Sanchez Et Al., (2008)
Sanchez Et Al., (2008)
Sanchez Et Al., (2008)
com
Abstract
The scale-up method for three-phase fluidized beds hydrodynamics proposed by Safoniuk et al. [M. Safoniuk, J.R. Grace, L. Hackman, C.A.
McKnight, Chem. Eng. Sci. 54 (1999) 4961], based upon the principles of dynamic similitude, was tested matching several systems operated at
high pressure with model systems operated at atmospheric pressure. Experiments were carried out to test this technique by comparing global phase
holdups, and flow regime in systems where the five dimensionless groups proposed by the method were matched, but which were operated at
significantly different pressures. The differences observed between the hydrodynamic parameters of the high pressure and model systems suggest
that the five dimensionless groups employed are not enough to fully characterize the global bed behavior. Similar findings have been reported by
Macchi et al. [A. Macchi, H. Bi, J.R. Grace, C.A. McKnight, L. Hackman, Chem. Eng. Sci. 54 (2001)] based on differences observed in the local
dynamic bed behavior between systems operated at atmospheric pressure.
# 2007 Elsevier B.V. All rights reserved.
rl d p U l
* Corresponding author. Tel.: +52 5804 4648; fax: +52 5804 4900. Rel ¼ ; liquid Reynolds number; (3)
E-mail address: rmr@xanum.uam.mx (R.S. Ruiz). ml
0920-5861/$ – see front matter # 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.cattod.2007.10.002
520 J.L. Sánchez et al. / Catalysis Today 130 (2008) 519–526
and 0–0.451
6.94 104
(0.08 MPa;
section, the test section, and the gas–liquid disengagement
0–5.655
section. A perforated plate was used as the distributor. Gasoil
33.333
19 8C)
Model
Matched systems VI
2.38
2.79
was used as the liquid phase, which consisted of a mixture of
heavy and light straight-run gasoils that contained 95% in
and 0–2.451
(15.60 MPa;
6.75 104
volume of the former. Nitrogen was used for the gas phase and
Prototype
3 mm spherical glass beads for the solid phase. Table 1 presents
0–5.655
34 8C)
16.93
the operating conditions and dimensionless groups for both
2.65
2.83
prototype and model systems.
It should be pointed out that while the Buckingham Pi
and 0–2.451
4.40 104
(0.08 MPa;
theorem also requires equality of Dc/dp for the two units, the
0–7.738
exact match of this dimensionless group, however, can be
33.333
22 8C)
Model
2.44
2.79
relaxed providing that it is sufficiently large that wall effects
Matched systems V
are negligible. For the prototype and model systems Dc/dp
and 0–2.451
(10.10 MPa;
4.53 104
Prototype
[7].
0–7.738
34 8C)
In the model system the height of the expanded bed was
16.93
2.77
2.87
determined from the axial pressure profiles as the position
where there is an abrupt change of the slope of the axial
and 0–2.549
2.79 104
(0.08 MPa;
along the column at every 7.5 cm interval, with the first one
0–6.548
33.333
25 8C)
Model
located 10 cm above the distributor. For a bed with low solids
2.51
2.80
Matched systems IV
entrainment rates and where solids holdups are assumed to be
independent of height throughout the entire expanded bed
and 0–2.549
2.55 104
(5.62 MPa;
Prototype
a mass balance on the particles in terms of the expanded bed
0–6.548
34 8C)
16.93
height, H, the cross-sectional area of the bed, A, and total solids
2.84
2.89
inventory, Ws, i.e.
1.32 104
Ws
(0.08 MPa;
e ¼ 1 es ¼ 1 : (6)
0–6.845
rs AH
33.333
30 8C)
Model
0.994
Matched systems III
2.63
2.81
Once the solids holdup, es, is known the overall gas and
liquid holdups can be determined from the following relation- 1.37 104
(2.86 MPa;
ships [10]:
Prototype
0–6.845
34 8C)
0.994
16.93
ðDP=gHÞ es ðrs rl Þ rl
2.79
2.90
eg ¼ ; (7)
rg rl
9.79 105
(0.08 MPa;
es þ el þ eg ¼ 1; (8)
0–8.250
33.333
32 8C)
Model
Operating conditions and dimensionless groups for matched systems
2.68
1.06
2.81
the liquid [10,13]. For low and moderately gas and liquid
0–8.250
34 8C)
16.93
0–9.524
33.333
35 8C)
Model
0–9.524
16.93
2.68
1.15
2.91
Dc/dp
Rel
Eo
bU
bd
Fig. 3. Bed porosity versus Reg for prototype and model systems with the
former operated at 5.62 MPa and both systems at: (a) Rel = 0.88 and (b)
Rel = 2.67.
Fig. 5. Gas and liquid holdups versus Reg for prototype and model systems with
the former operated at 5.62 MPa and both systems at: (a) Rel = 0.88 and (b)
Rel = 2.67.
matching model systems are also shown in Fig. 4. For all three
cases shown the gas holdup of the model increases with gas
velocity and does so with values higher than for the
corresponding prototype system. For the liquid holdups, the
model systems show a qualitatively similar behavior to those
observed for the prototype systems, however they were always
found to be smaller than the latter. The larger gas holdups
obtained for the model can be attributed to the noncoalescing
behavior of the oil fraction employed for such systems, and in
Fig. 4. Gas and liquid holdups versus Reg for prototype and model systems with which gas bubbles tend to rise as small and slow entities that
the former operated at three different pressures: (a) 0.79 MPa, (b) 2.86 MPa, produce relatively high gas holdups. On the other hand,
and (c) 10.10 MPa.
Paratherm NF heat transfer liquid was employed in the
prototype system and for which no foaming behavior has been
operating pressure through its effect on the bubble character- reported [2,9,11].
istics and on the flow regime [1,9]. An increase in pressure at The effect of liquid velocity on gas and liquid holdups for the
constants gas and liquid velocities produces a reduction of the model and prototype systems is shown in Fig. 5, for the
size and velocity of the gas bubbles which in turn increases the prototype operated at a pressure of 5.62 MPa. The gas holdups
gas holdup in the fluidized bed. for the prototypes are found to decrease slightly with the
The bed gas and liquid holdups for the prototype, for increase in liquid velocity. Similarly, the gas holdups for the
different operating conditions, and for the corresponding model models also decrease with liquid velocity, but does so at larger
systems are shown in Figs. 4 and 5. Fig. 4 presents the variation rates than in the prototypes, and this is particularly noticeable at
of the holdups for the prototype with gas Reynolds number for high gas velocities for which the gas holdups of the prototypes
three different operating pressures, 0.79, 2.86, and 10.10 MPa, exceed those of the models. Luo et al. [9] reported that the
and for an average liquid Reynolds number of 0.97. A pressure effect on gas holdup is more pronounced at high gas
continuous increase in gas holdup is observed with an increase velocities. As gas velocity is increased larger bubbles can be
in gas Reynolds number, which seems to be more pronounced at expected to occur and hence the effect of pressure on bubble
higher pressures. The liquid holdup, on the other hand, breakup phenomena becomes more evident. From comparison
decreases with an increase of gas flow rate and operating of the gas holdups for the prototype and the model systems it
pressure. The gas and liquid holdups for the corresponding seems that the response of the prototype at high pressure and
524 J.L. Sánchez et al. / Catalysis Today 130 (2008) 519–526
fluid velocities is reproduced only partially by the model increased regime transitions occurs at higher bed porosities,
system. It has been reported that pressure affects the and hence at higher gas velocities. The gas drift flux for the
hydrodynamics through the variation on the physical properties model systems is shown in Fig. 6(b), and in which the symbols
of the gas and liquid phases, therefore, in the prototype both the utilized for the data are the same to those of the prototypes in
gas and the liquid are being affected. On the other hand, the Fig. 6(a) that are being matched. In order to match the dimen-
model system was designed based on the five dimensionless sionless groups between the model and the prototype systems
groups presented in Eqs. (1)–(5), none of which considers the the operating temperature of the model systems had to be
properties of the gas phase. For the prototype operated at high modified so as to produce the necessary changes in liquid
pressure and gas flow rates it therefore seems necessary to properties. As it is shown in Fig. 6(b) an increase in the
utilize the extra dimensionless group suggested by Safoniuk transition gas velocities in the prototypes is also qualitatively
et al. [7] given by the gas to liquid density ratio, rg/rl. predicted by the model systems but in the latter it is produced
by decreasing the operating temperature.
3.3. Flow regime The prevailing bubble flow regime depends on both the gas
and liquid velocities. Fig. 7 shows the gas drift flux for both
The transition between the dispersed and coalesced bubble prototype and model systems at two different liquid velocities
regimes in high-pressure ebullated beds has been analyzed by for a given prototype pressure of 5.62 MPa. For the range of gas
many researchers utilizing the gas drift flux concept [3,9] The porosities in Fig. 7, and for both liquid velocities the prototype
gas drift flux, jcd, for three-phase fluidized beds can be systems seem to operate in the dispersed bubble flow regime.
expressed by [12] On the other hand, the model systems seem to show different
regime transition conditions for the two liquid velocities
1 eg
jcd ¼ ðU g el U l eg Þ (9) considered. As the liquid Reynolds number is increased the gas
el
holdup and hence the transition gas velocity decreases. It is then
which seems to increase with gas holdup at a much higher rate clear from this figure that the prototype systems are maintained
at the coalesce bubble flow regime as compared to that at the in the dispersed bubble flow regime for a broader range of gas
dispersed bubble flow regime. An increase of pressure has been and liquid velocities as compared to the matching model
reported to lead to an increase in the transition gas velocity from systems. The effect of pressure on the hydrodynamics of the
the dispersed to the coalesced bubble regimes. The gas drift flux prototypes have been modeled in the present work by matching
for the prototype operated at different pressures and the corre- of five dimensionless groups appear to be insufficient when
sponding matching model systems are presented in Fig. 6. As operating at high gas and liquid velocity conditions. Pressure
can be seen in Fig. 6(a), for the prototype system as pressure is affects hydrodynamics by affecting both liquid and gas
Fig. 6. Gas drift flux versus gas holdup for (a) the prototype systems operated at Fig. 7. Gas drift flux for both prototype and model systems with the former
different pressures and (b) the corresponding matching model systems. operated at 5.62 MPa and both systems at: (a) Rel = 0.88 and (b) Rel = 2.67.
J.L. Sánchez et al. / Catalysis Today 130 (2008) 519–526 525
Table 2 Table 3
RMSD and Fm between bed porosities for the matched systems Average RMSD and Fm between hydrodynamic parameters for the matched
systems
Matched system Rel RMSD Fm
Hydrodynamic parameter RMSD Fm
I 1.15 0.063 1.055
II 1.06 0.085 1.091 Bed porosity 0.108 1.115
III 0.99 0.093 1.098 Gas holdup 2.107 0.575
IV 0.88 0.101 1.108 Liquid holdup 0.237 1.284
2.67 0.129 1.147
V 0.77 0.126 1.140
2.34 0.119 1.133
VI 0.70 0.132 1.151 global hydrodynamics but it is clear that they seem to depend on
2.13 0.112 1.121 the coalescing nature of the liquids in the prototype and model
Mean 0.108 1.115 systems. The gasoil mixture employed in the models showed a
noncoalescing behavior and a tendency to foam as temperature
was decreased and the liquid velocity increased. This behavior
produced significantly larger gas holdups in the models as
properties and the aforementioned groups do not consider the compared to the prototypes even for relatively low gas
gas properties. As mentioned earlier, the use of a denser gas in Reynolds numbers. It is also apparent that the gas to liquid
the model system that would match the densities ratio, rg/rl, density ratio is a group that needs to be matched when modeling
could account to the effect of pressure on the gas phase. For the high-pressure systems, especially under relatively high gas and
operating conditions considered in Fig. 7, the density ratios for liquid flow rates for which the effect of pressure becomes more
the prototype and model systems were 7.02 102 and evident. Finally, it is evident that differences between the
9.79 104, respectively. Therefore, in order to match the coalescing behaviors of the liquids of the matched systems play
density ratio between both units gas with a density of 62.4 kg/ an important role that has to be accounted for in future work
m3 is required for the model system, and which is about two when selecting the liquid for the model system.
orders of magnitude larger than that of nitrogen at atmospheric
pressure and ambient temperature. As can be expected, 4. Conclusions
availability of a safe to use gas with such a density could be
a limitation to the exact matching of the density group. The scale-up method for three-phase fluidized beds
The differences in the hydrodynamic parameters between hydrodynamics proposed by Safoniuk et al. [7], based upon
the prototype and the model systems have been characterized the principles of dynamic similitude, was tested matching
by the root mean standard deviation (RMSD) and bias factor several systems operated at high pressure with model systems
(Fm) operated at atmospheric pressure.
rffiffiffi k Bed porosities were qualitatively similar for prototype and
2
1X model systems and the quantitative differences were generally
RMSD ¼ ð prototype ModelÞ= prototype ; less than 13%, however, such differences appeared to increase
k i¼1
X as the pressure of the prototype system was increased. In
k
Fm ¼ exp Inð prototype=ModelÞ : (10) general the gas holdup of the model systems overestimated
i¼1
those for the prototype systems, behavior that seams to be
attributed to the foaming character of the oil fraction used in
Table 2 presents these quantities for the bed porosity and six model systems that showed a tendency to accumulate small
different prototype operating pressures (see Table 1). The gas bubbles even at low gas velocities. The drift fluxes
results show that the differences between prototype and model calculated for both prototype and model systems showed that,
tend to be smaller for the lower pressure systems and that the although most of them operated in the dispersed bubble
largest RMSD obtained corresponds to the matching of the regime, the high-pressure systems appear to have larger gas
prototype operated at the highest pressure considered transition velocities between the dispersed and coalesced flow
(15.6 MPa). It is also evident from this table that Fm is always regimes. It seems that the use of denser gases in the model
larger than unity and which means that the bed porosities for the systems could help extend their respective gas transition
prototype are also always underestimated by the model. velocities.
The average RMSD and Fm values obtained for the The differences observed between the hydrodynamic
hydrodynamic parameters for all the matched systems parameters of the high pressure and model systems suggest
considered are presented in Table 3. The data are clearly that the five dimensionless groups employed are not enough to
skewed (0.575 < Fm < 1.284) and the best RMSD corresponds fully characterize the global bed behavior and that, although
to the bed porosity, of the order of 0.11, which is followed by matching the additional group given by gas to liquid density
that for the liquid holdup, and then, with a significantly large ratio could probably help to extend the dispersed bubble flow
deviation, by the gas holdup. regime in the model system, there is still lack of information
From the present results it seems that the dimensional regarding the coalescing behavior of the liquids used in the
similitude approach provides a useful tool for estimation of matched systems.
526 J.L. Sánchez et al. / Catalysis Today 130 (2008) 519–526
Acknowledgement [6] T.M. Knowlton, S.B.R. Karri, A. Issangya, Powder Technol. 150 (2005)
72.
[7] M. Safoniuk, J.R. Grace, L. Hackman, C.A. McKnight, Chem. Eng. Sci.
The authors thank Instituto Mexicano del Petróleo for the 54 (1999) 4961.
financial support. [8] A. Macchi, H. Bi, J.R. Grace, C.A. McKnight, L. Hackman, Chem. Eng.
Sci. 54 (2001) 6039.
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