handbook of fluidization and fluid-particle systems

HANDBOOK of FLUIDIZfiTION and FLUID-PARTICLE SYSTEMS edited by Wen-Ching Yang Siemens Westinghouse Power Corporation Pittsburgh, Pennsylvania, U.S.A. MARCEL DEKKER, INC. NEW YORK • BASEL ila DEKKER Copyright © 2003 by Taylor & Francis Group LLC Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress. ISBN: 0-8247-0259-X This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc. 270 Madison Avenue, New York, NY 10016 tel: 212-696-9000; fax: 212-685-4540 Eastern Hemisphere Distribution Marcel Dekker AG Hutgasse 4, Postfach 812, CH-4001 Basel, Switzerland tel: 41-61-260-6300; fax: 41-61-260-6333 World Wide Web http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/ Professional Marketing at the headquarters address above. Copyright # 2003 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. Current printing (last digit): 10987654321 PRINTED IN THE UNITED STATES OF AMERICA Copyright © 2003 by Taylor & Francis Group LLC CHEMICAL INDUSTRIES A Series of Reference Books and Textbooks Consulting Editor HEINZ HEINEMANN Berkeley, California 1. Fluid Catalytic Cracking with Zeolite Catalysts, Paul B Venuto and E. Thomas Habib, Jr. 2. Ethylene: Keystone to the Petrochemical Industry, Ludwig Kniel, Olaf Winter, and Karl Stork 3. The Chemistry and Technology of Petroleum, James G Speight 4. The Desulfurization of Heavy Oils and Residua, James G. Speight 5. Catalysis of Organic Reactions, edited by William R. Moser 6 Acetylene-Based Chemicals from Coal and Other Natural Resources, Robert J. Tedeschi 7 Chemically Resistant Masonry, Walter Lee Sheppard, Jr. 8 Compressors and Expanders: Selection and Application for the Process Industry, Heinz P. Bloch, Joseph A. Cameron, Frank M. Danowski, Jr, Ralph James, Jr, Judson S. Sweanngen, and Marilyn E. Weightman 9. Metering Pumps. Selection and Application, James P. Poynton 10. Hydrocarbons from Methanol, Clarence D Chang 11. Form Flotation: Theory and Applications, Ann N. Clarke and David J. Wilson 12. The Chemistry and Technology of Coal, James G. Speight 13. Pneumatic and Hydraulic Conveying of Solids, O. A Williams 14. Catalyst Manufacture: Laboratory and Commercial Preparations, Alvm B. Stiles 15. Characterization of Heterogeneous Catalysts, edited by Francis Delannay 16. BASIC Programs for Chemical Engineering Design, James H. Weber 17. Catalyst Poisoning, L. Louis Hegedus and Robert W McCabe 18. Catalysis of Organic Reactions, edited by John R Kosak 19 Adsorption Technology: A Step-by-Step Approach to Process Evaluation and Application, edited by Frank L. Slejko 20 Deactivation and Poisoning of Catalysts, edited by Jacques Oudar and Henry Wise 21 Catalysis and Surface Science: Developments in Chemicals from Methanol, Hydrotreating of Hydrocarbons, Catalyst Preparation, Monomers and Polymers, Photocatalysis and Photovoltaics, edited by Heinz Heinemann and Gabor A Somorjai 22 Catalysis of Organic Reactions, edited by Robert L. Augustine 23 Modern Control Techniques for the Processing Industries, T. H. Tsai, J W. Lane, and C. S. Lin 24 Temperature-Programmed Reduction for Solid Materials Characterization, Alan Jones and Brian McNichol 25 Catalytic Cracking: Catalysts, Chemistry, and Kinetics, Bohdan W Wojciechowski and Avelino Corma 26. Chemical Reaction and Reactor Engineering, edited by J. J. Carberry and A. Varma 27 Filtration: Principles and Practices: Second Edition, edited by Michael J Matteson and Clyde Orr 28 Corrosion Mechanisms, edited by Florian Mansfeld 29 Catalysis and Surface Properties of Liquid Metals and Alloys, Yoshisada Ogino 30 Catalyst Deactivation, edited by Eugene E Petersen and Alexis T. Bell 31. Hydrogen Effects in Catalysis: Fundamentals and Practical Applications, edited by Zoltan Paal and P G. Menon Copyright © 2003 by Taylor & Francis Group LLC 32. Flow Management for Engineers and Scientists, Nicholas P. Cheremisinoff and Paul N. Cheremisinoff 33. Catalysis of Organic Reactions, edited by Paul N. Rylander, Harold Greenfield, and Robert L. Augustine 34. Powder and Bulk Solids Handling Processes: Instrumentation and Control, Koichi linoya, Hiroaki Masuda, and Kinnosuke Watanabe 35. Reverse Osmosis Technology: Applications for High-Purity-Water Production, edited by Bipin S. Parekh 36. Shape Selective Catalysis in Industrial Applications, N. Y. Chen, William E. Garwood, and Frank G. Dwyer 37. Alpha Olefins Applications Handbook, edited by George R. Lappin and Joseph L. Sauer 38 Process Modeling and Control in Chemical Industries, edited by Kaddour Najim 39. Clathrate Hydrates of Natural Gases, E. Dendy Sloan, Jr 40 Catalysis of Organic Reactions, edited by Dale W Blackburn 41. Fuel Science and Technology Handbook, edited by James G Speight 42. Octane-Enhancing Zeolitic FCC Catalysts, Julius Scherzer 43. Oxygen in Catalysis, Adam Bielanski and Jerzy Haber 44. The Chemistry and Technology of Petroleum: Second Edition, Revised and Expanded, James G. Speight 45 Industrial Drying Equipment: Selection and Application, C. M. van't Land 46 Novel Production Methods for Ethylene, Light Hydrocarbons, and Aromatics, edited by Lyle F. Albright, Billy L. Crynes, and Siegfried Nowak 47 Catalysis of Organic Reactions, edited by William E. Pascoe 48 Synthetic Lubricants and High-Performance Functional Fluids, edited by Ronald L. Shubkin 49 Acetic Acid and Its Derivatives, edited by Victor H Agreda and Joseph R. Zoeller 50 Properties and Applications of Perovskite-Type Oxides, edited by L G Tejuca and J. L. G. Fierro 51 Computer-Aided Design of Catalysts, edited by E Robert Becker and Carmo J. Pereira 52. Models for Thermodynamic and Phase Equilibria Calculations, edited by Stanley I Sandier 53 Catalysis of Organic Reactions, edited by John R Kosak and Thomas A Johnson 54 Composition and Analysis of Heavy Petroleum Fractions, Klaus H. Altgelt and Mieczyslaw M. Boduszynski 55. NMR Techniques in Catalysis, edited by Alexis T. Bell and Alexander Pines 56. Upgrading Petroleum Residues and Heavy Oils, Murray R. Gray 57. Methanol Production and Use, edited by Wu-Hsun Cheng and Harold H. Kung 58. Catalytic Hydroprocessing of Petroleum and Distillates, edited by Michael C. Oballah and Stuart S. Shih 59. The Chemistry and Technology of Coal: Second Edition, Revised and Expanded, James G Speight 60. Lubricant Base Oil and Wax Processing, Avilino Sequeira, Jr 61. Catalytic Naphtha Reforming- Science and Technology, edited by George J. Antos, Abdullah M. Aitani, and Jose M. Parera 62. Catalysis of Organic Reactions, edited by Mike G. Scares and Michael L. Prunier 63. Catalyst Manufacture, Alvin B. Stiles and Theodore A Koch 64. Handbook ofGrignard Reagents, edited by Gary S. Silverman and Philip E. Rakita 65. Shape Selective Catalysis in Industrial Applications: Second Edition, Revised and Expanded, N. Y. Chen, William E. Garwood, and Francis G. Dwyer 66. Hydrocracking Science and Technology, Julius Scherzer and A. J. Gruia 67 Hydrotreating Technology for Pollution Control- Catalysts, Catalysis, and Processes, edited by Mario L. Occelli and Russell Chianelli 68. Catalysis of Organic Reactions, edited by Russell E. Malz, Jr. 69. Synthesis of Porous Materials: Zeolites, Clays, and Nanostructures, edited by Mario L. Occelli and Henri Kessler 70. Methane and Its Derivatives, Sunggyu Lee 71. Structured Catalysts and Reactors, edited by Andrzej Cybulski and Jacob A. Moulijn 72. Industrial Gases in Petrochemical Processing, Harold Gunardson 73. Clathrate Hydrates of Natural Gases: Second Edition, Revised and Expanded, E Dendy Sloan, Jr 74. Fluid Cracking Catalysts, edited by Mario L. Occelli and Paul O'Connor 75. Catalysis of Organic Reactions, edited by Frank E. Herkes 76. The Chemistry and Technology of Petroleum: Third Edition, Revised and Expanded, James G. Speight 77 Synthetic Lubricants and High-Performance Functional Fluids- Second Edition, Revised and Expanded, Leslie R. Rudnick and Ronald L. Shubkin 78 7776 Desulfurization of Heavy Oils and Residua, Second Edition, Revised and Expanded, James G. Speight 79. Reaction Kinetics and Reactor Design: Second Edition, Revised and Expanded, John B. Butt 80. Regulatory Chemicals Handbook, Jennifer M. Spero, Bella Devito, and Louis Theodore Copyright © 2003 by Taylor & Francis Group LLC 81 Applied Parameter Estimation for Chemical Engineers, Peter Englezos and Nicolas Kalogerakis 82 Catalysis of Organic Reactions, edited by Michael E Ford 83 The Chemical Process Industries Infrastructure Function and Economics, James R Couper, O Thomas Beasley, and W Roy Penney 84 Transport Phenomena Fundamentals, Joel L Plawsky 85 Petroleum Refining Processes, James G Speight and Baki Ozum 86 Health, Safety, and Accident Management in the Chemical Process Industries, Ann Mane Flynn and Louis Theodore 87 Plantwide Dynamic Simulators in Chemical Processing and Control, William L Luyben 88 Chemicial Reactor Design, Peter Harriott 89 Catalysis of Organic Reactions, edited by Dennis G Morrell 90 Lubricant Additives Chemistry and Applications, edited by Leslie R Rudnick 91 Handbook of Fluidization and Fluid-Particle Systems, edited by Wen-Chmg Yang 92 Conservation Equations and Modeling of Chemical and Biochemical Processes, Said S E H Elnashaie and Parag Garhyan 93 Batch Fermentation Modeling, Monitoring, and Control, All Qmar, Gulnur Birol, Satish J Parulekar, and Cenk Undey 94 Industrial Solvents Handbook, Second Edition, Nicholas P Cheremisinoff ADDITIONAL VOLUMES IN PREPARATION Chemical Process Engineering Design and Economics, Harry Silla Petroleum and Gas Field Processing, H K Abdel-Aal, Mohamed Aggour,, M A Nairn Process Engineering Economics, James R Couper Thermodynamic Cycles Computer-Aided Design and Optimization, Chin Wu Re-Engineering the Chemical Processing Plant Process Intensification, edited by Andrzej Stankiewicz and Jacob A Mouhjn Copyright © 2003 by Taylor & Francis Group LLC Preface Every chemical engineer, whether a student or practicing, has looked up technical information in Perry’s Chemical Engineering Handbook. Its compilation was one of the most important contributions to the chemical engineering education and profession. After more than six decades, it remains one of the field’s most useful general-purpose reference books. It was in this spirit of serving the profession that I undertook the task of compiling the Handbook of Fluidization and Fluid-Particle Systems. Through future revisions and additions, I sincerely hope that this hand- book will become an archivable reference volume for every practitioner in this field, spanning the boundary of various disciplines. Fluidization and fluid-particle system engineering is being applied in industries as diverse as basic and specialty chemicals, mineral processing, coal and biomass gasification and combustion for power gen- eration, environmental technologies, resource recovery, FCC petroleum refining, pharmaceuticals, biotechnology, cement, ceramics, and other solids handling and processing industries. The first focused handbook ever published in this extended field, it collects all relevant and important information in a single volume. Both fundamentals and applications are emphasized. Furthermore, all authors are internationally recognized practitioners in the area of fluidization and fluid-particle systems. This handbook contains 28 chapters and is authored by 34 internationally recognized experts from seven countries; half of them are professors. Particle characterization and dynamics—important in all aspects of particle production, manufacturing, handling, processing, and applications—are discussed in Chapt er 1. Chapter 2 presents the flow through fixed beds and summarizes packing characteristics of spherical and nonspherical particles, pres- sure-drop correlations for flow through fixed beds, and heat and mass transfer. Bubbling fluidized beds are pre- sented in detail in Chapter 3, which covers all important aspects including jetting phenomena and particle segregation, topics not addressed extensively in other books on fluidization. Other important design considerations are treated in separate chapters: elutriation and entrainment in Chapter 4, effect of temperature and pressure in Chapter 5, gas distributor and plenum design in Chapter 6, effect of internal tubes and baffles in Chapter 7, attrition in Chapter 8, and modeling in Chapter 9. Heat transfer (Chapter 10) and mass trans fer (Chapter 11) are also treated. The approaches for designing and scaling up fluidized bed reactors are elucidated in Chapter 12, ‘‘General Approaches to Reactor Design,’’ and Chapter 13, ‘‘Fluidized Bed Scaleup.’’ Important industrial applications for fluidized bed reactors are also discussed, including fluid catalytic cracking (Chapter 14), gasifiers and combustors (Chapter 15), chemical production and processing (Chapter 16), coating and granulation (Chapter 17), and fluidized bed drying (Chapter 18). The important variation of bubbling fluidized beds—the circulation fluidized beds—are discussed in detail in Chapter 19. Chapter 20 summarizes other nonconventional fluidized beds, including spouted beds, recirculating fluidized beds with a draft tube, jetting fluidized beds, and rotating fluidized beds. The solids hand ling, transport and circulating devices are described in Chapter 21, ‘‘Standpipe and Nonmechanical Valves,’’ and Chapter 22, Copyright © 2003 by Taylor & Francis Group LLC ‘‘Cyclone Separators.’’ Pneumatic transport is covered in Chapters 23 and 24. Instrumentation and measurement requirements are reviewed in Chapter 25. The last three chapters examine the fluidized beds and fluid-particle systems involving liquid. This handbook took more than four years to complete. Along the way, content was altered, format was changed, and chapters were revised to fit the page limitation. The final product is indeed one to be proud of by all who participated. A monumental endeavor such as this could not have been possible without the cooperation and dedication of all the authors, especially those who were asked to revise their chapters, sometime s several times. I am truly indebted to them all for taking the time out of their busy schedule and for their cooperation, dedication, and conscientious effort. The staff of the publisher, Marcel Dekker, Inc., also deserves credit for their patience and tenacity in shepherding the project to its eventual completion. Finally, I thank my family, especially my wife, Rae, for their continuou s encouragement. Wen-Ching Yang Copyright © 2003 by Taylor & Francis Group LLC Contents Preface Contributors 1ParticleCharacterizationandDynamics Wen-ChingYang 2FlowThroughFixedBeds Wen-ChingYang 3BubblingFluidizedBeds Wen-ChingYang 4ElutriatonandEntrainment JoachimWertherandErnst-UlrichHartge 5EffectofTemperatureandPressure J.G.Yates 6GasDistributorandPlenumDesigninFluidizedBeds S.B.ReddyKarriandJoachimWerther 7EffectofInternalTubesandBaffles YongJin,FeiWei,andYaoWang 8Attrition JoachimWertherandJensReppenhagen 9Modeling ThomasC.Ho 10HeatTransfer JohnC.Chen 11MassTransfer ThomasC.Ho 12GeneralApproachestoReactorDesign PeijunJiang,FeiWei,andLiang-ShihFan Copyright © 2003 by Taylor & Francis Group LLC 13FluidizedBedScaleup LeonR.Glicksman 14ApplicationsforFluidCatalyticCracking Ye-MonChen 15ApplicationsforGasifiersandCombustors RichardA.Newby 16ApplicationsforChemicalProductionandProcessing BehzadJazayeri 17ApplicationsforCoatingandGranulation GabrielI.TardosandPaulR.Mort 18ApplicationsforFluidizedBedDrying ArunS.MujumdarandSakamonDevahastin 19CirculatingFluidizedBeds JohnR.Grace,HsiaotaoBi,andMohammadGolriz 20OtherNonconventionalFluidizedBeds Wen-ChingYang 21StandpipesandNonmechanicalValves T.M.Knowlton 22CycloneSeparators T.M.Knowlton 23Dilute-PhasePneumaticConveying GeorgeE.Klinzing 24ElectrostaticsinPneumaticConveying GeorgeE.Klinzing 25InstrumentationandMeasurements MasayukiHorio,RafalP.Kobylecki,andMayumiTsukada 26Liquid–SolidsFluidization NormanEpstein 27Gas–Liquid–SolidThree-PhaseFluidization Liang-ShihFanandGuoqiangYang 28Liquid–SolidsSeparation Shiao-HungChiang,DaxinHe,andYuruFeng Copyright © 2003 by Taylor & Francis Group LLC Contributors Hsiaotao Bi Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, British Columbia, Canada John C. Chen Department of Chemical Engineering, Lehig h University, Bethlehem, Pennsylvania, U.S.A. Ye-Mon Chen Shell Global Solutions US, Houston, Texas, U.S.A. Shiao-Hung Chiang Department of Chemical and Petroleum Engineering, University of Pittsburgh, Pittsburgh, Pennsylvania, U.S.A. Sakamon Devahastin Department of Food Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand Norman Epstein Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, British Columbia, Canada Liang-Shih Fan Department of Chemical Engineering, The Ohio State University, Columbus, Ohio, U.S.A. Yuru Feng Department of Chemical and Petroleum Engineering, University of Pittsburgh, Pittsburgh, Pennsylvania, U.S.A. Leon R. Glicksman Departments of Architecture and Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, U.S.A. Mohammad Golriz Department of Applied Physics and Electronics, Umea ˚ University, Umea ˚ , Sweden John R. Grace Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, British Columbia, Canada Ernst-Ulrich Hartge Technical University Hamburg-Harburg, Hamburg, Germany Daxin He Department of Chemical and Petroleum Engineering, University of Pittsburgh, Pittsburgh, Pennsylvania, U.S.A. Thomas C. Ho Department of Chemical Engineering, Lam ar University, Beaumont, Texas, U.S.A. Masayuki Horio Department of Chemical Engineering, Tokyo University of Agriculture and Technology, Tokyo, Japan Behzad Jazayeri Fluor Daniel, Inc., Aliso Viejo, California, U.S.A. Copyright © 2003 by Taylor & Francis Group LLC [...]... powders are also listed in Table 10 Both the angle of repose and the angle of internal friction can be modified and reduced by flow aids such as aeration, vibration, and the addition of other powders Measurement of the Angle of Repose and the Angle of Internal Friction Two important characteristics of powder rheology are the angle of repose and the angle of internal friction Simple devices can be constructed... sensitivity of the instrument The light scattering theories employed for this technique are by Mie, Rayleigh, and Fraunhofer (Bohren and Huffman, 1986) When the dimensions of a particle are of the same order of magnitude of the wavelength of the incident light, Mie theory is used When the particle is much smaller than the wavelength of the light, the appropriate light-scattering theory is that of Rayleigh... Fig 12, is called the angle of internal friction of the powder The angle of internal friction is also an intrinsic property of the powder and can be considered as a shearing plane of the powder In order for the powder to flow, the angle has to be higher than the angle of internal friction of the powder Normal powders have angles of internal friction of around 70 The angles of internal friction for commonly... intensity of the scattered light is then related to the size of the particle In an ideal situation, a monotonic relationship exists between the intensity of the scattered light and the particle size and thus allows unique determination of the size of the particle In reality, the light-scattering properties of a particle depend in a very complex way on its refractive index and shape, and on the wavelength of. .. transparent walls and a small orifice at the bottom of the bed After filling the bed with the powder to be examined, the powder is allowed to flow out of the test device to the surface of the test stand The angle of the powder-free surface measured from the flat surface of the test stand, the angle b in Fig 12, is called the angle of repose This angle is an intrinsic characteristic of the powder and should be... center of a particle to the walls = mass of a particle = number of particles of size i or weight percent of particles of size i = radius of a sphere = Reynolds number based on the particle diameter = Reynolds number based on the terminal velocity of the particle = sieve aperture = sieve aperture at mode of particle size distribution = surface area of a particle = particle surface per unit volume of particle... to a stream of pulverized coal Copyright © 2003 by Taylor & Francis Group LLC under controlled conditions The weight loss of the coupon is an indication of the erosiveness of the particular coal and the potential damage to the processing and handling equipment, and other boiler components 3 FLUID DYNAMICS OF A SINGLE PARTICLE For a particle moving in a fluid, the force acting on the surface of a particle... velocity of porous spheres were conducted by Sutherland and Tan (1970), Ooms et al (1970), Neale et al (1973), Epstein and Neale (1974), and Matsumoto and Suganuma (1977) The terminal velocity of porous spheres was also experimentally measured by Masliyah and Polikar (1980) In the limiting case of a very low Reynolds number, Neale et al (1973) arrived at the following equation for the ratio of the resistance... method of determining particle density of porous aeratable powders The method depends on measurement of bed expansion of a gas fluidized bed of the powder in the region between the minimum fluidization and the minimum bubbling The Richardson and Zaki bed expansion equation was then applied to back out the particle density The Richardson and Zaki bed expansion equation and the minimum fluidization and minimum... first and its settling pattern is subsequently studied Classical techniques for measuring the sedimentation behavior include taking samples with a pipette, measurement of height of sediment layer at the bottom, and use of balance pan to measure the weight of settled particles Modern sedimentometers make use of the diffraction pattern of a light beam, the power loss of an x-ray, or a Doppler shift of a . of serving the profession that I undertook the task of compiling the Handbook of Fluidization and Fluid-Particle Systems. Through future revisions and additions, I sincerely hope that this hand- book. Chemistry and Applications, edited by Leslie R Rudnick 91 Handbook of Fluidization and Fluid-Particle Systems, edited by Wen-Chmg Yang 92 Conservation Equations and Modeling of . the area of fluidization and fluid-particle systems. This handbook contains 28 chapters and is authored by 34 internationally recognized experts from seven countries; half of them are professors.