Fluidization Technology and Its Applications: Joe Zhou Engineering Technology Center

FLUIDIZATION TECHNOLOGY
AND ITS APPLICATIONS
Joe Zhou
Engineering Technology Center
Company Confidential
ISPE student conference Copyright © 2010 Eli Lilly and Company
STATUS OF PROCESS PLANTS
• 70% OF PROCESSES INVOLVES SOLIDS

• MORE THAN 70% OF OPERATIONS INVOLVING
SOLIDS HAVE PROBLEMS
• AVERAGE PLANT OPERATED AT 64% OF
ITS DESIGN CAPACITY
• VERY FEW ENGINEERING SCHOOLS IN US
OFFER UNDERGRADUATE COURSES IN PARTICLE
TECHNOLOGIES
What is Fluidization?
Fluidization Regimes
Pneumatic transport
Fast fluidization
Bubbling
Turbulent
Fixed
ΔP
L
Uf
What is Fluidization?
Vent
W
• ΔP = g
A
ΔP Solids
• Bed Height = Bed ΔP2
ρp(1-ε)g
ΔP
Distributor ΔP1
ΔPPlenum
Hot
Air
Plenum
Ergun Equation
150 μ u0 Lb (1 − ε ) 1.75ρ u Lb (1 − ε )
2 2
Δp = + 0
Dp 2
ε 3
Dp ε 3
Viscous Kinetic
Fixed Bed “Friction Factor”
Minimum Fluidization
ρ f umf2 ⎡150(1 − ε mf )μ ⎤
(ρ p − ρ f )g = 3 ⎢ + 1.75⎥
D pε mf ⎢⎣ D p umf ρ f ⎥⎦
1
Wen and Yu: Φε 3
s mf ≅
14
Thus a reasonable estimate of minimum velocity can

be obtained from
⎡ D ρ f (ρ p − ρ f )g ⎤
3
= ⎢(33.7 ) + 0.0408 ⎥ − 33.7

2 p
Remf
⎢⎣ μ 2
⎥⎦
Particle Shape
Sphericity Φs which allows calculation of an equivalent

diameter.
asphere 6 Dp
Φs = =
a particle S particle / V particle
Where Dp is the diameter of a sphere of the same

volume as the particle
Particle Spherity
CRUSHED COAL 0.75

CRUSHED SANDSTONE 0.8 - 0.9
ROUND SAND 0.92 - 0.98
CRUSHED GLASS 0.65
MICA FLAKES 0.28
SILLIMANITE 0.75
COMMON SALT 0.84
Unit Diameter
Since this is not true pipe flow must use

hydraulic radius.
⎛ cross − sectional area for flow ⎞

Dh = 4 × ⎜⎜ ⎟⎟
⎝ wetted perimeter ⎠
GELDART CLASSIFICATION
10000
Density differences ρs - ρg (kg/m)
3
1000
A
10 100 1000
Mean particle diameter ds (μm)
GELDART CLASSIFICATION
Group C Group A Group B Group D

Flour FCC Sand Wheat
Cohesive Aeratable Bubble Readily Spoutable
≤ 20 μm 20 < dS ≤ 90 μm 90 < dS ≤ 650 μm > 650 μm
Fluidization of Nano-particles
Inter-particle Forces
Solid-Like/Fuid-Like Boundary
The boundary between solid-like and fluid-like regimes
is given by the jamming transition.
Richardson-Zaki law:
Bog = f ( , )
Application – Pellets Coating
MULTIPLE-LAYER
COATED BEAD
COATING
SUSPENSION
AIR
Application – Drying
Application – Combustion
Application – Oil Refinery
Application – Thermal Pyrolysis
Two-Phase Reactors
Gas /Liquid
Catalytic Fluidized
Reactors Bed
Fixed Bed
Liquid
Gas-Liquid Reactors
Gas-
Liquid
Liquid Bubble
Ga Column
s Gas-Liquid
CSTR
Gas
Three-Phase Reactors
Three Phase Catalytic Reactors
Liquid
Gas
Liqui Liquid Liquid

d Gas Gas Gas
Cocurrent Cocurrent Bubble Slurry Three-Phase Fluidized
Downflow Upflow Packed Column Column
Trickle Bed Bed
Liqui Gas-Liquid Catalytic CSTR
d Slurry Reactor
Ga
s
Bubble Behavior
Modeling
Ci=qLCi,L+qHCi,H
HIGH DENSITY LOW DENSITY
VH=AHH VL=ALH
QH=uHAH QL=uLAL
qH=QH/Q q=QL/Q
ΦH=AH/Ac ΦL=AL/Ac
INTERPHASE
MASS TRANSFER
FLOW Alkq(Ci,L-Ci,H) FLOW
uHdCi,H/dz uLdCi,L/dz
REACTION REACTION
ρHRi,HCH ρLRi,LCL
DISPERSION AC=AL+AH DISPERSION
-Dz,Hd2Ci,H/dz2 -Dz,Ld2Ci,L/dz2
Ci,IN
Q=UAC Q=QL+QH
Bubble Calculations
0 .8
⎛ ⎞
Db = 0.54 g − 0.2 (U f − U mf ) ⎜ h + 4 Ao ⎟
0 .4
DARTON ⎜ N o ⎟⎠
⎝
WERTHER [
Db = 0.00863 1 + 27.2(U f − U mf ) ] (1 + 6.48h )
1
3
0.1.21
CRANFIELD
Db = 2.255 (U f − U mf )1.11
& GELDART h 0.81
GELDART [
Db = 1.43 g − 0.2 Ao (U f − U mf ) ]+ 0.027 h(U
0 .4
f − U mf )
0.94
Db = g − 0.25 (U f − U mf ) h 0.75
0 .5
ROWE
h
− 0 .3
MORI & WEN Db = Dbm − (Dbm − Dbo ) e D
−3
Where Dbo = 3.76 ⋅ 10 U f − U mf ( ) and
[
Dbm = 0.374 π (U f − U mf )D 2 ]
0.4
Bubble Calculations
Air, Uf = 0.18 m/s, ATMOSPHERIC PRESSURE, 85 C
dp = 300 μm, ρp = 2000 kg/m3, εmf = 0.4
D = 0.91 m, z = 0.31 m
BUBBLE SIZE, mm
DARTON WERTHER CRANFIELD GELDART ROWE MORI &

& GELDART
WEN
61 55 55 87 99 24
Summary
• Be critical when use information in

literatures
• Never too late to learn
• Good fundamental understanding

is critical

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FLUIDIZATION TECHNOLOGY

AND ITS APPLICATIONS

• 70% OF PROCESSES INVOLVES SOLIDS

Thus a reasonable estimate of minimum velocity can

= ⎢(33.7 ) + 0.0408 ⎥ − 33.7

Sphericity Φs which allows calculation of an equivalent

Where Dp is the diameter of a sphere of the same

CRUSHED COAL 0.75

Since this is not true pipe flow must use

⎛ cross − sectional area for flow ⎞

Group C Group A Group B Group D

Liqui Liquid Liquid

dp = 300 μm, ρp = 2000 kg/m3, εmf = 0.4

DARTON WERTHER CRANFIELD GELDART ROWE MORI &

• Be critical when use information in

• Never too late to learn

• Good fundamental understanding

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