Fluidization

Fluidization
Objectives
• To acquire the knowledge for the calculation of minimum fluidization velocity
and pressure drop in fluidized columns.
• To demonstrate various fluidization patterns.
• To grasp the industrial relevance of fluidization.
 Fluidization
• When a fluid is passed downward through a bed of solids,
no relative movement between the particles occurs unless
the initial orientation of the particles is unstable.
• When a fluid is passed upward through the bed, and the
frictional drag on the particles becomes equal to their
apparent weight (which is the actual weight minus the
buoyancy force), the particles start to rearrange
themselves. As a result, they offer less resistance to the
flow of the liquid, and the bed begins to expand, leading to
an increase in voidage within the bed.
• The process persists as velocity increases, with the total
frictional force still balancing the weight of the particles.
The bed undergoes changes until it reaches its loosest
stable packing configuration. Further increases in velocity
enable particles to move beyond their stable state, leading
to their separation from one another. With further velocity
increases, individual particles become freely supported
within the fluid, no longer constrained by the bed's
structure.(Fluidization)
Fluidization type depending on gas velocity
Effect of Fluid Velocity on Pressure Gradient and Pressure Drop
• If the superficial velocity, is gradually increased, the pressure drop will
increase, but the particles do not move and the height (L) remains the same.
• At a certain velocity, the pressure drop across the bed counterbalances the
forces of gravity on the particles or the weight of the bed
• At point A = Any further increase in velocity, causes the particles to move
• At point B = Further increase in velocity, the particles become separate enough
to move about in the bed and true fluidization begins.
• From point B to point C = Once bed is fluidized, the pressure drop across the
bed stays constant, but the bed heights continues to increase with increasing
velocity.
• From point C to B = If the velocity is gradually reduced, the pressure drop
remains constant and the bed height decreases.
Fluidization Pattern
• Particulate fluidisation: Particulate fluidization refers to the fluidization
behavior observed in beds of solid particles when a fluid (usually a gas or liquid)
is passed through them.
• In particulate fluidization, the bed of particles expands and maintains a uniform
character as the fluid velocity is increased. The particles in the bed experience
progressive agitation, but they do not form distinct phases. Particulate fluidization
is typically associated with liquid-solid systems.

Coulson, J. M., & Richardson, J. F. (2019). Coulson and Richardson's Chemical Engineering (Sixth Edition, Volume 2a:
Particulate Systems and Particle Technology). Pages 449-554.
 Aggregative Fluidization is a fluidization process observed in gas-solid
systems when a gas flows through a bed of solid particles at high velocities. It
is characterized by the formation of two distinct phases within the bed.
The first phase, termed the dense emulsion phase, consists of solid particles
that accumulate and create a concentrated, continuous phase. The second phase,
known as the lean phase, emerges as gas bubbles are introduced. Aggregative
fluidization is commonly observed in gas-solid systems.

Coulson, J. M., & Richardson, J. F. (2019). Coulson and Richardson's Chemical Engineering (Sixth Edition, Volume 2a:
Particulate Systems and Particle Technology). Pages 449-554.
• The Froude number gives a criterion from which the type of fluidization can be
predicted.
U2mf
Fr=
𝑑𝑔
• Here Umf is the min. superficial velocity of flow ( min. fluidizing velocity )
• d: is the dia. of particles.
• g : is accerelation due to gravity .
Fr < 1 ; particulate fluidization.
Fr > 1 ; aggregative fluidization.
Rice et al. (1958) and Romeo et al. (1962) proposed four dimension less groups
to characterize the quality of fluidization,

N <100, particulate fluidization and

N>100, aggregative fluidization
 Minimum Fluidization Velocity: incipient fluidization
• Superficial fluid velocity at which the packed bed becomes a fluidized bed is
known as the minimum fluidization velocity, Umf
• Sometimes referred to as the velocity at incipient fluidization
• Umf increases with particle size and particle density and is affected by fluid
properties.
Calculation of the Fluidization Minimum Velocity
At the point of incipient fluidization drag force exerted by the fluid on
the particles is equal to the net weight of particles in the bed.
Fluid Solids
Fraction ε 1-ε
H
Volume ε(AH) (1 - ε)(AH)
Mass ε(AH)ρf (1 - ε)(AH)ρₚ

weight of a particle−𝑈𝑝𝑡ℎ𝑢𝑟𝑠𝑡 𝑜𝑛 the particle

Pressure drop=
𝑏𝑒𝑑 cross section A
 𝑭𝑷𝒂𝒓𝒕𝒊𝒄𝒍𝒆 𝒘𝒆𝒊𝒈𝒉𝒕 𝑭 𝒇𝒍𝒖𝒊𝒅 𝒖𝒑𝒕𝒉𝒖𝒓𝒔𝒕
𝜟P= -
𝑨 𝑨

𝑭𝑷𝒂𝒓𝒕𝒊𝒄𝒍𝒆 𝒘𝒆𝒊𝒈𝒉𝒕 = mg= 𝝆𝒑 𝑽𝒑 𝒈 = 𝝆𝒑 𝟏 − 𝜺 𝑨𝑯𝒈

𝑭𝒇𝒍𝒖𝒊𝒅 𝒖𝒑𝒕𝒉𝒖𝒓𝒔𝒕 = mg= 𝝆𝒇 𝑽𝒑 𝒈 = 𝝆𝒇 𝟏 − 𝜺 𝑨𝑯𝒈

⇒ 𝜟𝑷 = 𝝆𝒑 − 𝝆𝒇 𝟏 − 𝜺 𝑯𝒈 (1)

• Kozney-Carman equation works well for fine particles. (Typically, for a bed of
small particles (D p ≤ 0.1 mm), the flow conditions at this stage are such that the
Reynolds number is relatively small (Re ≤ 10 ) so that we can use the Kozeny-
Carman Equation, applicable to the viscous flow regime)
• But for larger particles, minimum fluidization velocity is high & Kozney-Carman
equation is inadequate (For large particles ( 1 D p ≥ mm), inertial effects are
important, and the full Ergun equation must be used to determine Umf)
• To derive expression for Umf, equate expression for pressure loss in a fluidized bed
with pressure loss across a packed bed
• Applying the Ergun equation,

Δ𝑃 150 1 − 𝜀 2 𝜇𝑢 1.75 1 − 𝜀 𝜌𝑓 𝑢2
= 2 2 3
+
𝐻 𝑑 𝜑 𝜀 𝑑𝜑𝜀 3
• Writing Ergun’s equation for minimum fluidization conditions & for spherical
particles
 =1

2 2
Δ𝑃 150 1 − 𝜀𝑚𝑓 𝜇𝑢𝑚𝑓 1.75 1 − 𝜀𝑚𝑓 𝜌𝑓 𝑢𝑚𝑓
= 3 + 3
𝐻𝑚𝑓 𝑑 2 𝜀𝑚𝑓 𝑑𝜀𝑚𝑓
• Substituting pressure drop from equation 1

150(1 −  mf )umf 1.75  f umf2

( −  f )g = +
d  d mf3
p 2 3
mf
• Multiply by f d3
2

( p −  f )g f d 3

=
150(1 −  mf )d f umf
+
1.75  2f d 2umf2
 2
 
3
mf  2 mf3
150(1 −  mf )Re mf 1.75 Re 2mf
Ga = +
 3
mf  mf3

Ga =
( p −  f )g f d 3
Galileo number also known as Archimedes
2 number

d f umf And Remf is the Reynolds number

Re mf =
 at incipient fluidization
• In order to obtain a value of Umf, we need to know the voidage of the bed
at incipient fluidization,
e = emf
• A typical value of emf is 0.4-0.45
Ga = 1406 Re mf + 27.3 Re 2mf

• It can be written in the form

 Re mf +  Re 2mf − Ga = 0

• This can be rearranged to give

0.5
    Ga 
2
  
Re mf =   +   − 
 2      2 
 Void Fraction at Min. Fluidization
•  mf depends on the shape of the particles. For spherical particles it is usually 0.4 – 0.45.
 Minimum Fluidization
What if emf(and maybe Φ𝑠 ) is unknown?
• Wen and Yu found for many systems (ratio of the diameter of a sphere of the same volume to
surface area ratio as the particle d, as used in the Ergun equation, to the diameter of a sphere with the same
volume as the particle dp

• In the ergun equation d is replace with Φ𝑠 dp

• d= Φ𝑠 dp 1
3
Φ𝑠 𝜀𝑚𝑓 ≅
14
Thus, a reasonable estimate of minimum velocity can be obtained from

𝑅𝑒𝑚𝑓 = 33.7 2 + 0.0408𝐺𝑎 0.5 − 33.7

 Bed Length at Minimum Fluidization

• Once we obtain the minimum void fraction, the bed length at minimum fluidization

𝑴𝑩𝒆𝒅
𝑯𝒃,𝒎𝒇 =
𝑨 𝟏 − 𝜺𝒎𝒇 𝝆𝒑

𝐻 𝑏,𝑚𝑓 represents the bed height (or bed length) at minimum fluidization.
𝑀𝐵𝑒𝑑 is the bed mass or weight.
A represents the cross-sectional area of the bed.
𝜀𝑚𝑓 is the minimum fluidization void fraction.
𝜌𝑝 is the density of the solid particles.
 Fluidized bed: Operation
• Porosity increases
• Bed height increases
• Fluidization can be sustained until terminal velocity is reached
• If the bed has a variety of particles (usually same material, but different sizes)
– calculate the terminal velocity for the smallest particle
• Range of operability = R
• Minimum fluidization velocity = incipient velocity (min range)
• Maximum fluidization velocity = terminal velocity (max range)

• R = Vt/VMf Theoretically R can range from 8.4 to 74

Minimum fluidization velocity as a function of terminal
falling velocity

• summaries the method for predicting Minimum fluidization velocity as a function of terminal falling
velocity of a particle. The terminal falling velocity ut in terms of Galileo number.
• For Stoke’s law region:

gDP2 ( P −  )
ut = In terms of Galileo Number
18
• Multiply b by
fd Ga
Re t =  Ga = 18 Re t
 18

 f ut d gd 3  f ( P −  f )
= Stokes law is valid only for
 18 2 Re<0.2 which becomes Ga<3.6
• For Newton’s law region:
gDP ( P −  f )
ut = 1.75
f
 2f d 2
• Squaring &multiplying [Link]
2
u  d
2 2 2
1.75 g f d ( p −  f )
2 3

=  Re t2 = 1.752 Ga
t f

 2
2
Ga = 0.33 Ret2 For Galileo number greater than 10^5

• Now if voidage at minimum fluidization velocity  mf is known,

• Then for given value of Galileo number , the ratio of ut Re t
=
Can be calculated from Ergun equation. umf Re mf
• For transition region:
• Which is valid in the range 3.6<Ga<10^5
(
Ga = 18 Ret 1 + 0.15 Ret0.687 )
Expansion of the fluidized bed : Particulate fluidization
𝜟𝑷 = 𝝆𝒑 − 𝝆𝒇 𝟏 − 𝜺 𝑯𝒈
 The Geldart Classification of Particles
Geldart Classification of particles categorizes particles into four distinct groups
(A, B, C, and D) based on their size and density relative to the fluid in which
they are suspended. This classification helps in understanding the fluidization
behavior of particles

Group C:cohesive, or very fine powders

• Normal fluidization is difficult. Rise as a plug of solids.
• Examples: Face powder, flour, and starch.

Group A:Aeratable,Small particle size or density less than 1.4 g/cc.

• Smooth fluidization at low gas velocity, small bubbles at high velocity.
• Major example is the FCC catalyst.
• Group B:sand like particles (40 µm<dp<500µm)
• Or density1.4 < P < 4 g/cc.
• Fluidize with vigorous bubbling & bubbles grow large.
• Majority of gas-solid reactions occur in this regime.

• Group D: Spoutable, large and/or dense particles

• Deep bed difficult to fluidize: spouting or shallow beds.
• Examples include drying grains, peas, roasting coffee beans, gasifying coals and
roasting of metal ores.

For any solids of known density & particle size: graph shows the type of
fluidization to be observed.
 Advantages of Fluidization
1. Smooth liquid like flow of particles allows contionus automatically controlled
operations.
2. Rapid mixing of solids leads to isothermal conditions throughout the reactor.
3. Suitable for high exothermic reactions.
4. H.T and M.T rates between gas & particles are high
5. H.T. Rates between bed and immersed object is high-requires less [Link].
Disadvantages of Fluidization
1. For catalytic reactions: movement of porous catalyst particles continuously
capture and release the gas reactant
2. So back mixing reduces the yield and performance
3. For non catalytic reactions at high temp
4. Erosion of pipes & vessels from abrasion of particles
Industrial Applications of Fluidized Bed