Fluidization in small-scale gas-solid 3D-printed fluidized beds

Design and Investigation of a 3D-Printed Micro-Fluidized Bed

Micro-fluidized bed has aroused much attention due to its low-cost, intensified-process and fast-screening properties. In this paper, a micro-fluidized bed (15 × 15 mm in cross-section) was designed and fabricated with the use of the stereolithography printing technique, for the investigation of bubbles’ hydrodynamics and comparison of the solids (3D-printed particles VS fungal pellets) fluidization characteristics. In a liquid–gas system, bubble flow regime started from mono-dispersed homogeneous regime, followed by poly-dispersed homogeneous regime, transition bubble regime and heterogeneous bubble regime with increasing gas flowrates from 3.7 mL/min to 32.7 mL/min. The impacts from operating parameters such as gas flowrate, superficial liquid velocity and gas sparger size on bubble size, velocity and volume fraction have been summarized. In liquid–solid fluidization, different solid fluidization regimes for both particles bed and pellets bed were identified. From the bed expansion results, much higher Umf of 7.8 mm/s from pellets fluidization was observed compared that of 2.3 mm/s in particles fluidization, because the hyphal structures of fungal pellets increased surface friction but also tended to agglomerate. The similar R–Z exponent n (5.7 and 5.5 for pellets and particles, respectively) between pellets and particles was explained by the same solid diameter, but much higher Ut of 436 µm/s in particles bed than that of 196 µm/s in pellets bed is a consequence of the higher density of solid particles. This paper gives insights on the development of MFB and its potential in solid processing.

Solid Circulating Velocity Measurement in a Liquid–Solid Micro-Circulating Fluidised Bed

Liquid–solid circulating fluidised beds (CFB) possess many qualities which makes them useful for industrial operations where particle–liquid contact is vital, e.g., improved heat transfer performance, and consequent uniform temperature, limited back mixing, exceptional solid–liquid contact. Despite this, circulating fluidised beds have seen no application in the micro-technology context. Liquid–solid micro circulating fluidised bed (µCFBs), which basically involves micro-particles fluidisation in fluidised beds within the bed of cross-section or inner diameter at the millimetre scale, could find potential applications in the area of micro-process and microfluidics technology. From an engineering standpoint, it is vital to know the solid circulating velocity, since that dictates the bed capability and operability as processing equipment. Albeit there are several studies on solid circulating velocity measurement in CFBs, this article is introducing the first experimental study on solid circulating velocity measurement in a CFB at micro-scale. The experimental studies were done in a novel micro-CFB which was fabricated by micro milling machining 1 mm2 cross-section channels in Perspex and in a 4 mm2 cross-section micro-CFB made by additive manufacturing technology. Soda-lime glass and polymethyl methacrylate (PMMA) micro-particles were employed as solid materials and tap water as the liquid medium. The digital particle image velocimetry (PIV) method was used as a measurement technique to determine the particle velocity in the micro-CFB system and validated by the valve accumulation technique using a novel magnetic micro-valve. The measured critical transition velocity, Ucr, is comparable to the particle terminal velocity, i.e., the normalised transition velocity is approximately 1 in line with macroscopic systems results and our previous study using simple visual observation. As in macroscopic CFB systems, Ucr decreased with solid inventory (1–9%) and finally becomes stable when the solid inventory is high enough (10–25%) and it increases with a reduction in particle size and density.

3D Printed Microfluidics

Traditional microfabrication techniques suffer from several disadvantages, including the inability to create truly three-dimensional (3D) architectures, expensive and time-consuming processes when changing device designs, and difficulty in transitioning from prototyping fabrication to bulk manufacturing. 3D printing is an emerging technique that could overcome these disadvantages. While most 3D printed fluidic devices and features to date have been on the millifluidic size scale, some truly microfluidic devices have been shown. Currently, stereolithography is the most promising approach for routine creation of microfluidic structures, but several approaches under development also have potential. Microfluidic 3D printing is still in an early stage, similar to where polydimethylsiloxane was two decades ago. With additional work to advance printer hardware and software control, expand and improve resin and printing material selections, and realize additional applications for 3D printed devices, we foresee 3D printing becoming the dominant microfluidic fabrication method.