Fixed bed and fluidized bed « Ref: BSL, McCabe & Smith = Why fixed (or fluidized) bed? @ Expensive Catalyst ¢ enzyme (immobilized) @ Large Surface area » Used in reaction/adsorption/ elution (for example) = Goal: Expression for pressure drop, try some examples IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed « Filled with particles » Usually not spherical @ To increase surface area @ To increase void fraction To decrease pressure drop » For analytical calculation, assume all particles are identical @ Usable, because final formula can be modified by a constant factor (determined by experiment) IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed = What are important parameters? = (For example, for adsorption of a protein from a broth) rate of adsorption (faster is better) ¢ saturation concentration (more is better) » From the product requirement (eg X kg per day), density and product concentration in broth ==> volumetric flow rate IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed Assume quick adsorption (rate of adsorption is high) Calculate the surface area of particles needed for operation Sphericity <=> specific surface area <=> average particle diameter Sphericity Qa) (* ) @ Volume of particle = V,, i, Vv. @ Surface Area of particle = A, @ Surface Area of sphere of same volume (V, =V,,) = A, @ Sphericity =A/A, @ May be around 0.3 for particles used in packed beds lower sphericity ==> larger surface area IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed = Specific surface area @=A,/V, ¢ Minimal value for sphere ¢ Some books use S to denote area (instead of A) @ Assume all the particles are identical ==> all particles have exactly same specific surface area Rings (Raschig,etc) — Tarus saddle Pall Ring IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed = What is the pressure drop we need, to force the fluid through the column? (i.e. what should be the pump spec) « We know the volumetric flow rate (from adsorption equations, productivity requirements etc) « We know the area per particle (we assume all particles are identical). And the total area for adsorption (or reaction in case of catalytic reactor). « Hence we can calculate how many particles are needed » Given a particle type (eg Raschig ring) , the approximate void fraction is also known (based on experimental results) IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed » What is void fraction? = Volume of reactor = Vp » Number of particles = N,, = Volume of one particle = V, » Volume of all the particles = V, * N, = Vai-parricies Vy Void fraction=¢ = 2. ew Va Vius-raericurs R Ve _Va=VoNp Vp = Knowing void fraction, we can find the reactor volume needed ¢ Alternatively, if we know the reactor volume and void a V, (I-e) fraction and the V,. we can find the number of particles “? — Vp IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed = To find void fraction experimentally = Prepare the adsorption column (or reactor...) and fill it with particles » Fill it with water = Drain and measure the quantity of water » (= void volume) » Calculate void fraction IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed » Since we know Vos No» €, we can find Vp = Choose a diameter and calculate the length (i.e. Height) of the column (for now) In normal usage, both the terms ‘height’ and ‘length’ may be used interchangeably (to mean the same thing) ¢ Adsorption rate, equilibrium and other parameters will also influence the determination of height & diameter = To calculate the pressure drop Note: columns with large dia and shorter length (height) will have lower pressure drop What can be the disadvantage(s) of such design ? (tutorial) IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed « Tocalculate the pressure drop You want to write it in terms of known quantities Length of column, void fraction, diameter of particles, flow rate of fluid, viscosity and density = Obtain equations for two regimes separately (turbulent and laminar) « Consider laminar flow « Pressure drop increases with velocity viscosity inversely proportional to radius Actually, not all the reactor area is available for flow. Particles block most of the area. Flow path is not really like a simple tube Hence, use hydraulic radius IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar flow) = Tocalculate the pressure drop, use Force balance Force=AP Area 2 0 Area where flow occurs = 2 «. Force=AP aD é = Resistance : due to Shear +, Force=r Contact area @ Find Contact Area @ Find shear stress » Until now, we haven’t said anything about laminar flow. So the above equations are valid for both laminar and turbulent flows IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar Flow) » Find contact area Wetted Area= A, Ve(Im8) 4 =v, (1-6) » To calculate the shear stress, FOR LAMINAR FLOW 2 pa V=v,,.) 1-5 Vinas = 2Vieg dr |,-« R « Here V refers to velocity for flow in a tube a HV ins — 4 HV 8H R R “Dp = However, flow is through bed, NOT a simple tube IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar Flow) « Find effective diameter (i.e. Use Hydraulic radius), to substitute in the formula « Also relate the velocity between particles to some quantity we know = To find hydraulic radius (and hence effective dia) Flow volume=eV, Wetted Area=N,A, 9 = Va(l=2) 4 V ? p » Hydraulic diameter D, <4 Flow Area =4 Flow Area* Column Height 4" ContactPerimeter ContactPerimeter * Column Height __, Flowvolume wetted area IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar Flow) 4e Dy = (l-e A, / BAY ne BV (12) % } u 4e = Vayg is average velocity of fluid “in the bed”, between particles = Normally, volumetric flow rate is easier to find IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar Flow) » Can we relate volumetric flow rate to V,,.? = Use anew term “Superficial velocity” (Vo) v= Volumetric flow rate ° Column Area « Le. Velocity in an ‘empty’ column, that will provide the same volumetric flow rate = Can we relate average velocity and superficial velocity? IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar Flow) A,/ A, / _ »/ _ pf — = ( al y,) = eae al va é & « Force balance: Substitute for t etc. 2 Fores=ap 7? eg Force=t Contact area 4 A, / 2nV, (1-2) sf } 2 ‘ WW A ap 2D 2 Ny 1 g)| Se 4 e& V, _zD° L = Volume of reactor (say, height of bed = L) A,/Y > py, (l-e)| “°K , ap 00, RG) ae 4 ee 4 IT-Madras, MeFixed bed - ‘anne drop calculation (Laminar Flow) A, AP ao, IA) ar 4) xD 400 e 4 = Pressure drop A p® ay, (t-e) ( “4, AP =e é€ = Specific surface area vs “average diameter” Vv, A, i 4 . [*] = Define “average Dia” of particle as p,-—° » Some books (BSL) use D, , [*] LIT-Madras, Momentum Transfer: July 2005-Dec 2003 Y,Fixed bed - pressure drop calculation (Laminar Flow) = Pressure drop 2 2t¥,(I~#) ( % ) 72uLV,(I-e) /D, = HEE) AP = Dee = However, using hydraulic radius etc are only approximations = Experimental data shows, we need to multiply the pressure requirement by ~ 2 (exactly, 100/48) erms of specific surface area In terms of average particle diameter As 2 2 f 150 wLV, (1-2)? 25uLV, (1-2) ( “4, | = —>27 COS AP =———__** 4 Dé 6e° IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Turbulent Flow) = Pressure drop and shear stress equations Force=AP =D e Force=t Contact area = Only the expression for shear stress changes « For high turbulence (high Re), \R be T faa =constant — Mg PVing oth e=constant 14 pV;;, H Vi = However y,, = “2 v2 £ t=K p—> € IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Turbulent Flow) = We have already developed an expression for contact area Wetted Area=W,4, _ Vell-e), ay, (ie) =e R vy, 0" ‘, « Hence, force balance Force=AP aD (ooh = Volume of reactor (say, height of bed = L) D? V,===L 4 ar-(xot [e002] IIT-Madras, Momentum Transfer: July 2005-Dec 2003 é=t Contact areaFixed bed - pressure drop calculation (Turbulent Flow) In terms of average particle diameter In terms of specific surface area weifeag] Slog] = Value of K based on experiments ~ 7/24 = What if turbulence is not high? « Use the combination of laminar + turbulent pressure drops: valid for all regimes! =the a e) _(7pLVy (1-e) = APrrtutent = 4D, AF asinar IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar OR Turbulent Flow) « If velocity is very low, turbulent part of pressure drop is negligible « If velocity is very high, laminar part is negligible = Some texts provide equation for friction factor f = +F. Toe = Ziaminar + Turbulent Pr, Vs0¥e, 2uV, (1-e) Ay WENN) 7 ve 2 Ps i Veven IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar OR Turbulent Flow) 2uv,(i-e)(“4, | ys eo Ke Af anti-2(% \) f = —_—__a=e =}|——_-4 "|, ¥y Yo / PVo 12 ye Vo « For pressure drop, we multiplied the laminar part by 2 (based on data) . For the turbulent part, the constant was based on data anyway. =|——__ 47s | o 48 pv, 12 3pV, 12 « Similarly.. IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed bed - pressure drop calculation (Laminar OR Turbulent Flow) A,/ 25u(1- ei 4 eae). faarolso,)) 5 3pV, 12 = 3pV, a « Multiply by 3 on both sides (why?) sy -(Seaea)2 f= (9). z D, pV, 4 D,pv » Packed bed friction factor = 3 f Egn in McCabe and Smith Reynolds number for packed bed IIT-Madras, Momentum Transfer: July 2005-Dec 2003Example » Adsorption of Cephalosporin (antibiotic) = Particles are made of anionic resin(perhaps resin coatings on ceramic particles) » void fraction 0.3, specific surface area = 50 m?/m*(assumed) « column dia 4 cm, length 1 m « feed concentration 2 mg/liter (not necessary to calculate pressure drop, but needed for finding out volume of reactor, which, in this case, is given). Superficial velocity about 2 m / hr = Viscosity = 0.002 Pa-s (assumed) = What is the pressure drop needed to operate this column? IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed Bed = What is the criteria for Laminar flow? DV, p = Modified Reynolds Number u(l-e) » Turbulent flow:- Inertial loss vs turbulent loss @ Loss due to expansion and contraction « Packing uniformity @ In theory, the bed has a uniform filling and a constant void fraction @ Practically, near the walls, the void fraction is more » Ergun Eqn commonly used, however, other 0.8 empirical correlations are also used & » e.g. Chilton Colburn eqn Ot f= A a a 4C 02 Re Re Edge Center Edge IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed Bed « Sphericity vs Void Fraction IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fixed Bed » Alternate method to arrive at Ergun equation (or similar correlations) = Use Dimensional analysis AP —dependent variable P (without subscript, means fluid density or Py) Dy LV Hs Deotunns E+ Oe. sphericity) APD; DV. D = peered) pv, L Ho Deotunn IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fluidized bed » When the fluid (moving from bottom of the column to the top) velocity is increased, the particles begin to ‘move’ at (and above) a certain velocity. « At fluidization, @ Weight of the particles == pressure drop (area) @ Remember to include buoyancy axD* 4 AP 7 =(p,-p,)(1-2)Y« Lp Nine IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fluidized bed: Operation « Empirical correlation for porosity = Types of fluidization: Aggregate fluidization vs Particulate fluidization = Larger particles, large density difference (Pgo) 1p - PLU) ==> Aggregate fluidization (slugging, bubbles, etc) = ==> Typically gas fluidization @ Even with liquids, lead particles tend to undergo aggregate fluidization « Archimedes number gp ,D* Ap Ar=——+— STARS, Neen DSNS LtFluidized bed: Operation Porosity increases Bed height increases Fluidization can be sustained until terminal velocity is reached If the bed has a variety of particles (usually same material, but different sizes) calculate the terminal velocity for the smallest particle Range of operability =R Minimum fluidization velocity = incipient velocity (min range) Maximum fluidization velocity = terminal velocity (max range) Other parameters may limit the actual range further ¢ e.g. Column may not withstand the pressure, may not be tall enough etc R=V/Vom Theoretically R can range from 8.4 to 74 IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fluidized bed: Operation 80 » Range of operation depends on Ar 40 R 0 10° 10¢ 108 Ar IIT-Madras, Momentum Transfer: July 2005-Dec 2003Fluidized bed: Operation = Criteria for aggregate fluidization ¢ Semi empirical ( D, Ap 05 > } > 0.6 (for liquid) PH > 0.3 (for gas) = Particulate fluidization @ Typically for low Ar numbers @ More homogenous mixture IIT-Madras, Momentum Transfer: July 2005-Dec 2003