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CHAPTER 1: INTRODUCTION
1.1.
1.2.
1.3.
1.4.
CHAPTER 1
1
Introduction:
1.1. Fluidized Bed Technology:
There are various attractions to generate power from biomass derived fuels such as coal, biomass etc.
through fluidized bed technology [18]. Fluidized bed has emerged as an environmentally acceptable
technology for burning wide range of solid fuels to generate steam and electricity power because of
its unique in situ capture of SO 2 and NOx. It is a compact, cheap and efficient method of using low
grade coals which are either difficult to be used or not possible to use in conventional processes [2].
Fluidization is a phenomenon where a granular material, such as sand, transforms from a solid-like
state into a fluid-like state [2]. Fluidization occurs when a fluid, liquid or gas, is passed up through
the granular material. Depending on the flow rate, the properties of the particles and the type of the
fluid several different states of fluidization are possible. If the flow rate is low, the fluid merely flows
through the empty spaces between the particles and the bed remains stationary. This situation is
called fixed bed. If the flow speed is increased, the drag forces between the fluid and the particles
become larger and the bed begins to expand in volume. Eventually a limit is reached where the drag
force is in balance with the gravitational force and the particles are suspended within the flow. At this
point the bed is considered to be at minimum fluidization state and the particles start to exhibit fluidlike behaviour [2]. After the minimum fluidization point, in case of gas-solids systems, the excess
gas usually starts to form channels and bubbles within the bed. The bubbles are formed near the gas
entry points at the bottom and they rise up through the bed finally bursting up when they reach the
bed surface. On the way up the bubbles change in size and shape as they collide with other bubbles
or break up into smaller bubbles. If the bed is relatively tall and narrow, the bubbles can fill up the
entire width of the bed and the flow becomes slugged. If one continues to increase the flow speed
beyond what is needed for bubbling flow, the nature of the particle bed changes again. The bed
height increases and its surface becomes less clearly defined. The bubble shapes become more and
more distorted and quite suddenly instead of bubbling flow, one can observe very complex,
turbulent-like motion of particle strands and clusters. This state is known as turbulent fluidization
and in this regime the mixing of particles is very vigorous [2].
With even higher flow velocities than what is required for turbulent fluidization a substantial amount
of the particles start to leave the bed as they become entrained in the up-going flow. Stable operation
at this point requires either constant supply of new particles or a recirculation path for the escaped
particles. At this point the behaviour of the bed can be controlled by adjusting the feed rate of
particles. If the feed rate is kept relatively high, so that the particles are not completely blown away,
2
the bed is called a fast fluidized bed. A fast fluidized bed typically consists of a relatively dense,
turbulent bottom bed which gets more dilute higher up. The dilute region contains particle clusters
which are rapidly breaking apart and reforming [2].
ackground:
Fig
1.2.2: Schematic diagram of circulating
fluidized bed [2]
Fritz Winkler from Germany was the first to obtain a patent for a fluidized bed hot gas generators in
1921 [3].Fluidized bed processes came into wide use in the petroleum industry in the 1940s [1].
These processes are also extensively used in the chemical and metallurgical fields. The first CFB
boiler, designed exclusively for the supply of steam and heat, was built in the Vereingte Aluminum
Werke at Luenen, Germany in 1982 [18]. This plant generated 84 MW total (9 MW electricity, 31
MW process steam, 44 MW molten salt melt) by burning low-grade coal washery residues in the
presence of limestone [3]. Today there are a number of CFB plants operating all over the world and
size of the plant installations are increasing. The worlds largest power plant (Lagisza) of capacity
460MWe began commercial operation in 2009, which marked the beginning of a new era in the
evolution of this technology. This is also the worlds first once through unit supercritical CFB boiler
[2]. Along with the commercial CFB units, various laboratory and pilot CFB units are developed to
investigate and optimize the operating parameters for higher efficiencies at lower emission level.
Continued research and development in the field of fluidization has led to the development of
pressurized bubbling fluidized bed (PCFB). The first pilot PCFB plant of capacity 10MW was
developed by Ahlstrom at Karhula, Finland in 1989 [18]. Due to multiple advantages of CFB
technology such as multi-fuel flexibility, compactness, uniform temperature throughout etc. CFB
gasification has also been developed side by side with CFB technology. The first commercial
atmospheric gasifier was installed in 1983 in Jacobstad, Finland [18]. In 1991, Foster Wheeler
supplied a PCFB gasification system to a 17 MW biomass-fired Integrated Gasification Combined
Cycle (IGCC) demonstration project a Varnamo, Sweden and it is the first biomass fired IGCC plant
in the world [18]. The potential of fluidized bed technology appears to be almost unlimited. As the
technology refinement opens up new vistas, PCFB power generation holds a greater promise to
generate power in a most cost effective and environment friendly way.
4
1.3.
Pressurized circulating fluidized bed (PCFB) combustor technology is a recent extension of the
fluidized bed technology family [1]. This type of circulating fluidized bed combustor operates at
elevated pressures, but still maintains all the advantages of the circulating fluidized bed system [18].
This technology is relatively new and is only at demonstration stage. An application of PCFB
combustor technology to combined cycle power generation has opened up an attractive alternative
due to its (1) high overall efficiency, (2) low emission and improved combustion, (3) good heat
transfer characteristics, (4) compact furnace size and (5) fuel flexibility. However, in order to fully
comprehend the advantages of pressurized circulating fluidized bed combustion, it is important to
understand the effect of operating pressure on different design parameters [18]. The bed-to-wall heat
transfer coefficient is one of the important parameters whose knowledge is required during both the
design and operating phase of a boiler [3]. There are two types of pressurized fluidized beds:
bubbling and circulating. While pressurized bubbling bed designs have been developed and are in
commercial operations, the circulating fluidized bed (CFB) designs are still in the pilot stage.
The PCFB unit, in general consists of a riser, a cyclone separator, a return leg called downcomer, a
loop seal and a feeding system. The performance of a PCFB unit is influenced by a number of
factors, including superficial velocity, solid circulation rate, solid inventory, and particle size
distribution [4]. Change of any of these parameters changes the bed hydrodynamics such as bed
voidage, and suspension density, and this causes a change in the heat transfer along the bed height.
Many researchers have reviewed the bed hydrodynamics and heat transfer at atmospheric conditions
[18].
1.4.
Motivation:
As mentioned earlier PCFB units have many advantages and the understanding of bed
hydrodynamics and heat transfer characteristics is very important for the proper design of PCFB
units. Very limited research has reported the effect of various parameters in a PCFB. In this view, the
present work concentrates in studying and investigating the effect of various operating parameters on
the hydrodynamic and heat transfer characteristics in a PCFB riser (laboratory unit).
CHAPTER 2
Literature Review:
A critical review of the available literature on the bed hydrodynamics heat transfer characteristics in
pressurized fluidized bed units which are relevant to the scope of the present study are presented in
this chapter. The summary of the literature review is also presented at the end of the chapter.
fraction of the bed occupied by bubbles. The bed voidage ( ) at any cross-section has been estimated
from the measured pressure drop (
pb
across it.
=Voidage
1-
For a fluidized bed, the pressure drop across the bed equals the weight of the bed, the fluid drag is
written as
From this equation
pb 1 L s g g
pb 1 L s g
hL
w g
100
pb
Again,
Where
hL
pb
Or,
hL
1000 g 1 L s g
100
1
Or,
10 hL
L s
1
or
10 hL
L s
The axial variation of voidage is typically a flattened S profile. At the bottom of the riser solid
fraction varies from 0.2 to 0.4, whereby it decreases and remains almost constant throughout the
height of the riser.
amount
of
solids
of the bed may be defined as suspension density. Mathematically, it can be expressed as,
sus=(1 ) +
s
It is reported that, the particle size and the solid inventory have a substantial influence on the
suspension density profile in a CFB furnace (Basu, 2006). It is claimed that with the decrease in
particle size, the suspension density increases. One can influence the suspension density by
changing the bed inventory and this was suggested by Yue et al. (2005).The suspension density
along the height of a CFB boiler varies exponentially as it does in the freeboard region of a
bubbling fluidized bed (Liand Kwauk, 1980 and Kunii and Levenspiel, 1991).
Minimum fluidization velocity is the basic information required for the design and development of
a fluidized bed. Many researchers have studied how an increased pressure effects the minimum
fluidization velocity. They have experimentally found that the effect of pressure on the minimum
fluidization velocity depends on the particle size. The results of their experiments show a clear
decrease in the minimum fluidization velocity with increasing pressure for particles larger than
100m. To estimate the effect of pressure on minimum fluidization velocity, Ergun (1952) has
developed an expression. The pressure drop per unit height of a packed bed of uniformly sized
particles, is correlated as
Type equation here .
For a fluidized bed, the pressure drop across the bed equals the weight of the bed, the fluid drag is
written as
The minimum fluid velocity at which the bed just becomes fluidized (U mf) may be obtained by
solving these two eq. simultaneously to obtain
The values of the empirical constants C1 and C2 as taken from experiments are 27.2 and 0.0408,
respectively (Grace, 1982).
In a CFB, fine solid particles (Geldart Group A and B) agglomerate and form clusters or strands in
a continuum of generally up-flowing gas containing sparsely dispersed solids. The continuum is
called the dispersed phase, while the agglomerates are called the cluster phase. The majority of the
bed particles move upwards through the core of the bed, but flow downwards along the wall in the
form of clusters of particles or strands.
The heat transfer to the furnace wall occurs through
conduction from particle clusters, convection from
the dispersed phase, and radiation from both phases.
Solid clusters sliding down the wall experience
unsteady-state heat conduction to the wall. The
clusters cool down while losing heat to the wall
through conduction and radiation.
If f is the average fraction of the wall area covered by
pressure. Then on the basis of experiments conducted, an empirical relation is also developed for
prediction of heat transfer coefficients, within the present range of experiments. The riser of a
CFB operating under a fast fluidized regime comprises two phases: clusters and dispersed phase.
At any instant the wall of the bed is covered partially by clusters and partially by dispersed phase.
Thus the bed-to-wall convective heat transfer coefficient, h conv would have two components: one
due to the clusters hc and other due to the dispersed phase, hd. The fraction of the wall covered by
the clusters c may be estimated as
1 w Y
0.5
c =K
Where K = 0.5,
w = ( r i=R )= 3.811 ,
c
is the voidage within the clusters. The average solid concentration in the clusters at the wall
(1- c ) of the bed was derived by Lints from the capacitance probe data of Wu et al. (1989) and
Longer et al.(1990) [1] as
0.54
1 c =1.23(1 )
Where
is the cross-section average voidage of the solids. The volume fraction of the solid in
hc =
1
dp
tc
+
10 K gf 4 K c C c c
0.5
10
K gf
at mean gas film temperature, t c is the average residual time of clusters on the wall.
K c ,C c c
are the thermal conductivity, specific heat and density of cluster respectively.
C c =[ ( 1 c ) C p + c C g ] and
Kp
Kg
( )
( )]+0.1 C
Kp
Kg
d p U mf
by less than 2% whereas the pressure changes from 100 kPa 1000 kPa at the same bed
temperature. The minimum fluidization velocity Umf may be predicted by the Ergun equation. The
maximum fall velocity of clusters Umf is taken as 1.26 ms-2 in the model calculation. The
convective heat transfer due to the upflowing dispersed phase as given by Basu for atmospheric
pressure could not reflect the effect of the pressure very well. Xavier and Davidson (1985) and
Martin (1985) found that the gas convective heat transfer coefficient varies approximately as the
square root of the gas density. So the equation developed by Wen and Miller in 1961 used by Basu
was modified as
hd =
K g C p dis
dp C g p
0.3
Ut
gdp
0.21
g
go
0.2
( )( ) ( )
pr
particle.
AUTHORS
OBSERVATIONS
REPORTED
(1)
The
bed-to-wall
convective
heat
transfer
coefficient increases with
increasing system pressures
and bed suspension density,
but not with particle size for a
11
experimental
Hydrodynamics,
erosion and heat
transfer in a
pressurized
fluidized bed:
influence of
pressure,
fluidization
velocity, particle
size and tube
bank geometry
Wiman
Almstedt
(1997)
and Measurements
of
hydrodynamics, local tube
erosion
and
local
instantaneous bed-to tube
heat transfer were carried
out in a cold pressurized
fluidized bed, with two
horizontal tube banks having
different tube packings. The
influence
of
pressure,
fluidization velocity,particle
size and tube bank geometry
was studied. Two size
distributions of silica sand
were used, one with a mean
particle diameter of dp = 0.7
mm and one with dp = 0.45
mm. The bed has a crosssection of 0.2 m x 0.3 m, and
was operated at pressures
between 0.t and 1.6 MPa and
at excess gas velocities of
0.2 and 0.6 m/s.
Effect
of Winaya
Developed a mechanistic
model based on cluster
renewal approach to predict
bed to wall heat transfer in
pressurized
circulating
fluidized bed (PCFB). The
model takes into account the
effect of pressure on cluster
density, cluster thermal
conductivity and particle
convection heat transfer
coefficient. The effect of bed
pressure and temperature on
bed to wall heat transfer
coefficient is investigated.
The model predictions are
validated
against
the
experimental data obtained
from a PCFB riser of 52.4
mm in diameter and 2020
mm
height.
The
experimental results are
reported for pressures up to
600
KPa
and
bed
temperature up to 6500C.
and Experiments are performed Heat
transfer
coefficient
14
pressure
and Basu (2000)
carbon dioxide
concentration on
heat transfer at
high temperature
in
a
PCFB
combustor.
Effect
of
pressure on loop
seal
operation
for a pressurized
circulating
fluidized bed
15
studies
on
fluidization
properties in a
pressurized
jetting fluidized
bed
Effects of
distributor design
on solids
distribution in a
CFB riser.
The influence of
distributor design
on fluidized bed
dryer
hydrodynamics
Wormsbecker
et al. (2007)
18
Mixing patterns
Ghaly
and Investigated the effects of
and residence
Macdonald
sand particle size, distributor
time
(2012)
plate shape and angle, bed
determination in a
height
and
fluidizing
bubbling fluidized
velocity on particle mixing
bed
and residence time in the
System.
fluidized bed reactor.
Distributor effects
near the bottom
region of a
turbulent
fluidized beds.
Celia sobrino,
Naoko ellis and
Mercedes
de
vega (2008)
Effect of
Distributors on
Fluidised Beds
Heat Transfer
from Immersed
Surfaces in Gas
j. m. paiva
The Design of
Distributors for
G .as-Fluidized
-Beds
Geldart 1985
21
Effect of
Distributors on
Gas-Solid
Fluidization
s. c. saxena,
a.chatterjee
and r. c. patel
1979
The
distributor
pressure
drop was found to increase
with fluidizing velocity, to
decrease with
percentage
open area of the distributor
plate,
and
to
be
independent of the bed
weight or height for a
given distributor design.
The
pressure
ratio,
APd/APb, was found to
increase
rapidly
with
increase
in
fluidization
velocity. The value of this
pressure ratio at minimum
fluidization was found to
be dependent on the bed
height, and its degree
depends sensitively
on
distributor design,
The bed expansion ratio
was found to increase with
the increase in excess
fluidizing velocity
and
decrease -with bed height.
The quantitative magnitudes
of these variations are
dependent on the distributor
design. A distributor with
greater pressure drop across
it gives rise to smaller
bubbles for the same excess fluidizing velocity than
a distributor with smaller
pressure drop [15]. This is
substantiated by the present
measurements of bed expansion ratio for the bubble
cap,
porous
plate and
Johnson screen distributors
22
Effect of
Distributor
Design on Heat
Transfer from an
Immersed
Horizontal Tube
in a Fluidized
Bed
23
(3) The minimum fluidization velocity, the bubbling velocity and the terminal velocity were
decreasing with increase of operating pressure
(4) The modified cluster renewal model predicts the heat transfer coefficient with a reasonable
accuracy. Increase in suspension density results in higher cluster solid fraction and particle
concentration near the wall, which results in higher heat transfer coefficient.
(5) The bed-to-wall convective heat transfer coefficient increases with increasing system pressures
and bed suspension density
(6) For a given CO2 concentration in a pressurized circulating fluidized bed combustor, radiation
heat transfer increases slightly with system pressure due to increased gas partial pressure and gas
emissivity.
(7) The distribution of the gas dictates the flow structure in the riser column.
(8) An increase in the angle of convex or a decrease in the angle of a concave of the distributor plate
resulted in an increase in the residence time.
CHAPTER 3
Objectives of the work and Time activity Schedule:
3.1. Objectives:
In the prospect of the above discussion, the aim of the present work is to study the effects of various
operating parameters on the hydrodynamics and heat transfer characteristics in a PCFB laboratory
scale unit. The following tasks are taken as objectives for this study:
1.
To investigate the variation of bed hydrodynamics along the riser and heat transfer
characteristics along the upper splash region of the riser under different heat flux and
2.
3.
operating pressure.
To fabricate the designed distributor plate.
To investigate the variation of the above mentioned parameters by using the designed gas
distributor plate and comparing the results with the straight hole distributor plate.
24
4.
To perform a CFD simulation of the above experiment in a commercial CFD software Ansys
Fluent.
Aug -
Oct-
Sept.
Nov.
Dec.
Dec-
January
April-
Jan.
March.
June.
Literature review.
Learning
of the
technical software.
Design of the distributor plate
Start of progress report and presentation.
Fabrication of the distributor plate.
Start of experimentation and data analysis.
CFD simulation of the experiment conducted and comparison
Thesis writing and final Submission
CHAPTER 4
Methodology:
The following methodology is chosen to fulfill the objectives:1. Experiments will be conducted on a PCFB laboratory scale setup of 54 mm internal riser
diameter and 2000 mm height which is installed at the Energy Efficiency Laboratory, Center
for Energy, IITG.
2. The experiments will be conducted by using two types of air distribution grid: (a) straight
hole distributor plate and (b) newly designed distributor plate.
3. The experiments will be performed at different superficial velocity, different heat fluxes and
different operating pressures.
4. The bed inventory will be ranging from 1.0 kg to 2.0 kg.
5. Sand particles of average size 300m will be used as bed material.
6. The bed hydrodynamics and heat transfer characteristics will be investigated by using both
types of distributor plates at the bottom of the riser and finally the obtained results will be
compared.
25
ma
c) Superficial Velocity, U = g X A b
d) Solid circulation rate, G s=
s X La X A d X (1 mf )
Ab t
h=
VI
A htp(T bs T bi )
Where,
ma = mass flow rate of the air through the orifice in kg/s,
= bed voidage.
L= difference between two consecutive pressure taps across which pressure drops.
s= density of sand in kg/m3 , hL= difference of height in manometric fluid measured in
cm of water column, g= density of air in kg/m3, Ab= cross-sectional area of the bed in m2.
La= solid accumulation height in m, Ad= cross-sectional area of the downcomer in m2.
mf
closing ball valve in s, V, I, Ahtp, Tbs and Tbi are the voltage supply, current supply, heat
transfer probe surface area, bulk surface temperatures and bed temperatures, respectively.
8. CFD simulation of the riser will be performed in a commercial CFD simulation software
named Ansys FLUENT and the results will be compared with the experimental results. All
CFD codes contain three main elements. a) Pre-processing b) Solver and c) Post-processing.
a). In Pre-processing, it consists of input of a flow problem by means of an operator friend
interface and subsequent transformation of this input into a suitable form which can be used
by the solver. This step is performed by software tools such a GAMBIT, TGRID and DM.
The pre-processing stage involves the following steps (Bakker, 2002).
Defining the geometry of the region for computational domain.
Generating the grids for subdivision of the domain into a number of smaller, nonoverlapping subdomains.
26
Specifying the appropriate boundary and continuum conditions at each cells, which
coincide with or touch the boundary.
b). The CFD solver does the flow calculations and produces the desired results. FLUENT
uses the finite-volume method to solve the governing equations for a fluid. It provides the
capability to use different physical models such as incompressible or compressible, inviscid
or viscous, lminar or turbulent,etc. Governing equations are non-linear and coupled, several
iterations of the loop are performed by solver before a converged solution is obtained
(Bakker, 2002). The main functions of the solver are:
c) Post-processing is the final step in CFD analysis, and it involves the results and
interpretation of the predicted flow data.
CHAPTER 5
Work Done So Far:
5.1. Preliminary experiment on the PCFB setup and observations:
A trial experiment has been performed on the PCFB setup which is installed in the Energy Efficiency
Laboratory, Center for Energy, IITG. This experiment was performed to investigate the bed
hydrodynamics with 400gm of sand particles of average diameter 300m as bed inventory. The
figure below shows the schematic diagram of the experimental setup.
27
The variation of bed voidage and suspension density were observed as follows:
28
Voidage Profile
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0.2
0.4
0.6
0.8
1.2
Voidage
1
0.5
0
10
20
30
40
50
60
70
80
Suspension Density
5.2. Design
of
the
distributor plate:
The distributor was designed based on design procedure by Kunni and Levenspiel (1991), and Basu
(2006). The figure below shows the different views of the designed distributor grid.
29
riser height and then it remains almost constant for the rest of the height of the riser. This may
be due to the less amount of bed inventory. The suspension density is also found to be
fluctuating in nature as it increases rapidly and then decreases and again increases and then
keeps on decreasing along the height of the riser.
2) The distributor plate was designed according to the design procedure by Kunni and
Levenspiel (1991), and Basu (2006). The details of the design procedure is more elaborately
explained reference #18. CATIA V5 software was used in designing and post processing the
diagrams showing different views.
CHAPTER 6
Conclusions:
Future work plan and expected outcome:
(1) The next set of experiments will be conducted in the next phase of the project. We will be
increasing the bed inventory and also the operating pressure which would certainly help us to
study the bed hydrodynamics more deeply.
(2) The heat flux to the heat transfer probe will also be varied accordingly.
31
(3) The newly designed distributor plate will be fabricated and it will be installed in the bottom
of the riser.
(4) The experiments will be conducted by using two types of distributor plates and the results
will be compared.
(5) CFD simulation of the above experiment will be done by using a commercial CFD software
known as FLUENT and the results will be compared with the experimental results.
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4) Gupta. A.V.S.S.K.S, Nag. P.K, Bed-to-wall heat transfer behavior in a pressurized circulating
fluidized bed, Int. J. Heat Mass Transfer 45 (2002) 34293436.
32
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