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Abstract
The application of fluidized bed combustion (FBC) technology to energy generation from sugar cane bagasse has been prevented, amongst
other reasons, by the difficulties associated with fluidizing this material. This difficulty arises because bagasse is often lightweight and of
unusual morphology, and manifests itself by either matting-up within the bed (if there is not enough inert diluent) or by segregating out,
usually floating to the surface (if the inert bed material is incorrectly chosen). So, the potential benefits of mixing inert solid and fuel,
desirable for efficient combustion, is lost. For FBC to be viable, proper mixing of inert fluidizing solids and fuels are necessary. A model is
presented in order to explain the mixing and segregation behaviour of binary particles in fluidized beds. The conditions corresponding to
equilibrium mixtures can be theoretically predicted from the physical properties of the system. Experimental observations in a gas fluidized
bed are shown to support the theory. Fluidized binary mixtures exhibit no tendency to segregate under a particular combination of solids and
fluid volume fractions. In these cases, the mixture remains stable, even in the absence of mixing forces. The application of the theory to
bagasse combustion in fluidized bed is discussed. q 1999 Elsevier Science Ltd. All rights reserved.
Keywords: Bagasse; Fluidized bed combustion; Energy generation
Fig. 1. Mixing and segregation behaviour of binary particles in fluidized bed (fluid velocity increasing from (a) to (e)).
M.G. Rasul, V. Rudolph / Fuel 79 (2000) 123–130 125
reached when the whole system is entirely mixed (Fig. 1(c)). volume fraction of particle 2. The bulk density of the mixed
This represents an equilibrium condition for that mixture bed and local voidage are given by,
from which it will not segregate on its own accord. The
rbm erf 1 a1 r1 1 a2 r2
4
inversion velocity depends on the bulk bed composition.
If the fluid velocity is then further increased, a new pure
layer of component 1 forms above the mixed part of the bed
e 1 2 a1 2 a2
5
(Fig. 1(d)). With further increase in fluid velocity, the bed For a binary mixture of fluidized particles, Eq. (2) becomes
may completely segregate again with component 2 at the
DP
bottom (Fig. 1(e)), if fluid velocity is less than Ut1. Details of a1
r1 2 rf g 1 a2
r2 2 rf g
6
this behaviour can be found elsewhere [10]. L
A variety of models for particulate liquid fluidized beds Combining Eqs. (1), (3) and (6),
have been proposed from quite different theoretical bases
[11–15]. However, a comparative study [10] showed that 17:3 n
a1
r1 2 rf g 1 a2
r2 2 rf g 10:336n
only the model developed by Gibilaro et al. [15] satisfactorily Re
explained the above observations, as outlined below. For
rf Uf2
expanded fluidized beds operating in the intermediate flow 1=n
a 1 a2
1 2 a1 2 a2 24:8
7
regime, the pressure drop over a wide range of both flow and davg 1
voidage conditions is given by Gibilaro et al. [15] as, For a given fluid velocity Uf, the volume fraction pair a 1
1=n and a 2 which satisfy Eq. (7) may be obtained. These then
DP 17:3 n rf Uf2
10:336 n
1 2 ee24:8
1 provide a corresponding mixture density locus using Eq. (4),
L Re d
as shown in Fig. 2 for rutile (avg d1 90:5 mm;
where n is the Richardson–Zaki [16] exponent given as, n r1 4200 kg=m3 ) and sand (avg d2 231 mm;
2:55 2 2:1tanh
20e 2 80:33 3 and Re is the Reynolds r2 2450 kg=m3 ) system fluidized in water at ambient
number given by Re rf Uf d=mf . The pressure drop over temperature. It is then postulated [15] from elementary
the fluidized suspension is also given by the weight of the stability considerations that the composition of bottom
particles, zone corresponds to the point for which the bulk density
DP is maximum. In effect, this minimizes the potential energy
1 2 e
rs 2 rf g a
rs 2 rf g
2 of the mixed part of the system.
L
In applying Eq. (1) to binary-solid fluidized beds, the aver-
age value of the particle diameter may be taken as, 3. Model interpretation and criteria of binary particles
d d
a 1 a2 to mix and invert
davg 1 2 1
3
a1 d 2 1 a2 d 1
The phenomena shown in Fig. 1 can be interpreted by the
where a 1 is the volume fraction of particle 1 and a 2 is the calculation of mixture bulk density and bulk density of each
126 M.G. Rasul, V. Rudolph / Fuel 79 (2000) 123–130
Fig. 3. Mixture and monocomponent bulk density as a function of superficial fluid velocity of rutile–sand system.
particle when fluidized separately. Fig. 3 shows the calcu- particles to mix completely and invert (with no external
lated bulk density of sand and rutile mixture (cf. Fig. 2) and mixing force) in a fluidized bed are as follows [10]:
the bulk density of a monocomponent bed of sand and rutile
• small particles are more dense (component 1);
as a function of superficial fluid velocity. Fig. 3 can be
• big particles are less dense (component 2);
interpreted and analysed as follows:
• r b1 intersects r b2 in operating flow range;
• Ut1 , Ut2 ; Ut1 . Umf 2 ; and
• For this particular mixture when Uf is at A, the maximum
• at least particle 1 is fluidized in operating flow range.
bulk density corresponds to a monocomponent bed of
component 1 (i.e. a2 0). The interpretation of this is Therefore, for a given mixture, suitable operating conditions
that the most stable particle arrangement corresponds to can be chosen, in order to completely mix both the compo-
complete segregation, i.e., two superimposed monocom- nents.
ponent zones with component 1 at the bottom (Fig. 1(a)).
• At fluid velocities in the range B (between A and C), the
maximum bulk density corresponds to a mixture of both 4. Experimental observations in gas fluidized systems
components. The densest mixture composition changes
with the fluid velocity, but can be calculated or measured. Mixing forces induced by bubbles bursting within a gas
In this flow range, the binary particles form a completely fluidized bed must be minimised in order to observe the
mixed bed or a mixed part at the bottom of the bed and a mixing/segregation behaviour under discussion. This can
pure layer of excess component floating at the top of be done by making the observation within the gas flow
mixed part depending on the flow conditions, as shown range between minimum fluidization velocity (Umf) and
in Fig. 1(b)–(d). minimum bubbling velocity (Umb). The minimum bubbling
• When fluid velocity is in the range C, the bed segregates velocity, Umb, is defined as the point at which the maximum
completely again, this time with component 2 at the dense phase voidage, e mb is attained. For fine particles
bottom (Fig. 1(e)). At fluid velocity equal to or greater (dp p 150 mm) this condition can be easily observed. For
than Ut of component 1, the bed is entirely filled with coarse particles (about dp . 150 mm) the maximum dense
monocomponent of particle 2, as all of particle 1 is phase voidage occurs at Umf and an increase in superficial
washed out of the bed at that velocity. velocity beyond this point produces bubbles [18]. The ratio
Umb =Umf gives a measure of the degree to which the bed can
Experimental verification of this theory in particulate be expanded. This ratio is relatively high for fine low
liquid fluidized bed can be found elsewhere [10,17]. The density solids and gas of high density and a value of 2.8 is
fluidized binary mixtures exhibit no tendency to segregate reported in the literature as a reasonably wide expansion of
under a particular combination of solids and fluid volume the bed [19–21].
fractions. The equilibrium conditions corresponding to Since, particulate expansion of the bed material in gas
complete mixing (Fig. 1(b)) can be theoretically predicted system occurs up to Umb, it is necessary to know Umb of
from the system physical properties. The criteria for binary the particles. Experimentally [19–21], it has been found
M.G. Rasul, V. Rudolph / Fuel 79 (2000) 123–130 127
Table 1
Experimental results of FCC and pumice
Particles Size range (mm) Average size (mm) Umf (mm/s) e mf (mm/s) Umb (mm/s) Umb/Umf (–)
that for fluid cracking catalyst (FCC) of size about 60 mm bed. Air was used to fluidize the bed and its flow rate was
and particle density range 950–1500 kg/m 3, the dense phase measured by calibrated rotameters.
voidage (e e) reaches its maximum
ee emb and then A binary mixture of 150 g FCC and 50 g pumice was
decreases to a constant value as the gas velocity is increased, fluidized and their mixing and segregation behaviour were
with a maximum Umb of 2.8Umf. Measured particle proper- observed at different superficial air velocity. At Uf 4:75
ties for FCC and pumice, given in Table 1, satisfy the mm/s, the bed was observed to be completely mixed. The
criteria for binary particles to mix and invert in the flow flow was then reduced slowly to Uf 3:17 mm/s, where it
range of Umf to Umb. The experimental verification was was kept for 2 h to reach the steady state. At steady-state,
carried out for these materials. the bed was observed to have an upper part dominated by
Fig. 4 shows the loci of the bed bulk densities for the pumice particles, which was expected at that flow. On the
above mixture as a function of the pumice volume fraction, other hand, at Uf 6:13 mm/s, the bed was observed to
a 2, evaluated from the Eqs. (3), (4) and (7). The figure have small discrete layer of floating FCC particles. These
shows that at a superficial air velocity of less than 4 mm/s, qualitative observations coincided with the predicted states,
the maximum bulk density corresponds to a monocompo- confirming that the prediction method is sound.
nent bed of FCC particles (i.e. a2 0), predicting complete
segregation, i.e. two superimposed monocomponent zones,
where FCC settles into the bottom layer. On the other 5. Application of the theory to bagasse fluidization and
hand, at a superficial velocity of more than 5 mm/s, the combustion
maximum bulk density corresponds to a monocomponent
bed of pumice particles (i.e. a1 0). At higher velocities The properties of the inert solid are the key to achieving
the pumice settles at the bottom of the bed with FCC at the satisfactory fluidization, and the size, density and shape are
top. In the air velocity range between 4 and 5 cm/s the bed the critical variables to consider. Based on the criteria
bulk density apparently remains about constant for all proposed in Section 3, the inert fluidizing solids must be
mixtures which indicates that the selected binary particles denser than bagasse and with a terminal free-fall velocity
will mix at all concentrations under this condition. smaller than that of bagasse. Possible inert materials include
Experimental observations were carried out in a fluidized pumice, porous alumina, cenolyte and expanded clays.
bed (i.d. 5 cm, height 1.8 m) made of perspex. A porous Bagasse properties such as particle size and shape, and
sintered plate distributor was fitted at the bottom of the the moisture content of the feed bagasse are also important.
If bagasse physical properties are determined first, then, this agreement with the prediction, confirming that the predic-
theory can be used to select the second solid. The bagasse tion method can be successfully used for selecting inert
used in this study was collected from Rocky Point mill, fluidizing solids to facilitate fluidization of bagasse includ-
Queensland, Australia and was washed and dried before ing other biomass. These conditions can be used for design-
use in the experiments. The physical properties including ing a fluidized bed combustor for bagasse.
particle density, hydrodynamic equivalent diameter and A number of other binary systems, Table 2, were inves-
drag co-efficient were determined [22]. The particle density tigated to illustrate segregation if an incorrect choice of inert
of the bagasse used in this study was found to be 492 kg/m 3 solids was made. The theory predicts that for these systems,
and a correlation to determine hydrodynamic equivalent mixtures 1, 2 and 3, respectively (Table 2) will always
diameter of the bagasse from the measurement of terminal segregate below Umb. The experiments were carried out
free-fall velocity using simple fluidization technique was with 200 g of FCC and 20 g bagasse. The bagasse was
proposed previously [22]. The hydrodynamic equivalent loaded first, then FCC was poured from the top. Initially,
diameter of irregular shape bagasse was used as the particle FCC flows down through the interstices of the bagasse parti-
size in the calculation of mixing and segregation behaviour cles. With little increase in the superficial velocity, the FCC
using this model. particles moved down. At steady state condition, the FCC
Based on the model presented here and theoretical bulk particles were observed at the bottom of the bed. The same
density evaluation, as illustrated in Fig. 5, a given mixture of segregation behaviour was obtained irrespective of how the
cenolyte (64 mm, 690 kg/m 3) and bagasse (200 mm, 492 kg/ particles were loaded in to the bed (either FCC at the top or
m 3) satisfy the above criteria within Umb of cenolyte. There- bagasse at the top initially). This experiment clearly shows
fore these two materials should mix completely under the that for particles of these physical properties, the binary
correct gas flow conditions. In the air velocity range system does not mix, but always segregates with the bagasse
between 4 and 6 mm/s the bed bulk density apparently layer at the top. The bulk density of FCC for all superficial
remains almost constant for all mixtures indicating that velocities within the range Umf to Umb remains greater than
these binary particles will mix at all concentrations under that of bagasse. Similar segregation behaviour was also
these conditions. The experimental observations show good observed for the binary mixture of PVC plastic
Table 2
Physical properties of particles
(d 64 mm) and bagasse (d 200 mm) where the bagasse Nevertheless, if mixing is desirable in the bed, then it would
again segregates out at the top of the bed. Other experiments clearly be advantageous to understand the conditions where
were carried out with 5 g polystyrene (d 2 mm) and 50 g segregation will not occur, even by not relying on mixing
bagasse (d 200 mm). In these experiments, bagasse stra- forces.
tified at the bottom of the bed. The experiments did not
show any mixing.
The theory allows a map to be drawn of the mixture 6. Conclusions
conditions under which proper fluidization and mixing
occurs, particularly as it depends on the density and size This study concentrated on the issue of bagasse fluidiza-
of the particles. This allows suitable operating conditions tion and combustion, and led to a significant improvement in
to be calculated. our understanding of segregation problem, which is
For an ambient gas fluidized bed, the numerically calcu- observed practically during combustion in fluidized beds
lated boundary line in terms of density ratio
r1 =r2 and size containing mixtures of bagasse and inert particles. A
ratios
d1 =d2 for which mixing/segregation will occur is model was presented to explain mixing and segregation
shown in Fig. 6. In this calculation, for particle 1 the size behaviour in fluidized beds. The conditions corresponding
range of 35–80 mm was considered to get wide expansion to equilibrium mixtures can be theoretically predicted from
between Umf and Umb. For regular shape particles, the the physical properties of the system. Experimental obser-
volume equivalent size or average size of closely cut sieve vations in a gas fluidized bed supported the theory. Flui-
fractions and for irregular shape particles, the hydrodynamic dized binary mixtures exhibit no tendency to segregate
equivalent diameters represent d1 and d2. Particles of any under a particular combination of solids and fluid volume
combination having density ratios and size ratios within the fractions. Therefore, if the properties of one the particle is
area bounded by this line will mix, whereas outside the line given, then the other particle can be selected to avoid segre-
binary particles will always segregate within the range Umf gation. More specifically, knowing the aerodynamic proper-
to Umb (i.e. in the absence of external mixing forces). Fig. 6 ties of bagasse, suitable inert fluidizing solids can be
also shows some experimentally demonstrated points selected from Fig. 6 to achieve successful fluidization and
supporting the predictive method. Therefore, knowing the proper mixing of bagasse, essential for efficient combustion
aerodynamic properties of bagasse, suitable inert fluidizing in a fluidized bed. Then, the operating conditions under
solids can be selected to avoid segregation of bagasse from which both the particles completely mix can be calculated
the inert particles. using the model presented here. These conditions can be
In practice, the gas velocities used in the fluidized bed used for designing a fluidized bed combustor for bagasse.
combustion are greater than Umb. This tends to produce Potentially economic alternatives for bagasse combustion,
bubbles, causing a mix-up of the bed materials, i.e. in using a fluidized bed [23] seems to be possible. Effective
virtually all practical gas-fluidized systems, mixing forces utilization of the bagasse available in Australia can help to
due to, e.g. bubbling or streaming exist, so that the range of supply quite a significant proportion of the total energy
conditions allowing stable mixtures to occur, is extended. requirement of the country. More specifically, if the bagasse
130 M.G. Rasul, V. Rudolph / Fuel 79 (2000) 123–130
combustion can be carried out in a fluidized bed, the Austra- [9] Davidson JF. J Inst Energy 1989:178.
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