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Suspended Solid Catalyst Reactors-1

Fluidized bed reactors (FBRs) utilize an upward gas flow to suspend solid catalyst particles, enhancing heat and mass transfer. The Geldart classification categorizes powders based on their fluidization behavior, while the dynamics of gas-solid interactions are critical for optimizing chemical processes. The K-L model provides a hydrodynamic-based approach to predict reactor performance, accounting for bubble behavior and solid circulation in bubbling fluidized beds.

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21 views33 pages

Suspended Solid Catalyst Reactors-1

Fluidized bed reactors (FBRs) utilize an upward gas flow to suspend solid catalyst particles, enhancing heat and mass transfer. The Geldart classification categorizes powders based on their fluidization behavior, while the dynamics of gas-solid interactions are critical for optimizing chemical processes. The K-L model provides a hydrodynamic-based approach to predict reactor performance, accounting for bubble behavior and solid circulation in bubbling fluidized beds.

Uploaded by

Biliat Ligomeka
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© © All Rights Reserved
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Reactors with Suspended Solid Catalyst, Fluidized

Reactors of Various Types

Fluidized bed reactors are systems in which a bed of solid particles is fluidized
(suspended) by an upward flow of gas. The solid catalyst particles are suspended
and behave like a fluid due to the gas flow.
The main advantage of FBRs is their ability to provide excellent contact between
gas and solid phases, leading to enhanced heat and mass transfer.
Catalyst scientists (called magicians) have developed extremely active catalysts

• Have higher reaction rates (larger rate constant, 𝑘′)


that:

• Allow for faster conversions


However, there's a limiting factor: the Thiele modulus, which compares:
• Reaction rate inside the catalyst pellet
• Diffusion rate of reactants into the pellet
• Hence, fluidized beds are better suited, as they freely suspend fine particles
without these drawbacks.
To keep thiele modulus in a usable range and avoid internal
diffusion limitations, we must:
• Use smaller catalyst particles
But small particles in a packed bed:
• Cause high pressure drops
• Risk channeling or plugging
Hence, fluidized beds are better suited, as they freely suspend fine particles without these
drawbacks.
BACKGROUND INFORMATION ABOUT SUSPENDED SOLIDS REACTORS
Geldart Classification of Powders (1973, 1978)
Geldart classified powders based on how they behave during fluidization,
depending on their particle size and density relative to the gas:
Group A (Aeratable) Group B (Bubbling) Group C (Cohesive) Group D (Spoutable)
Small, light particles. Medium-size, moderate- Very fine and cohesive Large and/or dense
density particles. particles. particles.
Smooth and uniform Bubbles form immediately as Do not fluidize well, tend toJetting and spouting
fluidization with minimal fluidization starts form clumps rather than uniform
bubbling. fluidization
Expands before bubbling Typical behavior seen in many Need mechanical help to mix. Example: Pellets or grains
starts. fluidized beds.
Common in catalytic Example: Sand Example: Talc, flour
processes, e.g., FCC.
Example: Alumina

These groups are typically plotted in a Geldart diagram with particle diameter vs. particle
density difference (Fig,. 20.2)
Distribution of Solids in a Vertical Fluidized Bed
Let, f(z) = volume fraction of solids at height z
As gas velocity increases, the behavior of the solid phase changes:

Low velocity Moderate Velocity High velocity


Solids are entrained and carried
Most solids stay near the bottom Solids begin to spread upward
up the column.
Expanded bubbling or turbulent Particles get distributed across
Dense packed or bubbling bed.
bed. the entire height
We get fast fluidized or
circulating fluidized beds.
G/S Contacting Regimes

Understanding the dynamics of gas-solid interactions in fluidized beds is crucial for optimizing
various chemical engineering processes.
Two fundamental concepts in this context are the Minimum Fluidization Velocity (Umf) and
the Terminal Velocity (Ut) of particles. These velocities define the flow regimes within a bed
and influence the efficiency of processes like catalytic reactions and particle separation

Minimum Fluidization Velocity (Umf)


This is the gas velocity at which the upward drag force equals the gravitational force on the
particles, causing the bed to fluidize.
To develop the language that tells what contacting regime we have at hand
consider solids of size dp, in a bed of cross-sectional area A which is fed gas at a
superficial gas velocity u0,as shown in Fig. 20.4.
To simplify the equations let us start by defining two dimensionless quantities

Minimum Fluidizing Velocity. The solids will be suspended when the pressure drop exceeds
the weight of solids. This happens when the gas velocity exceeds the minimum fluidizing
velocity umf. This velocity is given by Ergun (1952), and in dimensionless form is
Terminal Velocity (ut)

Individual particles are blown out of the bed when the gas velocity exceeds what is called the
terminal velocity, ut. Haider and Levens-pie1 (1989) give this velocity for spherical particles as
THE BUBBLING FLUIDIZED BED-BFB
A BFB occurs when gas flows upward through a bed of fine solid particles at
superficial gas velocities well above the minimum fluidization velocity
In this regime:
• Gas forms large bubbles that rise through the bed rapidly.
• The bed behaves like a boiling liquid – hence the term "bubbling."
• This dynamic causes non-uniform flow and bypassing of solids, reducing gas
solid contact.
Why Is It a Problem?

1. Non-Ideal Flow
• Bubbles short-circuit the bed, bypassing much of the solid phase.
• Gas that should ideally interact with catalyst particles often escapes too quickly.
• The result is conversion behavior that is less than plug flow, sometimes even
worse than mixed flow.

2. Unpredictable Conversion
• Inconsistent gas-solid contact leads to widely variable performance.
For a long time, engineers couldn't reliably estimate conversion — making scale-
up risky.
Dispersion and Tanks-in-Series Models
Use simple flow models to approximate the reactor, either by:
• Modeling it as a plug flow reactor with axial dispersion, or
• A series of continuous stirred tank reactors (CSTRs).
Problem
These models cannot explain why real BFBs sometimes show conversion lower
than even complete mixing.
They ignore phase segregation (bubbles, emulsion) and don’t account for real
hydrodynamics.
• Easy to apply
• Oversimplified - Can't explain poor conversions
RTD (Residence Time Distribution) Models
Use RTD curves to describe how long gas elements stay in the reactor and apply
a fixed reaction rate constant (k) to predict conversion.
Problem
• Gas near catalyst (emulsion) reacts faster.
• Gas in bubbles has little contact with catalyst, reacts slowly.
• RTD models assume equal access to catalyst, which is untrue in BFBs.
 Invalid assumption - All gas has the same access to catalyst
 Fails in systems with multiple phases (bubble vs emulsion)
Contact Time Distribution Models (Gilliland & Knudsen)
Improve on RTD by making k a function of time (i.e., gas staying longer in the
reactor - higher chance to contact catalyst)

Problem
• Hard to get meaningful E(t) (contact time distribution) from RTD data. Still lacks
a physical basis for phase behavior.
• Mathematically nice, but hard to apply
• Does not clearly explain gas-solid interactions
Hydrodynamic Flow Models in Fluidized Beds
To understand and model fluidized beds, we must analyze gas bubble behavior,
especially in fine particle beds where catalytic reactions are common.
1. Davidson’s Bubble Flow Model
• Developed by Davidson and Harrison (1963).
• Focuses on a single rising gas bubble in a bed at minimum fluidizing conditions.

Key findings
• Bubble rise velocity Ub​depends only on bubble diameter.
• The relative velocity between the bubble and surrounding gas (emulsion gas)
Ue affects flow pattern.
Gas Flow Regimes
• Fine Particle Bed:

Bubble forms a vortex ring with a thin gas cloud.


Cloud thickness ≈ 2% of bubble diameter (if )
Gas inside bubble remains segregated—important for mass transfer.
• Large Particle Bed:

Bubble rises slowly, no surrounding cloud.


2. Bubble Wake
• Every rising bubble drags solid particles in a wake behind it.
• Wake volume α ranges from 0.2 to 2.0 times the bubble volume:
Wake Volume = α × Bubble Volume
• Wake contributes to mixing and heat transfer.
THE K-L MODEL FOR BFB
Is a hydrodynamic-based flow model that builds on observed bubble behavior in
fine particle beds. It represents a step forward from curve-fitting or overly
simplified models, providing physically meaningful predictions of reactor behavior.
Core Assumptions of the K-L Model
1.Spherical, uniform bubbles (diameter db​) move through the bed, following
Davidson's model.
2.Each bubble is surrounded by a thin cloud; the upflow of gas through this cloud is
neglected due to its small volume.
3.The emulsion phase remains at minimum fluidization conditions.
4.Solids circulate: dragged upward in the wake behind bubbles, and flow
downward in the rest of the bed.
5.The gas in the emulsion does not significantly flow up or down – in some cases,
flow may even reverse due to solid motion.
The K-L model can predict:
• Flow rates in different regions (bubble, emulsion, wake)
• Interchange rates (e.g., between bubble and emulsion)
• Volumes of each region
• Reactor performance, including conversion for catalytic reactions
Application to Catalytic Reactions
To predict the performance of a bubbling fluidized bed reactor for a first-order
catalytic gas-solid reaction.

Important assumptions
• We ignore the flow of gas through the cloud since the cloud volume is very
small for fast bubbles.
• We ignore the flow of gas, either up or down, through the emulsion since this
flow is much smaller than the flow through the bubbles.

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