed regime map for a bed of solid particles with a diameter of 144mm_ ‘was verified by a map reported in the literature. In most operating, conditions, the model was able to predict the appropriate regime. Figure 10. Variations of solid volume factions on the symmetry ne of 2 bed with Fi, =25 em for diferent supercar veloc, [THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING Jo1661")06 os oa 03 02 ol ° @ Figure 11. Contours of said volume fraction in the transition from jet-n-lidised-bed to spouting for Hy = 7m: (a) jen flldised-bed at a5 mis spouting at @ ©) Figure 12. Contours of sold volume fraction for the change of flow pters from transition ta inceherent spouting for Hy 21 em: (3) Uwansition regime at v= 2.30mJs, (&) incoherent spouting atu 2.35 m/s 06 os oa 03 02. oa (a) Figure 13. Contours of slid volume fraction ofthe siferent flow patterns forthe supericial air velocity of 3 m/s: (a) spouting for. spouting fr Hy = 21 em, () slugging for H, = 25m, Litgeas] He CANADIAN JOURNAL OF CHEMICAL ENGINEERING | o) 0mm, (0) After the successful predictions of the flow regimes by the ‘numerical model, a regime map was introduced for a bed of solid particles with a diameter of 3.77mm, The new numerically ‘obtained map was composed of sx different flow regimes. NOMENCLATURE Cy drag coefficient, dimensionless d, solid particle diameter (m) restitution coefficient, dimensionless € gravitational acceleration (m/s*) B> radial distribution coefficient, dimensionless Hy static bed height (m) 1 nity mateix Ky gas-solid momentum exchange coefficient (kg/s -m°) Ko, conductivity of granular temperature (kg/m 3)) P gas pressure (Pa) P, solid pressure (Pa) Re — Reynolds number, dimensionless time (s) 4 airinlet velocity (m/s) V velocity vector (m/s) © © em, (B) incoherent L voLuMe 91, NoveMBER 2015 |Figure 14. Normalised fluctuations of bed pressure drop versus flow time {ot aiferent static bed heights a large superficial ar velocty of u= 3m/s for = 6mm and d,~ 144mm. The low regimes are (a) spouting at = 7m, (b) incoherent spouting at Hy = 21m and (6) slugging at Wy=25em an Figure 15, The regime maps obtained by numerical simulations for = 6mm and d, 3.77 mI nteraljet flow, jevinfudised-bed flow SI, sagging flowy: S,incaherent spouting flow: Greek Symbols 4 width of the column atthe upper section (mm) Y width ofthe column at the Lower section (m) Ye, dissipation of granular temperature (kg/(en )) Lvotume 91, NovemueR 2015 | 5 height of the column (m) 2 volume fraction, dimensionless ymax ‘Maximum solid packing, dimensionless bulk viscosity (kgy/(ms)) @ internal angle of the lower section (°) @, granular temperature (m*/s" 2° ar entry slot width (mm) viscosity (kg/(ms)) density (kg/m') © phase stress-strain tensor (Pa) Subscripts sg ms minimum spouting 3 solid ACKNOWLEDGEMENTS. ‘The authors wish to thank the Natural Sciences and Engineering Research Council (NSERC) for providing funding for this study. REFERENCES [1] R.N, Marzeto, J.T. 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