FLUIDISED BED REACTORS
INTRODUCTION
• The catalytic reactor (which is in common use) is analogous to
the CSTR in that in content, though heterogeneous, are well
mixed and this results in an even temperature distribution
throughout the bed.
• It consists of a vertical cylindrical vessel containing fine solid
catalyst particles. The fluid stream (usually a gas) is introduced
through the bottom at a rate such that catalyst particle are
suspended in the fluid stream without being carried out.
• With this reactor, it is possible to regenerate the catalyst
continuously without shutting down the reactor. This reactor is
particularly suitable when the heat effects are very large or
when frequently catalyst regeneration is required.
• Fluidization occurs when small solid particles
are suspended in an upward flowing stream of
fluid.
• The fluid velocity is sufficient to suspend the
particles, but it is not to large enough to carry
them out of vessel.
• The solid particles swirl around the bed rapidly,
creating excellent mixing among them.
• The material “fluidized” is almost always a solid
and the “fluidizing medium” is either a liquid or
gas.
• The characteristics and behavior of a fluidized
bed are strongly dependent on both the solid
and liquid or gas properties.
APPLICATIONS
Fischer-Tropsch Synthesis.
Phthalic anhydride synthesis.
Methanol to gasoline and olefin processes.
Cracking of Hydrocarbons (Fluid Catalytic Cracking, etc).
Coal combustion.
Coal gasification
Cement clinker production.
Titanium dioxide production.
Granulation drying of yeast.
Absorption
Nuclear energy (Uranium processing, nuclear fuel fabrication,
reprocessing of fuel and waste disposal).
ADVANTAGES
• Uniform Particle Mixing- Due to the intrinsic fluid-like behavior of the
solid material, fluidized beds do not experience poor mixing as in
packed beds.
• Uniform Temperature Gradients- Local hot or cold spots within the
reaction bed, often a problem in packed beds, are avoided in a fluidized
situation such as an FBR.
• Ability to Operate Reactor in Continuous State-The fluidized bed nature
of these reactors allows for the ability to continuously withdraw product
and introduce new reactants into the reaction vessel.
DISADVANTAGES
• Increased Reactor Vessel Size- Because of the expansion of the bed
materials in the reactor, a larger vessel is often required than that for
a packed bed reactor thereby increases initial capital costs.
• Pumping Requirements and Pressure Drop- More pumping power
and thus higher energy costs are needed. In addition, the pressure
drop associated with deep beds also requires additional pumping
power.
• Particle Entrainment- the separation of the entrained particles can be
a very difficult and expensive problem to address.
• Lack of Current Understanding-It is very difficult to predict and
calculate the complex mass and heat flows within the bed. Due to this
lack of understanding, a pilot plant for new processes is required.
• Erosion of Internal Components- The fluid-like behavior of the fine
solid particles within the bed eventually results in the wear of the
reactor vessel thus requiring high maintenance.
• Pressure Loss Scenarios- If fluidization pressure is suddenly lost, the
surface area of the bed may be suddenly reduced which can cause
problems like inconvenience or runaway reactions.
