Optimizing Design and Operational Parameters for Enhanced Mixing and Hydrodynamics in Bubbling Fluidized Bed Gasifiers: An Experimental and CFD-Based Approach

Abstract

An experimental investigation of hydrodynamics of gas-solid flow is carried out by engaging different designs of air distributor plates. An analysis of three different plates, i.e., perforated, 45° slotted and novel hybrid plate, revealed the difference in pressure drop and minimum fluidization velocities (Umf) for varying input operational variables. Umf is found to be lowest for perforated and highest for 45° slotted plate, whereas pressure drop is found to be highest for 45° slotted plate and lowest for novel hybrid distributor plate. The bubbles rise velocity ratio (Umf,b/Umf,f) is noticed minimum for 45° slotted plate due to relatively larger bubbles originating from the bigger slot openings and maximum for perforated distributor plate owing to smaller bubbles with dominant axial rise. Furthermore, the bed height rise ratio (h/L) is observed as a minimum for perforated distributor and maximum for 45° slotted plate due to larger bubbles through 45° slots rupturing the bed surface, causing more bed expansion. Furthermore, CFD analysis is also carried out to observe the insight flow dynamics using the distributor plates. The simulations use a two-fluid model (TFM) and K-Epsilon turbulence models. CFD model shows promising results in agreement with the experimental results. CFD results revealed that the lower portion enhanced lateral dispersion/mixing of solid particles due to 45° angular openings of an air inlet. In contrast, the perforated plate exhibited a straight upward motion of small air bubbles, causing no radial/lateral mixing. CFD results for the hybrid plate show the mixed axial as well as lateral mixing of solids by revealing velocity distribution; therefore, the novel hybrid plate is found to be an optimum distributor plate due to its lowest pressure drop, adequate Umf, intermediary bed height rise ratio and moderate bubble rise velocity ratio across the bed.

Numerical Simulation of Hydrodynamics and Heat Transfer in a Reactor with a Fluidized Bed of Catalyst Particles in a Three-Dimensional Formulation

“…These are various perforated plates, baffles, louver baffles, etc. [54][55][56][57][58][59][60]. Distribution devices make it possible to structure the bed, to get rid of the formation of particularly large bubbles that negatively affect the process, and to further intensify mixing [54][55][56][57][58][59][60].…”

“…[54][55][56][57][58][59][60]. Distribution devices make it possible to structure the bed, to get rid of the formation of particularly large bubbles that negatively affect the process, and to further intensify mixing [54][55][56][57][58][59][60]. The effect on the hydrodynamics of several types of distribution device designs was studied experimentally and by simulation in [54][55][56][57][58][59][60].…”

“…However there are few studies of the effect of internal devices in the form of vertical baffles of various configurations on the hydrodynamics of a fluidized bed. At the same time, vertical baffles are less susceptible to erosion than perforated plates and have less effect on the abrasion of particles, and also allow for controlling the operating regime of each layer independently of each other in the presence of several separated layers of particles in one reactor if it is possible to control the flow of the medium using a distribution device [54][55][56]. In addition, the variety of distribution devices, the properties of the media and solid particles make it necessary to select the parameters of the model when simulating new equipment and check the adequacy of the description.…”