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Fixed bed and fluidized bed

Ref: BSL, McCabe & Smith

Why fixed (or fluidized) bed?


Expensive

Catalyst
enzyme (immobilized)
Large Surface area

Used in reaction/adsorption/ elution (for example)

Goal: Expression for pressure drop, try some


examples

Fixed bed

Filled with particles


Usually not spherical
To increase

surface area
To increase void fraction

To decrease pressure drop

For analytical calculation, assume all particles are


identical
Usable,

because final formula can be modified by a


constant factor (determined by experiment)

Fixed bed

What are important parameters?


(For example, for adsorption of a protein from a
broth)
rate

of adsorption (faster is better)


saturation concentration (more is better)

From the product requirement (eg X kg per day),


density and product concentration in broth ==>
volumetric flow rate

Fixed bed

Assume quick adsorption (rate of adsorption is high)


Calculate the surface area of particles needed for
operation

Sphericity <=> specific surface area <=> average particle diameter

Sphericity

Volume

Ap,
Vp

of particle = Vp
Surface Area of particle = Ap
Surface Area of sphere of same volume (Vs =Vp) = As
Sphericity = As/Ap
May be around 0.3 for particles used in packed beds
lower sphericity ==> larger surface area

As,
Vs

Fixed bed

Specific surface area


= Ap

/Vp
Minimal value for sphere
Some books use S to denote area (instead of A)
Assume all the particles are identical

==> all particles have exactly same specific surface area

Rings (Raschig,etc)

Tarus saddle

Pall Ring

Fixed bed

What is the pressure drop we need, to force the fluid through


the column?

(i.e. what should be the pump spec)

We know the volumetric flow rate (from adsorption


equations, productivity requirements etc)
We know the area per particle (we assume all particles are
identical). And the total area for adsorption (or reaction in
case of catalytic reactor).
Hence we can calculate how many particles are needed
Given a particle type (eg Raschig ring) , the approximate
void fraction is also known (based on experimental results)

Fixed bed

What is void fraction?


Volume of reactor = VR
Number of particles = Np
Volume of one particle = Vp
Volume of all the particles = Vp * Np = VALL-PARTICLES
VVOIDS
VR
V V N
R P P
VR

Void fraction

VR VALL PARTICLES

VR

Knowing void fraction, we can find the reactor volume


needed

VR 1
Alternatively, if we know the reactor volume and void
N
fraction and the Vp, we can find the number of particles P
VP

Fixed bed

To find void fraction experimentally


Prepare the adsorption column (or reactor....) and fill it
with particles
Fill it with water
Drain and measure the quantity of water
(= void volume)
Calculate void fraction

Fixed bed

Since we know Vp, Np, , we can find VR


Choose a diameter and calculate the length (i.e. Height)
of the column (for now)
In

normal usage, both the terms height and length may


be used interchangeably (to mean the same thing)
Adsorption rate, equilibrium and other parameters will
also influence the determination of height & diameter

To calculate the pressure drop


Note:

columns with large dia and shorter length (height)


will have lower pressure drop
What can be the disadvantage(s) of such design ?
(tutorial)

Fixed bed

To calculate the pressure drop


You want to write it in terms of known quantities
Length of column, void fraction, diameter of particles, flow rate of
fluid, viscosity and density
Obtain equations for two regimes separately (turbulent and laminar)
Consider laminar flow
Pressure drop increases with
velocity
viscosity
inversely proportional to radius
Actually, not all the reactor area is available for flow. Particles
block most of the area. Flow path is not really like a simple tube
Hence, use hydraulic radius

Fixed bed - pressure drop


calculation (Laminar flow)

To calculate the pressure drop, use Force balance


Force P Area

Area where flow occurs =


Force P

D2
4

D2
4

Resistance : due to Shear

Force Contact area

Find Contact Area


Find shear stress

Until now, we havent said anything about laminar


flow. So the above equations are valid for both
laminar and turbulent flows

Fixed bed - pressure drop


calculation (Laminar Flow)

rR

Vp

Ap

=VR 1

r2
V Vmax 1 2
R

Ap
Vp

FLOW

Vmax 2 Vavg

Here V refers to velocity for flow in a tube


2 Vmax 4 Vavg

R
R

VR 1

To calculate the shear stress, FOR LAMINAR


dV

dr

VR VP N P
VR

NP

Find contact area


Wetted Area= N p Ap

8 Vavg
D

However, flow is through bed, NOT a simple tube

VR 1
VP

Fixed bed - pressure drop


calculation (Laminar Flow)

Find effective diameter (i.e. Use Hydraulic radius), to


substitute in the formula
Also relate the velocity between particles to some quantity
we know
To find hydraulic radius ( and hence effective dia)
Flowvolume VR

Wetted Area= N p Ap

VR 1
Vp

Ap

Hydraulic diameter
DH 4

Flow Area
ContactPerimeter

Flow Area * Column Height


ContactPerimeter * Column Height

Flow volume
wetted area

Fixed bed - pressure drop


calculation (Laminar Flow)
DH

4
Ap
1

V
p

Ap
8

V
1

8 Vavg
avg
Vp

DH
4
A

2 Vavg 1 p
Vp

Vavg is average velocity of fluid in the bed, between


particles
Normally, volumetric flow rate is easier to find

Fixed bed - pressure drop


calculation (Laminar Flow)

Can we relate volumetric flow rate to Vavg ?


Use a new term Superficial velocity (V0)
Volumetric flow rate
V0
Column Area

V0

Q
D2

I.e. Velocity in an empty column, that will provide the


same volumetric flow rate
Can we relate average velocity and superficial velocity?
Vavg

V0

Fixed bed - pressure drop


calculation (Laminar Flow)
A

2 Vavg 1 p
Vp

2 V0 1 p
Vp

Force balance: Substitute for etc.


Force P

D2
4

Force Contact area

Ap
2

V
1

0
Vp
Ap
D2

VR 1
2
Vp
4

Volume of reactor (say, height of bed = L)


2

Ap
2 V0 1
Vp D 2
D2

L
2
4

4
2

VR

D2
4

Fixed bed - pressure drop


calculation (Laminar Flow)
2

Ap
2

V
1

V D2
0
D2
p

L
2
4

4
2

Pressure drop
P

2 LV0 1

Ap
Vp

Specific surface area vs average diameter


Ap

Vp

Define average Dia of particle as


Dp

Some books (BSL) use Dp

6
Ap

Vp

Fixed bed - pressure drop


calculation (Laminar Flow)

Pressure drop

2 LV0 1

6
Dp

72 LV0 1

D p 2 3

However, using hydraulic radius etc are only


approximations
Experimental data shows, we need to multiply the
pressure requirement by ~ 2 (exactly 100/48)

In terms of average particle diameter

150 LV0 1
D p 2 3

In terms of specific surface area

2A

25 LV0 1 p
Vp

6 3

Fixed bed - pressure drop


calculation (Turbulent Flow)

Pressure drop and shear stress equations


Force P

D2
4

Force Contact area

Only the expression for shear stress changes

For high turbulence (high Re),

f
=constant
1 V 2
2 avg
2
=constant 1 Vavg
2

However

Vavg

Re

V0

=K

V02

Fixed bed - pressure drop


calculation (Turbulent Flow)

We have already developed an expression for contact area


Wetted Area= N p Ap

VR 1
Vp

=VR 1

Vp

Hence, force balance


D2

Force P

Contact area

Ap

V02
K 2 VR 1

Vp

Ap

Ap

Volume of reactor (say, height of bed = L)


VR

D2
4

Ap

V02
P K 3 L 1

Vp

Fixed bed - pressure drop


calculation (Turbulent Flow)
In terms of average particle diameter

V02
6
P K 3 L 1

Dp

In terms of specific surface area

Ap

V02
P K 3 L 1
Vp

Value of K based on experiments ~ 7/24

What if turbulence is not high?

Use the combination of laminar + turbulent pressure drops:


valid for all regimes!
2
7 LV02 1
150 LV0 1
PLaminar

Ptotal

150 LV0 1
Dp 2 3

Dp
2

7 LV02 1
4 D p 3

PTurbulent

4 D p

Ergun Equation for


packed bed

Fixed bed - pressure drop calculation


(Laminar OR Turbulent Flow)
Ptotal

150 LV0 1
Dp 2 3

7 LV02 1
4 D p 3

Ergun Equation for


packed bed

If velocity is very low, turbulent part of pressure drop is


negligible
If velocity is very high, laminar part is negligible

Some texts provide equation for friction factor

1 V 2
2 avg

laminar turbulent
f
1 V 2
2 avg

Ap
2 V0 1 V 7 V 2
p

2
2

24

f
1 V 2
2 avg

Fixed bed - pressure drop calculation


(Laminar OR Turbulent Flow)

Ap
2 V0 1 V
V02
p

K 2
2

f
2
1 V0 2
2

Ap
4

V 7

V0

12

For pressure drop, we multiplied the laminar part by 2


(based on data) . For the turbulent part, the constant was
based on data anyway.
Similarly...

Ap
Ap
25

100 4 1 V 7
p

f
48

V0


12

3V0

7
12

Fixed bed - pressure drop calculation


(Laminar OR Turbulent Flow)

Ap
25

Vp 7


f
3V0

12

Multiply by 3 on both sides (why?)


150 1 7
150 1 7
3f
3f

6
25

Dp 7

3V0

12

Dp V0

Dp V0

Packed bed friction factor = 3 f


150 1
fp 3 f
1.75
Re p

Eqn in McCabe and Smith

Reynolds number for packed bed

Example

Adsorption of Cephalosporin (antibiotic)


Particles are made of anionic resin(perhaps resin coatings on ceramic
particles)
void fraction 0.3, specific surface area = 50 m2/m3(assumed)
column dia 4 cm, length 1 m
feed concentration 2 mg/liter (not necessary to calculate pressure drop, but
needed for finding out volume of reactor, which, in this case, is given ). Superficial
velocity about 2 m / hr
Viscosity = 0.002 Pa-s (assumed)
What is the pressure drop needed to operate this column?

Fixed Bed

What is the criteria for Laminar flow?


Modified Reynolds Number
Turbulent flow:- Inertial loss vs turbulent loss

Loss due to expansion and contraction

Packing uniformity

D pVo

In theory, the bed has a uniform filling and a constant void fraction
Practically, near the walls, the void fraction is more

Ergun Eqn commonly


used, however, other
empirical correlations are
also used
e.g. Chilton Colburn eqn

A
B
f
n C
Re Re

0.8

0.4
0.2
Edge

Center

Edge

Fixed Bed

Sphericity vs Void Fraction

~0.4

Fixed Bed

Alternate method to arrive at Ergun equation (or similar correlations)


Use Dimensional analysis

P dependent variable

( with out subscript, means fluid density or f )


D p , L, Vo , , Dcolumn , , f (i.e. sphericity)
2
DpVo Dp
P Dp
f(
,
, ,f )
2
Vo L

Dcolumn

Fluidized bed
When the fluid (moving from bottom of the column to the top) velocity is increased, the
particles begin to move at (and above) a certain velocity.

Fluidized bed

At fluidization,

Weight of the particles == pressure drop (area)


Remember to include buoyancy
P

D2
4

s f

s f

1 V

D2
4

IIT-Madras, Momentum Transfer: July 2005-Dec 2005

IIT-Madras, Momentum Transfer: July 2005-Dec 2005

IIT-Madras, Momentum Transfer: July 2005-Dec 2005

Fluidized bed: Operation

Empirical correlation for porosity

V
n

Vt

Types of fluidization: Aggregate fluidization vs Particulate


fluidization
Larger particles, large density difference (SOLID - FLUID)
==> Aggregate fluidization (slugging, bubbles, etc)
==> Typically gas fluidization
Even with liquids, lead particles tend to undergo
aggregate fluidization
Archimedes number
g D3

Ar

p
2

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)
Other parameters may limit the actual range further
e.g. Column may not withstand the pressure, may not be tall
enough etc
R = Vt/VOM
Theoretically R can range from 8.4 to 74

Fluidized bed: Operation


80

Range of operation
depends on Ar

40

100

104
Ar

108

Fluidized bed: Operation

Criteria for aggregate fluidization


Semi empirical

D p

2
s

0.5

0.6 ( for liquid )


0.3 ( for gas )

Particulate fluidization
Typically for low Ar numbers
More homogenous mixture

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