Characterization and Development of Packed-Fluidized Bed Reactors
Doktorsavhandling, 2024

Packed- or confined fluidized beds utilize fixed packings inside a bed of fluidizing particles. This novel concept can have advantages with respect to gas-solid contact and solids flow patterns. This could be of importance for many fluidized bed conversion technologies, such as chemical-looping. In this thesis, different aspects of packed fluidized beds are explored, using experimental and modeling tools. The study includes an investigation of the effects of packings on heat and mass transfer, as well as solids flow patterns. For this purpose, different types of packings are selected and assessed.

Initially, the heat transfer coefficient to a horizontal tube submerged in a packed-fluidized bed, pressure drop, and vertical solids segregation are experimentally evaluated for bed temperatures ranging from 400°C to 900°C and superficial gas velocities from 0.04 m/s to 0.411 m/s. Subsequently, the conversion of gaseous fuels during CLC is investigated. CLC experiments are conducted using CH4, CO, and syngas (50/50% H2/CO) as fuels, at temperatures between 840°C and 940°C. Next, gas-solid mass transfer in a bubbling packed-fluidized bed is studied. This is achieved through targeted experiments using a bed of moist silica gel, where the rate of H2O desorption is monitored during the experiments. A detailed mass transfer analysis is performed using a model that accounts for various steps in the mass transfer chain. Finally, the residence time distribution of bed material in a bubbling packed-fluidized bed with throughflow is examined. The cold-flow reactor setups allow for continuous cross-current and counter-current flow of particles and fluidizing gas. The effects of packing type, fluidization number, bed height, and solid throughflow rate are analyzed. The axial dispersion and tank-in-series models are utilized to categorize flow patterns of particles in packed-fluidized beds.

The results show that the nature of the packings have significant impact on the behavior of bubbling-fluidized beds. Packings with low void factor such as ASB have a lower heat transfer coefficient, higher pressure drop, and more significant vertical segregation, compared to a bubbling bed without packings. However, packings with high void factors such as RMSR showed an improvement in heat transfer coefficient (up to 1243 W/m2K) at higher gas velocities compared to a bubbling bed with no packings (up to 1124 W/m2K). Also, beds with RMSR and Hiflow packings had lower pressure drop, lower vertical segregation, and higher fuel conversion in CLC compared to a bubbling bed with no packings. Furthermore, the inhibition of bubble formation and growth in the packed-fluidized bed enhances the emulsion-bubble mass transfer by up to 23% compared to a bed without packings. As part of this work, it was also shown that low void factor packings can alter the mixing behavior of solids in BFBs. Without packings, the fluidizing solids are well mixed, similar to a continuous stirred tank reactor (CSTR), while packings could transmit the flow pattern to be more similar to a plug flow reactor (PFR). This was confirmed by the reactor modeling, with the tank-in-series model resulting in an increase in the number of reactors in series from 1 up to 10 reactors when using packings. Furthermore, the vessel dispersion number can be reduced up to tenfold in such packed-fluidized beds.

This work demonstrates that the use of packed-fluidized beds or confined fluidization has a significant effect on important phenomena in a bubbling fluidized bed. This could be of significance in a number of new and novel technologies, including chemical-looping combustion or gasification and hydrogen production systems.

Mass transfer

Heat transfer

Chemical-looping combustion

Residence Time Distribution.

Confined fluidization

Bubbling fluidized bed

Packed-fluidized bed

Random packing

Lecture hall SB-H5 Campus Johanneberg, Chalmers
Opponent: Christoph Pfeifer, Professor, Institute for Chemical and Energy Engineering, University of Natural Resources and Life Sciences (Vienna)

Författare

Nasrin Nemati

Chalmers, Rymd-, geo- och miljövetenskap, Energiteknik

Experimental Investigation of the Effect of Random Packings on Heat Transfer and Particle Segregation in Packed-Fluidized Bed

Industrial & Engineering Chemistry Research,;Vol. 60(2021)p. 10365-10375

Artikel i vetenskaplig tidskrift

Chemical-looping combustion in packed-fluidized beds: Experiments with random packings in bubbling bed

Fuel Processing Technology,;Vol. 222(2021)

Artikel i vetenskaplig tidskrift

Nemati N.; Mattisson T.; Pallarès D; Guío-Pérez D.C.; Rydén M.; Impact of random packing on residence time distribution of particles in bubbling fluidized beds: Part 2 - counter-current flow reactors. Chemical Engineering Science 2024.

Packed-Fluidized Bed Reactors: Boosting the Efficiency of Thermochemical Processes

Thermochemical processes are the heart of many industrial operations. Key applications include generation of heat and power, production of H2, chemicals and fuels, and climate mitigation by CO2 capture. Conventional reactor types used for these processes often underperform compared to the theoretical maxima, leading to energy losses, high costs, and excessive material use. This highlights the need for advancements in reactor design, to meet the growing demands for energy and resource efficiency.

In this context, the packed-fluidized bed reactor is a promising innovation. This novel reactor concept seeks to combine the strengths of both packed-bed and fluidized-bed reactors.  Compared to conventional fluidized beds, the concept addresses key challenges by improving gas-solid contact, reducing bubble size, and inhibiting slugging. These improvements can lead to more efficient, cost-effective, and resource-efficient processes, offering significant advantages over current reactor designs.

In this work, I have conducted experimental and modeling studies to explore the potential of packed-fluidized beds in both hot and cold setups. My findings suggest that this reactor concept could significantly enhance key performance indicators, making it a promising candidate for current and future industrial applications. Ultimately, this research may contribute to more energy-efficient processes, reduced costs for climate mitigation by CO2 capture, and support the transition towards a circular economy.

Produktion av vätgas och biokol från trädbränslen med ny process som utnyttjar steam-iron-reaktionen och järnmalms-koncentrat

Energimyndigheten (P2022-00544), 2022-11-01 -- 2025-04-30.

Tillämpning av packad-fluidiserad bädd för energiomvandling

Energimyndigheten (46525-1), 2019-01-01 -- 2023-12-31.

Drivkrafter

Hållbar utveckling

Innovation och entreprenörskap

Ämneskategorier

Energiteknik

Naturresursteknik

Kemiska processer

Kemiteknik

Styrkeområden

Energi

ISBN

978-91-7905-711-4

Doktorsavhandlingar vid Chalmers tekniska högskola. Ny serie: 5557

Utgivare

Chalmers

Lecture hall SB-H5 Campus Johanneberg, Chalmers

Online

Opponent: Christoph Pfeifer, Professor, Institute for Chemical and Energy Engineering, University of Natural Resources and Life Sciences (Vienna)

Mer information

Senast uppdaterat

2024-09-20