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Drying Technology
An International Journal
To cite this article: Huolong Liu, Seongkyu Yoon & Mingzhong Li (2016): Three-dimensional
computational fluid dynamics (CFD) study of the gasparticle circulation pattern within a fluidized
bed granulator: By full factorial design of fluidization velocity and particle size, Drying Technology,
DOI: 10.1080/07373937.2016.1230628
Article views: 47
Download by: [University of Massachusetts Lowell], [Huolong Liu] Date: 19 April 2017, At: 13:18
DRYING TECHNOLOGY
http://dx.doi.org/10.1080/07373937.2016.1230628
ABSTRACT KEYWORDS
The fluidization velocity and mean particle size were selected to be numerically investigated Computational fluid
pertaining to their effects on the gasparticle circulation pattern within a fluidized bed granulator dynamics; fluidization;
by three-dimensional computational fluid dynamics (CFD) simulation applying an EulerianEulerian fluidized bed granulator; full
two-fluid model. The CFD simulations were designed by full factorial design method and the factorial design; gasparticle
hydrodynamics
developed CFD model was experimentally validated. The fluidization process was proved to reach a
quasi-steady state. The gasparticle circulation pattern and particle concentration distribution were
analyzed based on fluidization velocity and mean particle size. A mathematical model was
developed to provide guidance on how to change fluidization level during one experiment.
CONTACT Huolong Liu Huolong_Liu@uml.edu Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Ave.,
Lowell, MA 01850, USA.
Color versions of one or more of the figures in this article can be found online at www.tandfonline.com/ldrt.
2017 Taylor & Francis
2 H. LIU ET AL.
particle size distribution by affecting the drying one phase is considered as a discrete phase interacting
capacity.[16] At the initial stage of granulation, it is with the other phases.[30,3643]. To date, several models
reported that higher fluidization velocity produces a built upon the EulerianLagrange framework have been
higher granule growth rate because of the higher developed such as the CFDdiscrete element method
frequency and energy of collisions between granules. (CFDDEM), dense discrete phase model (DDPM),
However, larger granules were finally obtained from and multiphase-particle-in-cell (MP-PIC) method. With
low fluidization velocity due to the small shear force the advance in computational resources and capacities,
at lower fluidization velocity.[16,17] For a batch fluidized these methods become increasingly popular for the
bed granulation process, it is inherently unstable and modeling of particulate flow and some study cases in
sensitive to the bed humidity. If drying is insufficient, fluidized bed could be found. However, because of the
high humidity generated by less efficient fluidizing air computational limitations of the EulerianLagrange
flow during the granulation process could pose a danger model which is normally limited to a relatively small
of overwetting of particles, resulting in a nonretrievable number of particles, the EulerianEulerian model is
bed collapse.[18,19] It has been found that the fluidization the preferred choice for simulating the gasparticle
velocity should be adjusted to prevent the bed collapse hydrodynamics of a fluidized bed. The effectiveness of
during the spray fluidized bed granulation.[20] the EulerianEulerian model of CFD has been exten-
Particle size is another important granulation sively validated by the experiments.[30,37,38,44]
characteristic which plays a crucial role in fluidization. Thus, the aim of this study is focused on providing
The average particle size increases under different an understanding of how the gasparticle circulation
granulation mechanisms during experiment, which pattern and hydrodynamics within the spray fluidized
results in different particle holdups and fluidization bed granulation are influenced by the fluidization
levels within the granulator. Fan et al.[21] claimed that velocity and particle size by CFD simulation. The fluidi-
gasparticle circulation pattern is strongly affected by zation velocity was changed from 0.6 m3/h to 1.8 m3/h
particle size. For glass beads with a size of 0.81 mm, and the particle size was changed from 164 m to
the mean glass flow was predominantly upward on 500 m to simulate the granule growth during
one side of the bed and downward as a return flow on granulation process. Both ranges for fluidization
the other side, while for the glass beads with a size of velocity and particle size are true values adopted from
250450 m, a typical upward along the center and the authors preliminary experimental work.[11] Based
downward along the annulus (UCDW) pattern can be on these two variables, a total of nine CFD simulations
observed. Laverman et al.[22] observed the same particle were designed by the full factorial design method with
flow pattern for various types and a broad range of three levels for each variable. The CFD model was
particle size and the difference was in the fluidization solved in the software package of FLUENT 13.0 (Ansys
velocity at which the number of vortices changed. Inc., USA) using the EulerianEulerian approach by the
However, particle flow pattern was not found to be kinetic theory of granular flow (KTGF) and was
affected by the particle size.[2325] validated both experimentally and theoretically.[45] By
A large number of experimental studies have been changing the fluidization velocity and particle size in
performed regarding gasparticle flow pattern identifi- the simulation design, their effects on gasparticle
cation within spray fluidized bed granulation processes circulation pattern, particle velocity distribution,
for different process parameters and physical properties. particle concentration distribution, and particle circu-
However, the complex hydrodynamics of fluidized bed lation time were investigated, respectively. Finally, a
granulation still need to be investigated for further mathematical model was developed to describe the
understanding owing to complicated phenomena such relationship between particle circulation time, fluidiza-
as particleparticle, particledroplet, and particle tion velocity, and particle size, which provides guidance
bubble interactions. Recently, CFD has emerged as an on how to change the fluidization level by adjusting the
effective tool for investigating gasparticle fluidized fluidization velocity during one experiment.
bed hydrodynamics. In the literature, CFD has been
widely applied for modeling multiphase flow of wet
Simulation design and experimental setup
granulation process to reduce the design time and
cost.[2635] In general, two different approaches of In this work, the particle circulation pattern is quanti-
CFD modeling are used to model a gassolid fluidized tatively represented by the particle circulation time.
bed: the EulerianEulerian approach, in which all The granulation process is simulated by the increasing
phases are considered as interpenetrating continua particle size and changing fluidization velocity in the
and the EulerianLagrangian approach in which at least simulation design. To investigate the relationship
DRYING TECHNOLOGY 3
is applied incorporating the KTGF. In this approach, Table 3. Detailed governing, constitutive, and closure
the different phases are treated mathematically as equations in simulation.
interpenetrating continuums,[46] where gas phase is Continuity equations for gas and solid
@ ag qg
defined as the primary phase and the particle phase is @t r ag qg~ vg 0 4
@ as qs
defined as the dispersed particulate phase. Conservation ~
@t r as qs v s 0 5
Conservation of momentum of gas and solid
equations were derived for each phase and linked by @ ag qg~ vg
r ag qg~ vg~vg ag rp r ag sg
interphase momentum transfer coefficients and press- @t
ure. The hydrodynamic model of gassolid fluidized Kgs ~vs ~ v g ag qg~
g 6
@ as qs~ vs
beds is based on conservation of mass and momentum. r as qs~ vs~
vs as rp rps r as ss
@t
In the present study, the gassolid two-phase flow is vg ~
Kgs ~ vs as qs~g 7
nonreactive, isothermal, and transient. The TFM Gas-phase/solid-phase
stress
tensors
T
requires constitutive equations to describe the rheology sg lg r~ vg r~ vg 8
T
of solid phase. When the particle motion is dominated ss ls r~ vs as ks 23 ls r ~
v s r~ vs I 9
by collision interactions, the concepts from fluid kinetic Bulk solid viscosity qffiffiffiffi
theory can be introduced to describe the effective stres- ks 43 as qs ds g0 1 es Hps 10
ses in the solid phase resulting from particle streaming
collision. Furthermore, these constitutive relations for Algebraic
granulartemperature equation
the solid-phase stress, based on kinetic theory, were 0 ps I ss : r~
vs cHs 11
derived by Lun et al.,[47] which have been accepted Collision dissipation of energy
121 e2 g0
widely. A standard mixture k model was used to cHs ds pffipsffi qs a2s H1:5
s 12
solve the transport equations. The governing equations Hs 13 vs0 vs0 13
including mass and momentum conservation equation
Solid pressure
of gas and solid phases, constitutive equations, and ps sss[1 2g0s(1 es)] (14)
closure relations used in this study are summarized in
Radial distribution function
Table 3. 1=3 1
as
g0 1 asmax 15
the momentum balance equation for the solid phase. Interphase drag force
as ag qg j~ vg j
vs ~
The finite volume approach by a commercial CFD soft- kgs 34 CD ds ag 2:65 for ag > 0:8 20
as qg ~v
ware package FLUENT 13.0 (Ansys Inc., USA) was used a2 l
kgs 150 asg dg2 1:75 jdss g j for ag 0:8
~
v
21
h s 0:687 i
for solving the computational model in a 3-D domain CD ag24Res 1 0:15 ag Res 22
comprising all the interior volume of the conical product qg ds j~ vg j
vs ~
Res 23
chamber in the fluidized bed granulator in double lg
Table 4. Parameters used in the CFD simulation. the initial primary MCC particles was between 8 and
Property Value 9 cm. The initial bed height of packed solid particles
Initial bed height (cm) 8.75 was therefore, set as 8.75 cm in the CFD simulations.
Initial solid packing 0.53
Maximum solid volume fraction 0.63 The particle volume fraction was set as 0.53 based on
Particle restitution coefficient 0.9 ratio of the volume of the actual primary particles used
Time step (s) 0.0001
Convergence criteria 1.0 10 3 in the experiments and the initial bed volume packed in
Operating pressure (Pa) 101325 the simulations.[11]
Maximum iterations every step 200
For the boundary conditions, the distributor was
CFD, computational fluid dynamics.
modeled as a porous plate placed at the bottom of the
conical product chamber in which the uniform air was
algorithm was used for the pressurevelocity coupling, in
injected into the bed. The particles were not allowed
which the coupling terms were solved implicitly to form
to penetrate the distributor. The pressure outlet was
a part of the solution matrix. The CFD simulations were
used as a boundary condition at the top of the conical
performed on a 2-GHz Intel four-core processor desktop
chamber, which was assumed to have a constant static
computer with 4-GB RAM using an XP platform.
atmospheric pressure as a reference operating pressure.
A no-slip condition was set for walls, which means no
Initial and boundary conditions
momentum waste occurred when the air and solid col-
In each CFD simulation of a fluidized bed, particles lided with the wall. The restitution coefficient was set as
were assumed to be spherical and monodispersed. Based 0.9 for the particles in the simulations. Configuration of
on the experiments, it was found that the bed height of the simulated fluidized bed and its boundary conditions
Figure 2. Mesh sensitivity study results: (a) solid volume fraction on cross-sectional plane XY; (b) solid volume fraction on
cross-sectional plane YZ; (c) pressure drop; and (d) bed height.
6 H. LIU ET AL.
Figure 5. Particle velocity vector plot when particle size D 164 m at fluidization velocity: (a) 0.6, (b) 1.2, and (c) 1.8 m3/h.
The effect of fluidization velocity on the particle generated by the fluidizing air. The reason why the par-
circulation pattern at small particle size (164 m) is ticles could remain fluidized in the bed is that the par-
given in Fig. 5. It is clearly shown that solid particles ticle weight is balanced by drag force generated from the
move upward from the central region and flow down- pressure drop. For upward flowing particles, on the
ward along the wall for all fluidization velocities from lower half bed domain, where the drag force is larger
0.6 to 1.8 m3/h, which has also been experimentally than the particle weight, the particles are accelerated
observed by Lin et al.[23] Large vortices were observed by the upward force difference, while the particle velo-
randomly distributed in the area between central region city starts to decrease where the drag force is smaller
and wall at lower fluidization velocity (0.6 m3/h), and than particle weight on the upper half bed domain.
they are shrunk and break up into more small size The same theory can be utilized to explain the particle
vortices as the fluidization velocity increases to velocity evolution for the downward flowing particles.
1.8 m3/h. For both upward moving particles and down- Figure 6 shows the influence of fluidization velocity
ward moving particles, maximum velocity was reached on particle circulation pattern at medium particle size
at middle bed height and minimum velocity was of 332 m. First, smaller average particle velocity was
observed at the top and bottom of fluidized bed. This shown compared to that in Fig. 5 at each fluidization
could be explained by the interaction between particle velocity, which could be explained by the increased
weight and pressure drop along the bed height particle weight. At lower fluidization velocity (from
DRYING TECHNOLOGY 9
Figure 6. Particle velocity vector plot when particle size D 332 m at fluidization velocity: (a) 0.6, (b) 1.2, and (c) 1.8 m3/h.
0.6 m3/h to 1.2 m3/h), an identical stable particle The influence of fluidization velocity on particle
circulation pattern was indicated by all types of particle circulation pattern at large particle size of 500 m is
velocity vector fields, where particles moved upward shown in Fig. 7. Further, reduced average particle
from central region and fell downward along the wall, velocity was observed due to further increased particle
forming large vortices between them. In the meantime, weight. It was found that the same particle circulation
small particle vortices were observed at the corner patterns as in Fig. 6c are happened for all fluidization
between wall and air distributor, which indicated the velocities at particle size of 500 m, where almost all
moving trail of particles accumulating in this region. particles are moving upward along XY plane and fell
At high fluidization velocity (1.8 m3/h), a new particle downward to the air distributor along the ZY plane.
circulation pattern occurred where solid particles At a lower fluidization velocity of 0.6 m3/h, laminar
moved upward along plane XY and fell downward along particle flow was found and only two large symmetric
plane ZY, shown in Fig. 6c. From Fig. 6c, it was vortices appeared on the ZY plane. As fluidization
indicated that both small and long vortices appeared velocity increased, the particle flow became more turbu-
simultaneously and located randomly at any position lent and the large vortices were forced to break into small
within the fluidized bed but not only at area between vortices. The upward moving particles brought by the
the central region and wall. arising bubbles conflicted with the dropping particles
10 H. LIU ET AL.
Figure 7. Particle velocity vector plot when particle size D 500 m at fluidization velocity: (a) 0.6, (b) 1.2, and (c) 1.8 m3/h.
by the splashed air bubbles, creating a sharp interior because high particle concentration generates high fric-
boundary. tional force between particles and obstructs the increase
in downward particle velocity. For smaller particle size
of 164 m, the simulation results showed that particles
Effect of fluidization velocity and particle size are most likely concentrated at the middle section
on particle concentration distribution domain of the bed, while for particle size of 332 and
Figure 8 shows the time-averaged solid concentration 500 m, particles are likely concentrated at the upper
contour on the cross-sectional plane at different bed section domain of the bed. At the small particle size
heights for simulations of all fluidization velocities of 164 m in Fig. 8a, the particle concentration
and particle sizes. The cross-sectional plane was created distribution changes slightly with the increasing fluidi-
at 10, 30, 50, 70, and 90% of bed height. It is indicated zation velocity. Time-averaged particle concentration
that an obviously high particle concentration was dis- distributions at all fluidization velocities are small,
tributed on the annulus area against the wall where par- which could be explained by the sufficient fluidization
ticles fell downward and low particle concentration was due to small particle size. However, at the medium
found on the central region where particles moved particle size of 332 m in Fig. 8b and the large particle
upward. This phenomenon can explain the difference size of 500 m in Fig. 8c, the particle concentration
between the upward and downward particle velocities, decreased significantly as the fluidization velocity
DRYING TECHNOLOGY 11
Figure 8. Time-averaged solid concentration distribution at horizontal cross-sectional planes of 10, 30, 50, 70, and 90% of bed
heights: (a) particle size of 164 m, (b) particle size of 332 m, and (c) particle size of 500 m.
increased. For medium (332 m) and large (500 m) granulator and increase in both number and size, which
particles, obvious higher particle concentrations were is clearly observed for particles of 332 and 500 m in
observed on each cross-sectional planes comparing to size. However, the bubbles distorted significantly and
that of small particles (164 m). merge frequently at high fluidization velocity, which
The effect of particle size and fluidization velocity on generates twisty bubbles as shown in Fig. 9b and 9c.
the particle concentration distribution at the vertical It can also be seen that the fluidized bed expansion
plane XY is also investigated as shown in Fig. 9. The decreases as particle size increases. Under the same flui-
fluidized bed expansion increases with fluidization velo- dization velocity, more bubbles and a heterogeneous
city for all the particle sizes. As the fluidization velocity fluidization state are generated by the larger particle
increases, bubbles appear initially at the bottom of size.
12 H. LIU ET AL.
Figure 9. Time-averaged particle concentration distribution at vertical cross-sectional plane XY: (a) particle size of 164 m,
(b) particle size of 332 m, and (c) particle size of 500 m.
DRYING TECHNOLOGY 13
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