CPFD simulation of solids residence time and back-mixing in CFB risers

Hydrodynamics of a cold circulating fluidized bed for methanol-to-olefins (MTO) process: experimental and computational investigation

The present study aims to investigate the hydrodynamic behavior of gas-solid flow in a pseudo-two-dimensional cold circulation fluidized bed specifically designed to mimic a plane cut of an industrial methanol-to-olefins (MTO) bed. The solid velocity pattern was experimentally examined using the Particle Image Velocimetry with Digital Image Analysis (PIV-DIA) technique. The hydrodynamics of this pseudo-2D bed were studied using the twoPhaseEulerFoam solver in OpenFOAM, and the adjusted solver was validated through solid particle velocity and solid volume fraction comparisons, showing good agreement with experimental data. Additionally, the study explores different geometries, including symmetric and asymmetric baffles, to understand their impact on the mixing characteristics of the circulating fluidized bed for MTO. The findings highlight the significant role of asymmetric baffles in enhancing mixing behavior. Furthermore, the DIA technique was employed to study the effects of bubbles on gas-solid mixing, revealing that the low mixing region of the bed limited the diameter of bubbles.

Comparison of Experimental Results from Operating a Novel Fluidized Bed Classifier with CFD Simulations Applying Different Drag Models and Model Validation

A cold-flow lab-scale cross-flow fluidized bed classifier was simulated using the CFD software Barracuda VR®. The purpose of the study was to identify the most suitable drag model and make the model adjustments that provide the best representation of the flow situation in the classifier when comparing the results with the experimental data. Two particle types were used in the simulations and in the experiments: zirconia (median diameter 69 µm, skeletal density 3830 kg/m3) and steel (290 µm, 7790 kg/m3). Ten different cases, with different solids loading values, were investigated: three with pure zirconia particles, three with pure steel particles, and four with a mixture of zirconia (28%) and steel (72%). Several different drag models were tried out in the simulations. However, none of the available models were able to predict the classification efficiency observed in experiments with their default settings. Although most of the drag models correctly predicted the inversely proportional behavior of the classification efficiency vs. solids loading, the classification efficiency was overpredicted. It was observed that a combined WenYu/Ergun drag model gave a wide range of accuracy, by being able to capture the behavior of both dense and dilute particle systems. Even though the predictions of the classification efficiency for steel particles were acceptable, a larger deviation was observed with Geldart A zirconia particles. CFD simulations with the WenYu and Ergun combined drag model were used for further validation against the experimental observations. In this case, previously published experimental data for fluidization of pure Zirconia particles were used. The fluidization of zirconia was modelled in Barracuda VR® with adjustment of the combined WenYu/Ergun drag model parameter (k1), to obtain a suitable validation. Furthermore, the effect of adding the blended acceleration model (BAM) for the fluidization simulations is discussed. It was observed that the fixed bed pressure drop was very accurate compared to the experimental observation, but the pressure drop after the fluidization was slightly overpredicted.

Effect of carbon residues structures on burnout characteristic by FTIR and Raman spectroscopy

Fly ash (-FA) from seven typical power plants in Shanxi province (North China) were collected to explore the effect of carbon residues (-CR) structures on their burnout characteristic. Burnout characteristic is expressed by the loss on ignition (LOI) content in fly ash. Raman spectroscopy and Fourier Transform infrared (FTIR) spectroscopy are used to characterize the structure of CR. The structure parameters include Raman parameter (the full width at half maxima (FWHM) ratio of D₁ and G, I_D1/I_G) and FTIR parameter (asymmetric stretching intensity ratio of CH₂ and CH₃ groups, A(CH₂)/A(CH₃)). Three samples come from circulating fluidized bed (CFB), and four samples are from pulverized coal boilers (PC). Then two types of power plants are numbered from one to three according to the increasing degree of feed coal (-C) metamorphism. The CFB-1-FA, CFB-2-FA, and CFB-3-FA have loss on ignition (LOI) of 9.01%, 16.4%, and 21.6% respectively, while the LOI contents are 1.99%, 4.62%, 23.7%, and 5.00% for the PC-1-FA, PC-2-FA, PC-3-FA, and PC-4-FA. The results show that carbon residues in the PC fly ash mainly have the shorter and branched aliphatic side chains with lower A(CH₂)/A(CH₃) value. While carbon residues in the CFB fly ash have relatively longer aliphatic chains, and intramolecular aromatization is the main reaction during combustion. The I_D1/I_G of the CFB carbon residues are generally higher than it for the PC samples, indicating a more ordered structure. Oxygen-deficient environment and the longer residence time at temperature around 900 °C in the CFB boiler promote the ordering progress of the CR. The ordered CR suppresses its burnout and leads to an increase LOI content in fly ash. In turn, sufficient oxygen and temperature around 1200 °C in the PC boiler make the CR further oxidize and decompose. The CR become less ordered and are prone to burn out, resulting in a reduction of the LOI content.

Hydraulic Characteristics, Residence Time Distribution, and Flow Field of Electrochemical Descaling Reactor Using CFD

This paper uses computational fluid dynamics (CFD) to simulate flow field distribution inside an electrochemical descaling reactor in three dimensions. First, the reactor flow field was obtained by steady-state simulation, and the grid independence was verified. Then, the steady state of the flow field was judged to ensure the accuracy of the simulation results. Transient simulations were performed on the basis of steady-state simulations, and residence time distribution (RTD) curves were obtained by a pulse-tracing method. The effects of plate height and plate spacing on reactor hydraulic characteristics (flow state and backmixing) were investigated using RTD curves, and the results showed that increasing the plate height and decreasing the plate spacing could make the flow more similar to the plug flow and reduce the degree of backmixing in the reactor. The flow field details provided by CFD were used to analyze the reactor flow field and were further verified to obtain the distribution patterns of dead and short circuit zones. Meanwhile, information regarding pressure drops was extracted for different working conditions (490, 560, and 630 mm for pole plate height and 172.6, 129.45, and 103.56 mm for pole plate spacing), and the results showed that increasing the pole plate height and decreasing the pole plate spacing led to an increased drop in pressure. In this case, a larger pressure drop means higher energy consumption. However, increasing the pole plate height had a smaller effect on energy consumption than decreasing the pole plate spacing.

Shape Effect of the Riser Cross Section on the Full-Loop Hydrodynamics of a Three-Dimensional Circulating Fluidized Bed

In this work, numerical simulation is carried out in a three-dimensional full-loop pilot-scale circulating fluidized bed to explore the shape effect of the riser cross section on the typical flow characteristics of the bed via the multiphase particle-in-cell (MP-PIC) method. The gas and solid phases are modeled with the large eddy simulation and Newton's law of motion in the Eulerian and Lagrangian frameworks, respectively. The proposed model has been well validated with experimental data, followed by evaluating the typical core-annulus structure and the nonuniformity of the solid phase distributed along the radial and axial directions of the riser. Then, the particle-scale information of the solid phase distributed in different parts of the system is explored. The results demonstrate that (i) the square riser gives rise to a higher solid inventory in the standpipe owing to the stronger circulation intensity; (ii) the thickness of the solid back-mixing layer reduces along the riser height; the solid back-mixing tends to concentrate in the four corners, while it is not obvious near the sidewalls of the square riser; and (iii) nonuniform distribution of the particle-scale information of the solid phase (e.g., mass, flux, drag force, and slip velocity) can be observed. The square riser gives rise to comparatively more uniform axial mass distribution, a larger rising solid flux, larger horizontal transportation velocity between the core and annulus regions, and a larger horizontal dispersion coefficient in the riser, as compared with the corresponding ones in the circular riser.

3D CPFD Simulation of Circulating Fluidized Bed Downer and Riser: Comparisons of Flow Structure and Solids Back-Mixing Behavior

The difference of gas-solids flow between a circulating fluidized bed (CFB) downer and riser was compared by computational particle fluid dynamics (CPFD) approach. The comparison was conducted under the same operating conditions. Simulation results demonstrated that the downer showed much more uniform solids holdup and solids velocity distribution compared with the riser. The radial non-uniformity index of the solids holdup in the riser was over 10 times than that in the downer. In addition, small clusters tended to be present in the whole downer, large clusters tended to be present near the wall in riser. It was found that the different cluster behavior is important in determining the different flow behaviors of solids in the downer and riser. While the particle residence time increased evenly along the downward direction in the downer, particles with both shorter and longer residence time were predicted in the whole riser. The nearly vertical cumulative residence time distribution (RTD) curve in the downer further demonstrated that the solids back-mixing in the downer is limited while that in the riser is severe. Solids turbulence in the downer was much weaker compared with the riser, while the large clusters formation near the wall in the riser would hinder solids transportation ability.