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Model Development
Markus Henneberg*, Stefan Heinrich, Matthias Ihlow and Lothar Mörl
Otto-von-Guericke-University Magdeburg, Institute for Process Equipment and Environmental Technology, P.O. Box
4120, D-39016 Magdeburg, Germany
F
or conventional fluidized bed drying with hot air as the drying
medium, the transient profile of the particle moisture is often The presented study describes the processes and
determined through humidity measurements of the inlet and mechanisms of batch fluidized bed drying. The
outlet air through mass balance. Temperature profiles on the other hand influencing factors of hot air drying are theoretically
are simple and may be determined without high apparatus costs. The and experimentally examined, in order to present the
present study helps establish a relation between the temperature and relations between temperature and humidity profiles
humidity profiles, as well as all other relevant drying parameters, as for and all other drying parameters. A physical model is
instance gas mass flow, gas temperature and particle mass, while costlier presented to facilitate the calculation of the drying
processes under defined conditions. Three succeeding
humidity measurements can be avoided. The mass and energy balances
drying stages are therefore modeled. Mass and
of all components involved; fluidization gas, fluidized bed particles, and
energy balances including all components taking part
apparatus walls, are formulated, taking into account an inactive bypass. in the process are formulated. The model clarities the
The fluidized bed drying mechanisms, with hot air as fluidization and drying process under the assumption of pure heat
drying medium, are explained, so that any drying time profile may be transfer mechanisms. It does not contain adaptive
simulated. A batch fluidized bed drying is used as the basis of the parameters and takes into account an inactive bypass
presented study. fraction of the fluidization and drying medium. The
In order to implement the mathematical model of the batch evaluation of the model was successful for two
operation also for the continuous process, the longitudinal mixing of the fluidized bed plants with nominal widths of 100 mm
product in a continuous drying apparatus, for example in a fluidized and 400 mm. The experiments showed sufficient
accuracy and transferability of the model to
channel, should not be considered, in other words, its insignificance
equipment of application-oriented dimensions.
should be presupposed, in order to be able to calculate a continuous
process through a batch model. The space coordinates of the continu- On décrit dans la présente étude les procédés et
ous and the time coordinates of the batch fluidized bed apparatus are mécanismes de séchage en lit fluidisé discontinu. Les
related through a constant drying rate. facteurs importants du séchage à air chaud sont
examinés de façon théorique et expérimentale dans le
Theoretical Basis and Thermodynamic Modeling but d’expliquer les relations entre les profils de
The batch fluidized bed using air as the fluidization and drying medium, température et d’humidité et tous les autres
can be divided into three defined stages: the particles heating phase (H), paramètres de séchage. On présente un modèle
the first drying period (I), and the second drying period (II). In these physique pour faciliter le calcul des procédés de
séchage dans des conditions définies. Trois étapes de
three stages, different mass and energy balance mechanisms are
séchage consécutives sont modélisées. Les bilans de
involved. The model allows the calculation of various time-dependent
matière et d’énergie faisant intervenir tous les
process parameters: particle moisture content and particle temperature, composants qui prennent part au procédé sont
apparatus wall temperature, as well as the time and bed height-dependent formulés. Le procédé de séchage est modélisé en
air temperature profile. supposant des mécanismes de transfert de chaleur
In the present model, the temperature difference is assumed to be the purs. Il ne comporte pas de paramètres adaptatifs et
driving force of the drying potential. The fluidized bed air drying is prend en compte une fraction de dérivation inactive
therefore seen as a process merely considering heat transfer mechanisms. du milieu de fluidisation et de séchage. L’évaluation
The energy required for the evaporation of the contained water is du modèle s’est avérée concluante pour deux lits
transferred to the particles through heat and enthalpy flows. In this case fluidisés de largeur nominale de 100 mm et 400 mm.
Les expériences montrent une précision et une
of air drying, water evaporates from the product surface and leaves the
transférabilité suffisantes du modèle à des
équipements de dimensions industrielles.
176 The Canadian Journal of Chemical Engineering, Volume 81, April 2003
fluidized bed as humid air. Conventional drying with hot air is dx
commonly described through mass transfer. According to
Baehr and Stephan (1994) the influence of a self-forming f = dt (1)
Ê dx ˆ
boundary layer for the diffusive mass transfer is calculated Á ˜
Ë dt ¯ I
taking the Stefan correction into account. In a similar way to
the Stefan correction for the mass transfer, the Ackermann correc-
tion for the heat transfer takes into account the partial flow that where the normalized moisture content of the solid is,
disappears at the phase boundary (Baehr and Stephan, 1994).
The Ackermann correction according to Gnielinski et al. (1993) X - Xhyg
for the heat transfer coefficients in the first approximation is x= (2)
considered equal to unity. Xkr - Xhyg
The bubble behaviour in the fluidized bed is modeled according to
Hilligardt and Werther (1986). It contains a bypass, allowing and the expression (dx/dt)I is the normalized drying rate in the
the calculations of mixed temperature of the active and passive first drying period, which depends only on the external process
air flow over the bed. parameters. The F profile on the other hand is mass and form
dependent, and takes into account the particle properties in
Model Assumptions relation to the characteristics of the drying behaviour. F is an
The following was assumed: expression of the wetting efficiency of the particle surface
• ideal mixing of the solids in the suspension phase, according to Mörl et al. (1981) and Heinrich et al. (1999),
• ideal plug-flow of the steam in the suspension phase which in the first drying stage is considered to be equal to unity.
• uniform chamber wall temperature, The first drying period ends with the reaching of the critical
• low Biot number (thermal resistance in the solid is assumed particle moisture Xkr, for example:
negligible),
• particles are spherical and monodisperse, and JP ,I = JSat (3)
• particle form and size are independent from the moisture
content.The model also takes into account the influence of XP I ≥ Xkr (4)
possible existing non-homogeneities in the fluidized bed,
e.g., bubbles. This means:
• Along with the aforementioned homogeneous suspension Second Drying Period (II)
phase of solid particles and suspension gas, a bubble phase In the second drying period, the drying rate steadily decreases
is also present, characterized as an inactive bypass by with the particle moisture, whereas this moisture-dependence is
Schlünder and Tsotsas (1988). In the mass- and energy induced by the particles (capillary porous properties, form, heat
balances, the gas mass flows are reduced by the bypass conduction, inhomogeneities). As far as the modeling of the
fraction. second drying period is concerned, although numerous different
The scaling is performed analogous to the form of van Meel models are available, a solution is reached only in special cases
(1958), with a normalized drying rate and a normalized and after experimentally determining certain parameters (grain
moisture content of the particles. porosity, caloric conductibility, etc.) (Heinrich et al., 1999). For
the calculation of the drying rate in the second drying period, a
Particle Heating (H) functional approach to describe the normalized drying curve of
A particle moisture increase through condensation due to the product is adopted, according to which the dependence F
drying with moist air is ruled out, as well as a particle moisture = f(x) in Equation (1) is approximated to be:
reduction due to evaporation.The first stage is characterized by
the heating of the drying product up to the saturation
temperature. The heating stage ends, when the particle F = 5x (5)
temperature JP reaches the saturation temperature JSat
corresponding to the system pressure and to the air inlet
temperature. At this point begins the next stage (JE £ JP,H < JSat). When this dependence is unknown, it can easily be estimated
by use of the available experimental apparatus. The second
First Drying Period (I) drying period, and thereby the drying process, ends when the
The first drying period corresponds to the drying of a free fluid hygroscopic equilibrium moisture Xhyg of the product is
surface (Gnielinski, 1993). A boundary condition for this model reached:
stage is a particle moisture content X over the critical moisture
content (X ≥ Xkr). The drying rate depends on the external
process parameters (temperature, pressure, heat transfer JSat < JP ,II < JSt ,in (6)
coefficients), particle moisture content independent, and
constant. The particles dry until they reach critical moisture Xkr > XP ,II ≥ Xhyg (7)
content Xkr. The heat supplied to the particles is used
exclusively for the evaporation of the particle moisture. The
particle temperature remains in this way constant (JP,I = const.) Mass and Energy Balances
and equal to the air saturation temperature corresponding to The air and particle mass balances, as well as the air particle,
the system pressure (JP,I = JSat). The normalized drying rate in and wall energy balances, based on a differential volume
dimensionless form is defined as: element, are formulated (Figure 1).
The Canadian Journal of Chemical Engineering, Volume 81, April 2003 177
The heat transfer coefficient gas–particle aGP can be Gas Energy Balance
calculated according to Gnielinski (1980). Groenewold and
Tsotsas (1997, 1998) propose a modified equation for low
Reynolds number (low Nusselt number or Sherwood number ∂HG Ê ∂H˙ ˆ
= H˙ G - Á H˙ G + G dz ˜ - dQ˙ GW - dQ˙ GP - dH˙ St ,tr (15)
problems (see Kunii et al., 1991). The heat transfer coefficient ∂t Ë ∂z ¯
between particles and apparatus walls aPW is calculated using
the formulas given by Martin (1994). The heat transfer coefficient
For the heat and enthalpy flows holds:
between gas and chamber walls aGW is calculated according to
the equation of Shi (1997). Kast and Klan (1994) give an
approximation for the wall–environment heat transfer coefficient
aWE.
H˙ G = m [ (
˙ G cair Jair + Y c st Jair + DhV ,0 )] (16)
dz
Gas Mass Balance
dQ˙ GW = aGW AW
hbed
(Jair - JW ) (17)
dz
∂mG
=m
Ê
˙ G - Ám˙G+
∂m˙G ˆ
dz ˜ - dm
˙ st ,tr (8) dQ˙ GP = aGP AP
hbed
(Jair - JP ) (18)
∂t Ë ∂z ¯
and
Particle Mass Balance
The particle mass changes due to the water mass released from
the steam mass flow,
˙ St,tr = dm
dH (
˙ St ,tr cSt Jair + DhV ,0 ) (19)
178 The Canadian Journal of Chemical Engineering, Volume 81, April 2003
dHW
= Q˙ PW ,tot + Q˙ GW - Q˙ WE (29)
dt
(
Q˙ GW = aGW AW Jair - JW ) (31)
and
dJw
mW cW
dt
(
= aPW ,tot Aw (JP - JW ) + aWG AW Jair - JW )
For the heat and enthalpy flows holds: (33)
- aWE AW (JW - JE )
(
Q˙ GP = aGP AP Jair - JP ) (23)
The chamber wall temperature can be expressed in a
(24)
QPW ,tot = aPW ,tot Aw (JP - JW ) dimensionless form as follows:
and dQW mP cP
dt
=
NTUGP mW cW
[
NTUPW ,tot (QP - QW )
(34)
˙ St,tr = m
H (
˙ St ,tr cSt Jair + DhV ,0 ) (25)
( )
+NTUWG Qair - QW - NTUWE (QW - QE ) ]
And by introducing the above equations in Equation (21):
Process Description and Experimental Set-up
d (mP cP JP ) The pilot plants used within the framework of this study, WSA
dt
( )
= aGP AP Jair - JP - aPW ,tot AW (JP - JW )
DN100 and WSA DN400 of the Otto-von-Guericke-University,
(26)
were operated with hot air as the drying medium for granular
+m (
˙ St .tr cSt Jair + DhV ,0 ) products, whereas WSA DN100 could also use steam.
A scheme of the pilot plant WSA DN100 is presented in
Figure 2. The cylindrical fluidized bed drying chamber of this
The dimensionless particle temperatures for the first and plant has a nominal width of 100 mm and is equipped with a
second drying period are expressed as follows: collapsible distributor plate, in order to discharge the dried
product from the fluidized bed directly after the end of the
process. The maximum air flow of 200 kg/h with a maximum
QP ,I = QSat = 0 (27)
temperature of 300°C is achieved with an exhauster after the
fluidized bed chamber. The pilot plant is equipped with a
with
double sluice for the particle feeding and discharge. In case of
an abrasive or dustforming drying medium, the plant is optionally
dQP
=0 operated with a cyclone to separate the entrained fine particles.
dtI Figure 3a shows a photograph of the fluidized bed pilot plant
WSA DN100.
dQP 1
dtII
=
NTUGP
[
NTUGP Qair - QP ( ) (28)
The fluidized bed plant WSA DN400 (Figure 3b) is a continuous
agglomeration and granulation drying plant with a nominal
width of 400 mm. It can also be used for batch drying. The
]
- NTUPW ,tot (QP - QW ) (1 - F) maximum air flow of 3000 kg/h was achieved with a fresh air
ventilator before, and an exhauster after the fluidized bed
chamber. The maximum process temperature could be up to
Wall Energy Balance
The balancing of the heat flows transferred to the apparatus 400°C. In contrast to the experiments at the WSA DN100 a
wall from the entire bed gives the following: connecting nozzle allows sampling even during the
experiments.
The Canadian Journal of Chemical Engineering, Volume 81, April 2003 179
Figure 2. Simplified air drying process flow chart of the fluidized bed
pilot plants DN100/DN400.
180 The Canadian Journal of Chemical Engineering, Volume 81, April 2003
Figure 4. Experiment 3: comparison between measured (experiment)
and calculated (simulation) curves.
increase was due to the decreasing mass and particle heat The normalized initial particle moisture for the simulation of
capacity. The process went on to the next stage, namely the Experiment 3 was 2.2. The initial particle moisture value
second drying period. The particles warmed up gradually and remained constant through the first heating stage. After the
the drying rate decreased. The drying process diminished to the particles reached the saturation temperature, the first drying
point where after 150 s the particle temperature reached the period began. This stage was characterized by the approximate
average air temperature. At this point the final moisture was constancy of the drying rate. The drying rate marginal decrease
reached, with a value of 0.04, according to the process parameters. is explained by the decreasing wall temperature. After reaching
In Figure 6 the drying process is represented using the normalized the critical moisture, corresponding to a normalized moisture of
drying curve according to van Meel (1958). unity, the normalized drying rate decreased to a value lower
The Canadian Journal of Chemical Engineering, Volume 81, April 2003 181
Table 2. Process parameters.
182 The Canadian Journal of Chemical Engineering, Volume 81, April 2003
Figure 10. Experiment 6: calculated temperatures. Figure 11. Experiment 6: calculated normalized drying curve.
The Canadian Journal of Chemical Engineering, Volume 81, April 2003 183
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184 The Canadian Journal of Chemical Engineering, Volume 81, April 2003