Chapter 5

Fluidization

Instructor: Dr. Mohammad Al-Harahsheh

Department of Chemical Engineering
Jordan University of Science and Technology
 Introduction

When a fluid is pumped upward through a bed of fine solid particles at
a very low flow rate the fluid percolates through the void spaces
(pores) without disturbing the bed. This is a fixed bed process

The pressure drop is proportional to the rate of flow

( − ∆P )
Q = KA
l

If the upward flow rate is very large the bed mobilizes pneumatically
and may be swept out of the process vessel (transport of particles).

At an intermediate flow rate the bed expands and is in what we call an
expanded state. The frictional drag on the particles becomes equal to
their apparent weight the bed expands and the voidage increases. If
the fluid velocity increases further the individual particles separate
from one another and become freely supported in a fluid. The bed is
called here fluidized
 The Phenomenon of Fluidization

Or aggregative fl.
groupa3.mpg

groupb1.MPg

Particulate fl.
groupb2.MPg Increasing fluid velocity

groupc.MPg

slugging.MPg

Increasing fluid velocity

JUST Department of Chemical Engineering ChE 362 Unit Operations Chapter 5-3
JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-4

When a fluid is pumped upward through a bed of fine solid particles at a very low flow rate
the fluid percolates through the void spaces without disturbing the bed. The particles are in
direct contact with each other, supporting each other’s weight. This is a fixed bed process.

At an intermediate flow rate the bed expands and is in what we call an expanded state. In
the expanded bed the particles have a mean free distance between the particles and the
particles are supported by the drag force of the fluid. The expanded bed has some of the
properties of a fluid and is called a fluidized bed. There is a minimum fluidization velocity,
VoMF, at which the bed just begins to fluidize.

If the upward velocity is very large the bed mobilized pneumatically and may be swept out
the process vessel.

Batch Fluidization, particles stay in bed

Fixed Bed, no movement of particles (VoMF < Vo < ut) Mobilized bed, particles entrained
(Vo < VoMF) (Vo > ut)

JUST Department of Chemical Engineering ChE 362 Unit Operations Chapter 5-5
 Definition

Fluidization is the operation by which solid particles are transformed into
fluidlike state through suspension in a gas or liquid.

cyclone2.MPg

Particle size: 10 µm – 6 mm

Bed diameter: 0.1 m – 10 m

Bed height: few cm – 10 m

Superficial velocity: 0.01 m/s – 10 m/s

JUST Department of Chemical Engineering ChE 362 Unit Operations Chapter 5-6
 Liquidlike Behavior of a Fluidized Bed

Light objects float on top of the bed (i.e., objects less dense than the bulk
density of the bed)

The surface stays horizontal even in tilted beds

The solids can flow through an opening in the vessel just like a liquid

Levels between two similar fluidized beds equalize their static pressure
heads

The beds have a “static” pressure head due to gravity, given by ρgh

duck1.MPG

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-7

 Advantages of Fluidization

Smooth, Liquid-like behaviour of particles → easy to control and automate

Rapid and well mixing of solids:

→ Uniform temperature and concentrations

→ Resists rapid temperature changes, hence responds slowly to changes in

operating conditions and avoids temperature runaway with exothermic
reactions

Circulate solids between two fluidized beds → possible to remove (or add)
the large quantities of heat produced (or needed) in large reactors

Applicable for large or small scale operations

Heat and mass transfer rates are high → requiring smaller surfaces.

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-8

 Disadvantages of Fluidization

Bubbling beds of fine particles are difficult to predict.

Rapid mixing of solids causes non-uniform residence times for continuous

flow reactors

Particle breakup.

Pipe and vessel walls erode due to collisions by particles.

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-9

 Industrial Applications of Fluidized Beds
 Chemical reactors

 Combustion

 Roasting of ores

 Heat exchange

 Drying of solids

 Coating

 Granulation

 Adsorption/desorption

 Regeneration of catalysts

JUST Department of Chemical Engineering ChE 362 Unit Operations Chapter 5-10
 Fluidized bed solid cooler

FCC unit
JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-11
 FCC unit

ChE 362 Unit Operations Chapter 1-12

JUST Department of Chemical Engineering
 Conditions for Fluidization
Fine material

∆P 150Voµ (1 − ε )
2
= ≡ Vo MF
L φs2 D p2ε3

A: ∆P across the bed counterbalances the force of gravity on the particles

B: The particles become separated enough to move about in the bed and true
fluidization begins

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-13

 Voidage at Minimum Fluidization Velocity

εMF depends on the shape of the particles. For spherical particles εMF is
usually 0.4 – 0.45.

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-14

 Relation Between Bed Height and Voidage

Mass of solid particles, ms = LA C (1 − ε)ρp = constant

→ L1A C (1 − ε1 )ρp = L 2 A C (1 − ε 2 )ρp

L1 (1 − ε 2 ) (1)
or =
L 2 (1 − ε1 )
εM F
εM

L M (1 − ε MF ) (2)
Example : =
L MF (1 − ε M )

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-15

 Pressure Drop
Fg
FD = ∆PA c
Fg = ( LA c (1 − ε)ρP ) g
FB = ( LA c (1 − ε)ρ ) g
FD FB
FD = Fg − FB

∆P
⇒ = (1 − ε)(ρP − ρ)g (3)
L

At minimum fluidization:

∆P
= (1 − ε MF )(ρP − ρ)g (4) ≡ Vo MF
L MF

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-16

 Minimum Fluidization Velocity
1. Ergun equation:

∆P 150Voµ (1 − ε ) 1.75ρVo2 1 − ε
2
(5) ∆P
= + = (1 − ε MF )(ρP − ρ)g
L 2 2 3
φs D pε φs D p ε3 L MF

At minimum fluidization: Vo = Vo MF ; L = L MF ; ε = ε MF ; ∆P = Eqn.(4)

2
1.75  D p Vo MFρ  (1 − ε ) D p Vo MFρ D3p ρ(ρP − ρ)g
(5) →   + 150 3 2
MF
− =0 (6)
ε MF φs 
3
µ  ε MF φs µ µ 2

1.75 (1 − ε MF )
( )
2
Re MF + 150 ReMF − Ar = 0 (7)
ε MF φs
3
ε MF φs
3 2

D3pρ(ρP − ρ)g
Ar ≡
µ2
Ar: is the dimensionless number known as the Archimedes number

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-17

 Minimum Fluidization Velocity
a. For ReMF < 1 (small particles):

Inertia term in equation (6) is negligible:

g(ρP − ρ) ε3MF 2 2
Vo MF = φs D p (8)
150µ 1 − ε MF

b. For ReMF > 1000 (large particles):

Viscous term in equation (6) is negligible:

1
 φs D p g(ρP − ρ)ε3MF  2
(9)
Vo MF ≅ 
 1.75ρ 

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-18

 Minimum Fluidization Velocity
2. Wen and Yu correlation (DP > 100 µm):
Vmf is a function of both εmf and ϕs which are difficult to estimate.

What if εMF (and may be φs) is unknown?

1 (1 − ε )
Wen and Yu found for many systems: φs ε MF ≅ and 3 MF2 ≅ 11
3

14 ε MFφs

(
Re MF = 33.7  1 + 3.59 × 10−5 Ar ) − 1
0.5
→ (7)
 
(10)

3. Baeyens and Geldart correlation (DP < 100 µm):

g 0.934 (ρP − ρ)0.934 D1.8

Vo MF =
p (11)
1110 µ 0.87
ρ 0.066

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-19

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-20
 Example
A bed consists of uniform particles of diameter of 3mm and density
4200kg/m3. what will be the minimum fluidizing velocity in a liquid of
viscosity 3 mN.s/m2 and density 1100 kg/m3

D p3 ρ ( ρ p − ρ )
Ar = g = 1.003 ×105
µ2

For Dp>100µm

(
Re MF = 33.7  1 + 3.59 × 10−5 Ar ) − 1
0.5

 

Re MF = 38.58
3 × 10−3
VoMF = 38.58 −3
= 0.0354m / s
3 ×10 *1100
What answer would be if use Eq. (7)? VoMF = 0.0363m / s Error 2.5%

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-21

 ( o)
Operating Velocity V
Vo MF < Vo < u t

Vo MF based on D p = Ds ( )smallest particle

u t based on Dp = D p
1
D p = Ds =
( Dp )
n
∑ xi
i =1 i

(1) For ReP < 1 (small particles):

g (ρp − ρ ) D2p g(ρP − ρ) ε3MF 2 2 ut 8.33 (1 − ε MF ) (12)
ut = Vo MF = φs D p → =
18µ 150µ 1 − ε MF Vo MF φs2ε3MF

ut
For sphere with ε = 0.45; ⇒ V = 50 so if bed fluidizes at 10mm/s it could be operated with
MF
oMF
500mm/s with minimum particle carry over
If wide particle size distribution there will be more carryover  can be returned by
cyclone
Sphericity plays marginal role because with low ϕ higher ε  its effect is cancelled

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-22

 Operating Velocity ( Vo )

(2) For ReP > 1000 (large particles):

1
gDp ( ρ p − ρ )  φs D p g(ρP − ρ)ε 3
 2 ut 2.32
ut = 1.75 Vo MF ≅ 
MF
 → = 32 (13)
ρ  1.75ρ  Vo MF ε MF
ut
For sphere with ε MF = 0.45; ⇒ V = 7.7 more entrainment will be expected when operation
is at several times the V oMF
oMF

Considered as slight disadvantage of fluidizing large particles

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-23

 Example:
Solid particles: Dp = 0.12 mm, φs = 0.88, ρP = 1000 kg/m3
ms = 300 kg, AC = 0.3 m2, εMF = 0.42
Calculate L MF , ∆PMF , Vo MF
Solution:
For air @ 2 atm, 25 oC: ρ = 2.374 kg/m3, µ = 1.845 × 10-5 Pa.s
m
Volume of solid particles, Vs = s = 0.3 m3 = constant
ρP
→ Vs = L MF A C (1 − ε MF ) → L MF = 1.724 m Air @ 2 atm, 25 oC

∆P
= (1 − ε MF )(ρ P − ρ)g → ∆P = 0.0978 × 105 Pa
L MF

Using Ergun eqn (6): Vo MF = 0.00503 m/s

Using Wen and Yu correlation (10): Vo MF = 0.0046 m/s Error =8.5%

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-24

 Types of Fluidization
Particulate Fluidization Bubbling Fluidization

Fluid mainly liquid mainly gas

(ρP - ρ) small large
DP small large

even and smooth fluidization uneven fluidization

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-25

 Expansion of Fluidized Beds
The fluidized bed expands as the superficial velocity increases.

∆P  ∆P 
= (1 − ε)(ρP − ρ)g (3) as ( Vo ↑ ) → ( ε ↑, L ↑ ) →  ↓
L L 

(a) Particulate Fluidization:

The expansion is uniform and the Ergun
eqn, which applies for fixed beds, holds
approximately for the slightly expanded
bed (assuming laminar flow):
∆P 150Voµ (1 − ε )
2
= (14)
L φs2D p2ε3

ε3 150Voµ
= (15)
g ( ρ p − ρ ) φs D p
(3) & (14) → 1 − ε 2 2
Liquid Liquid Liquid

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-26

 ε3 150Voµ
=
1 − ε g ( ρ p − ρ ) φs2 D 2p

For 510 µm particles:

Actual values less
than predicted due
variation in ɛ

Figure 7.13 Bed expansion in particulate fluidization

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-27

 Expansion of Fluidized Beds
- The expanded bed height may be obtained from
(1 − ε MF )
L = L MF (15)
(1 − ε)
- For particulate fluidization of large particles in water,

Figure 7.15

m
Vo  ε 
=  (16)
Vo MF  ε MF 

D p Vo MFρ
Re MF =
µ
JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-28
 Example:
Fluidized bed of glass beads: Dp = 1.1 mm, φs = 1, ρP = 1.24 g/cm3, εMF = 0.40
1. Calculate Vo
MF
2. What velocity is required to expand the bed by 25%?
Solution:
For water @ 20 oC: ρ = 1 g/cm3, µ = 0.01 Poise
2
1.75  D p Vo MFρ  (1 − ε MF ) D p Vo MFρ D p ρ(ρP − ρ)g
3

  + 150 3 2 − =0
ε MF φs 
3
µ  ε MF φs µ µ 2

D p Vo MFρ water @ 20 oC
→ Vo MF = 0.194 cm/s → Re MF = = 2.65
µ
L (1 − ε MF ) (1 − 0.4)
For 25% expansion: L = 1.25 LMF ⇒ = → 1.25 = → ε = 0.52
L MF (1 − ε) (1 − ε)
m 3.9
Vo  ε  Vo  0.52 
Fig.7.15 : m ≈ 3.9 → = → =   → Vo = 0.54 cm/s
Vo MF  ε MF  0.194  0.4 

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-29

 Expansion of Fluidized Beds
(b) Bubbling Fluidization (two-phase model):
Here expansion comes mainly from the space occupied by gas bubbles

fb: fraction of bed occupied by bubbles ( ub )

u b : average bubble velocity

1-fb: fraction of bed occupied by dense phase

(Vo MF )

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-30

 Expansion of Fluidized Beds

(b) Bubbling Fluidization:

Volume balance for the gas phase:

Vo A c = f b u b A c + (1 − f b )VoMFA c (17)
Volume balance for the particle phase: ub

L MF = L (1 − f b ) (18)
L
LMF
Area = AC

Combining the above equations:

Q MF = Vo MFA c Q = Vo A c
L u − VoMF
= b (19)
L MF u b − Vo

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-31

 The bubble velocity in a fluidized bed is given by empirical Eq:

u b ≅ 0.71 gDb (20)

Db: the bubble diameter, m z

0.54
( )
0.8
D b = 0.2 ( Vo − Vo MF ) z + 4N −0.5
0.4
(21)
g

z: level in bed, m

N: number of holes in distributor per unit area, m-2

JUST Department of Chemical Engineering Ch E 362 Unit Operations Chapter 5-32

Categorization of Solids 1

Fine low density particles fluidise more evenly

compared to large dense once provided that particles
are not so small to give rise of the effect of London-
van-der Walls forces

The more spherical the particles the better they will
fluidise. Needle shaped particles are the most difficult
to fluidise

Particles of mixed sizes will usually fluidise more
evenly than those of uniform size

The presence of small proportion of fine particles will
aid fluidisation of course particles by coating them
with a lubricating layer
Categorization of Solids 2
 Categorization of Solids 3

Group A particles (30-100µm) are characterized by

• Bubbling bed fluidization,
• The bed expands considerably before bubbling occurs,
◊ Gas bubbles rise more rapidly than the rest of the gas,
◊ Bubbles spit and coalesce frequently through the bed,
◊ Maximum bubble size is less than 10 cm,
• Gross circulation of solids occurs.
• Example: cracker catalyst.
Group B (100-800 µm) particle beds are the most common. These
beds
• Are made of coarser particles than group A particles and more dense,
• Form bubbles as soon as the gas velocity exceeds Vmf,
• Form small bubbles at the distributor which grow in size throughout the bed,
• No evidence of maximum bubble size
• Have bubble sizes independent of the particle size
• Example: Sand.
Categorization of Solids 4

Group C (20µm) particles

• Are difficult to fluidize and tend to rise as a slug of solids,
• Form channels in large beds with no fluidization, and
• Tend to be cohesive.
• Example: flour, fine silica.
Group D (1000µm) particles
• Are very large, dense particles,
• Form bubbles which coalesce rapidly and grow large,
• Form bubbles which rise slower than the rest of the gas phase,
• Form beds whose dense phase surrounding the bubbles has low voidage,
• Cause slugs to form in beds when the bubble size approaches the bed diameter,
and
• Spout from the top of the bed easily.
• Example: wheat, metal shot.