Duhok Polytechnic University
Technical College Of Engineering
Chemical Engineering Department
FLUIDIZED BED REACTOR
Chemical Reactor Design Prepared by :
Stage “4”
Group “B” Mahdi Salih Yaseen
Lecturer
Dr. Arkan Jasim
2023 - 2024
Contents
1. Introduction…………………………………………………………………………..3
2. Applications………………………………………………………...………………..4
3. Fluidization…………………………………………………………………………..4
4. Fluidization of Regimes………………………………………………………….…..4
5. Overlap Phenomenon………………………………………………………………..5
6. Bed at Fluidization Conditions …………………………………………….………..5
7. Distributor Plate Design……………………………………………………………..5
8. Bubble Caps……………………………………………………..…………………..6
9. Bubble Caps Design…………………………………………..……………………..6
[Link]………………………………………………………………………..……..6
[Link] Design……………………………………………………..………………..7
[Link] of Fluidized Bed Reactor………………………………………….…………..8-9
[Link]……………………………………………………………….…………..9
[Link]………………………………………………………….……………..10
[Link]…………………………………………………………………...………..11
Introduction
Stirred tank and packed bed continuous flow reactors, the two most popular designs, are combined
to create a fluidized-bed reactor (FBR). Its mass and heat transport properties are superb. Cells are
affixed to materials in FBR as granules or biofilm. They can remain suspended because of the
upward wastewater flow's tugging force. As a result, they exhibit increased catalytic activity and
are known to accelerate the breakdown of organic wastes.
Chemical and food sectors make extensive use of fluidized bed reactors. Compared to other reactor
types, fluidized beds, such as gas-solid, liquid-solid, and gas-liquid-solid three phase reactors, are
more successful at enhancing mixing, heat, and mass transfers. Particle segregation, which causes
poor fluidization by accumulating relatively big or high density particles on the distributor plate
during bed operation, is one of the issues preventing steady functioning of the fluidized beds. The
effective transfer of heat to biomass particles is made possible by fluidized bed reactors; however,
the biomass particles must be relatively small (2–3 mm). For biomass fast pyrolysis, entrained,
circulating fluidized beds (CFBs) as well as bubbling fluidized beds can be used.
Applications
Fluidized bed reactors are used in many different sectors, such as:
• Chemical and petrochemical processes include fluidized catalytic cracking,
polymerization, gas-solid interactions, and catalytic reactions.
• The process of producing energy involves burning solid fuels, gasifying biomass,
liquefying coal, and capturing carbon.
• Environmental engineering includes air pollution control, wastewater treatment, and
burning of hazardous waste.
• Food and pharmaceutical: Particle coating, granulation, and drying techniques.
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Fluidization
Particles in a Fluid Bed: Average particle size and Angular
Shape Factor
0.4 is the void fraction (bulk density).
Fluidization Regimes
• The minimum fluidization in a packed bed
• Unsteady Fluidization
• Slugging (occasionally)
• Tumultuous fluidization
Overlap of Phenomenon
• Mass transfer is dependent on particle Re number
• Kinematics is dependent on the solid composition of the bed.
• Heat Transfer Requires Gas and Solid Content in Bed Regards
• Dynamics of Fluids
• Fluidization: Particle function Re - Terminal settling rate against gas velocity - particle
elution rate - distribution plate design to avoid channeling
Bed at Fluidization Conditions
• Good Heat Transfer
• Good Mass Transfer
• Surface Area for Reaction is Low
• Solids Content is Low
• Void Fraction is High
• Pressure Drop is Low.
Distributor Plate Design
• The pressure drop at the distributor is equal to ½ of the total
pressure drop (bed and distributor) - The pressure drop across the
distributor plate should be 30% of this total.
• A popular design is the bubble cap
Bubble Caps
• Advantages
– Weeping is reduced or totally avoided
• Sbc controls weeping
– Good turndown ratio – Caps stiffen distributor plate – Number
easily modified
• Disadvantages
– Expensive – Difficult to avoid stagnant regions – More subject to
bubble coalescence – Difficult to clean – Difficult to modify
Bubble Cap Design
• Pressure drop controlled by
– number of caps – stand pipe diameter – number of holes
• Large number of caps
– Good Gas/Solid Contact
• Minimize dead zones
• Less bubble coalescence
– Low Pressure Drop
Cyclone
• Used to capture eluted particles and return to fluid bed
• Design to capture most of eluted particles
• Pressure Drop Big particles
P i (V) 0.24 V^2
Cyclone Design
• Inlet Velocity as a function of Cyclone Size
𝑄𝑅
𝑉𝑖𝑛 ( 𝐷𝑐 ) =
𝐷𝐶 2
4.2
𝑫𝒄 = 𝑪𝒚𝒄𝒍𝒐𝒏𝒆 𝑫𝒊𝒂𝒎𝒆𝒕𝒆𝒓
• Cut Size ( 𝑫𝟓𝟎% )
1
𝐷 2
9. 𝜇. 𝑐
𝐷50 (𝐷𝑐 ) = [ 4 ]
𝜋. 𝑁(𝑉𝑖𝑛 (𝐷𝑐 )). 𝑉𝑖𝑛 (𝐷𝑐 ). (𝜌𝑆𝑖 − 𝜌)
• Cyclone Cut Size
- Diameter where 50% leave, 50% captured
1
𝐷
9.𝜇. 𝑐 2
4
- 𝐷50 = [ ]
𝜋.𝑁.𝑉𝑖𝑛 .(𝜌𝑆𝑖 −𝜌)
• Size Selectivity Curve
𝐷 3.12
𝑆𝑆(𝐷) = 1 − 𝑒𝑥𝑝 [−0.693 ( ) ]
𝐷50
24 in cyclone
. . . . 14 in cyclone
+ + + D50 for 24 in cyclone
. . . . . . 20 in cyclone
× × × Diameter of Eluted Particules
Types of Fluidized Bed Reactor
❖ Bubbling Fluidized Bed Reactor (BFB):
The fluid velocity in a BFB reactor is low enough to
sustain the mobility of individual particles and create
bubbles inside the bed. Heat and mass transport are aided
by the agitation and mixing that these bubbles produce.
BFB reactors are frequently utilized in processes
including catalytic cracking, wastewater treatment, and
biomass combustion.
❖ Circulating Fluidized Bed Reactor (CFB):
Higher fluid velocities in CFB reactors result in the
movement of particles throughout the reactor. Heat
transmission efficiency is increased and mixing is improved
by this circulation. In fluid catalytic cracking (FCC) units
for petroleum refining, coal combustion for electricity
generation, and chemical industrial processes, CFB reactors
are commonly utilized.
❖ Two phase fluidized bed reactors (HTFT) :
High-temperature fluidized bed reactors (HTFBR), often
referred to as two-phase fluidized bed reactors, are
sophisticated reactor systems utilized for a range of high-
temperature chemical reactions, including catalytic
reactions, thermal treatments, and gas-solid interactions.
These reactors use a fluidized bed of solid particles
suspended in a gas phase and are intended to function at
temperatures that are high—typically above 500°C.
❖ Fluidized Bed Combustor (FBC):
Specialized fluidized bed reactors called FBC
systems are made to burn solid fuels like trash,
coal, and biomass efficiently. Comparing these
reactors to traditional combustion systems
reveals benefits including reduced emissions,
more fuel flexibility, and enhanced combustion
efficiency.
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Advantages of Fluidized Bed Reactor
❖ Enhanced Heat and Mass Transfer: Because of their large surface area for gas-solid
contact, fluidized bed reactors have good heat and mass transfer properties. As a result,
reaction rates and product yields are increased and mixing and reaction kinetics are made
more efficient.
❖ consistent Temperature Distribution: By reducing temperature gradients and hot spots,
the fluidized bed facilitates a consistent temperature distribution across the reactor. This is
advantageous for procedures that need consistent reaction conditions and exact temperature
control.
❖ High turbulence and mixing conditions: in fluidized bed reactors allow for the efficient
use of catalysts and reactants, leading to high reactor efficiency. High reactor efficiency and
shorter residence durations are the outcomes, which raise productivity and cut operating
expenses.
❖ Flexibility in Feedstock and Catalysts: A variety of feedstocks, such as solid, liquid, and
gaseous materials, can be used in fluidized bed reactors. Additionally, they can be used with
different kinds and sizes of catalysts, giving reaction conditions and catalyst selection
flexibility.
❖ Good Solids Mixing and Fluidization: The fluidized bed ensures uniform particle
distribution, prevents channeling, and eliminates hot spots by providing good solids mixing
and fluidization. As a result, reactants and catalysts are distributed evenly, resulting in
consistently high-quality products.
Disadvantages of Fluidized Bed Reactor
❖ High Initial Investment: Especially for high-temperature and high-pressure applications,
the design, fabrication, and installation of fluidized bed reactors can be expensive.
Compared to fixed-bed reactors, the initial capital investment is higher because to the
complicated design requirements and specialized equipment.
❖ Particle Attrition and Agglomeration: Particles in the fluidized bed may continually
move and collide, which can cause particle attrition and agglomeration. This may lead to
the accumulation of fines, a decrease in catalyst activity, and problems with bed
defluidization and channeling that affect operations.
❖ Managing and processing solid materials in fluidized bed reactors can provide certain
challenges, particularly when dealing with materials that possess poor flow characteristics
or high abrasiveness. Systems for feeding, withdrawing, and handling particles must be well
planned to reduce problems like clogging and uneven particle distribution.
❖ Restricted Temperature and Pressure Range: The operating temperature and pressure
ranges of fluidized bed reactors are often restricted. High pressures may necessitate reactor
designs and safety precautions, while high temperatures can cause material degradation,
particle sintering, and reactor corrosion.
❖ The performance of a fluidized bed reactor : is greatly influenced by the selection of bed
material. The material that is chosen needs to have the right qualities, like excellent heat
conductivity, chemical inertness, mechanical strength, and resistance to agglomeration and
attrition. It can be difficult to choose the best bed material, particularly in corrosive or
abrasive settings.
Conclusion
For a variety of petrochemical, chemical, and environmental processes, fluidized bed reactors are
adaptable and effective technologies. Although fluidized bed reactors have certain drawbacks,
such as a high initial cost, particle attrition, and difficulties with bed materials.
Fluidized bed reactors are appealing choices for processes needing fast reaction rates, accurate
temperature control, and flexibility in operating conditions because of their improved heat and
mass transfer properties, uniform temperature distribution, and flexibility in feedstock and
catalysts. Their broad use in both industrial and research contexts is further facilitated by their
scalability and capacity to manage high gas velocities.
Gas-solid interactions, catalytic conversions, biomass pyrolysis, and waste treatment are just a few
of the processes that still heavily rely on fluidized bed reactors, which are highly productive,
efficient, and environmentally sustainable. Fluidized bed reactors are anticipated to continue being
essential parts of contemporary chemical and industrial processes thanks to continuous
improvements in design, materials, and control systems, which will spur innovation and
advancement across a range of industries.
