Bubbling Fluidized Bed

Gas-Solid Fluidization

Reference:
Chapter 3, Handbook of Fluidization and Fluid-Particle Systems, WC Yang, CRC Press, 2003
Chapter 9.3-9.4, Principles of Gas-solid Flows, LS Fan and C Zhu, Cambridge, 1998
Chapter 6, Fluidization Engineering, Kunii & Levenspiel, Butterworth-Heinemann, 1991

1
2
 Vv
v

As U increases, bed expands / ε increases.

3
 Bubbles 1/5
X-ray View of Bubble

Photograph of a Bubble of NO2 in a

2-D Bed Showing the Bubble Cloud
and Wake (Fast Bubble)
--- Rowe and Partridge (1965)
Fast Moving Bubble with Cloud

Applying the Fundamentals

4
 Bubbles 2/5

• Particles are carried upward in the bed from bubbles with

the wake and the drift
• The wake is 20 to 60% of the bubble gas volume
• The drift is approximately equal to the wake volume

Applying the Fundamentals

5
 Bubbles 3/5
• Two basic bubble types:
• Fast bubble (clouded bubble) Ub > Umf/εmf
• Slow bubble (cloudless bubble) Ub < Umf/εmf
• Bubbles usually have a spherical or ellipsoidal cap shape
• Cloud = region established by gas which circulates in a closed loop
between bubble and surroundings

6
 Bubbles 4/5
• Bubbles differ among Geldart Groups
• Usually clouded bubbles for Groups A and B
• Usually cloudless bubbles for Group D
• Wake plays important role in solids mixing
• Wake rises with bubble thereby causing global solids circulation
• Smaller θw = flatter bubble, larger wake to bubble ratio

7
 Bubbles 5/5

• As pressure increases
•

Bed Height
Bed density decreases
•

Bed Height
More gas goes into the emulsion
• Bed height increases
• Bubbles get smaller
• Especially for Geldart Group A material

Low Pressure High Pressure

Applying the Fundamentals

8
 Bubble Coalescence and Breakup 1/3
• Bubbles may coalesce to form bigger bubbles or break up to form
smaller ones

Indentation on the
upper boundary of
the bubble
Regional resulting from the
minimum disturbance
pressure induced by
relative motion
with the particles

9
 Bubble Coalescence and Breakup 2/3

• Bubble size increases with bed depth due to coalescence

• Bubbles move in “tracks” and cross-coalesce between tracks
• Bubble volume remains approximately the same with height

Applying the Fundamentals

10
Bubble Coalescence and Breakup 3/3

Terminal
Velocity

• Bubbles in a fluidized bed of Geldart Group A powder

reach an equilibrium size quickly
• Bubbles in a fluidized bed of Geldart Group B powder
can get very large (> 1 meter)
Applying the Fundamentals
11
 Ergun Equation 1/3
• Ergun equation relates the pressure drop in a packed bed to the flow
rate and the properties of particle and gas
2 2
ΔP (1− ε mf ) µU mf 1− ε mf ρ U
f mf
Ergun: = 150 +1.75
H mf ε mf3 φ 2 d p2 ε mf3 φ d p
Viscous Term Inertial Term
• Ergun equation implies that the energy loss through the bed can be
computed simply by summing up the two components, one caused by
the viscous effect and the other due to the inertial effect
• Ergun equation was developed for packed beds à applies from U = 0 to
U = Umf

12
 Ergun Equation 2/3
ΔP (1− ε mf )2 µU mf 1− ε mf ρ f U mf2
Ergun: = 150 3 2 2
+1.75 3
H mf ε mf φ d p ε mf φ d p
ΔP
From previous slide, we know = (1− ε mf )( ρ P − ρ f )g
H mf
Equating the 2 equations at U = U mf gives:
(1− ε mf )2 µU mf 2
1− ε mf ρ f U mf
150 3 2 2
+1.75 3 = (1− ε mf )( ρ P − ρ f )g
ε mf φ dp ε mf φ d p
ρ f d p3
Multiply throughout by 2 gives:
µ (1− ε )
2 2 2 3
(1− ε mf ) U mf ρ f d p 1 U mf ρ p d p ( ρ P − ρ f )gρ f d p
150 3 2
+1.75 3 2
= Recall:
ε mf φ µ ε mf φ µ µ2
ρ f d pU mf
(1− ε mf ) 1 Re p,mf =
150 3 2 Re p,mf +1.75 3 Re 2p,mf = Ar µ
ε mf φ ε mf φ
ρ f ( ρ p − ρ f )gd p3
Ar =
13
µ2
 Ergun Equation 3/3

• With a packed bed of solids, a known gas flow rates

and a measured pressure drop, the following can be
determined if the others are known
• Sphericity
• Bed voidage fraction or loading
• Sauter mean particle size

Applying the Fundamentals

14
Pressure Drop, ΔP 1/3
! Frictional $ ! Specific Weight $ ! Static $
# &=# &−# &
" Pressure Gradient % " of Suspension % " Head %
! Dynamic $ ! Total $ ! Static $
or, # &=# &−# &
" Pressure Drop % " Pressure Drop % " Pressure Drop %
ΔP
= ρB g − ρ f g
H
ΔP &
∴ = 'ρ P (1− ε ) + ρ f ε () g − ρ f g = (1− ε )( ρ P − ρ f )g
H
In the case of gas-solid fluidization, ρ P >> ρ f
ΔP
⇒ = (1− ε )ρ P g
H
Prove that ΔP = W/A
H ρ P (1− ε )gA mg W
ΔP = H (1− ε )ρ P g = = =
A A A
15
 Pressure Drop, ΔP 2/3
Only for Geldart Group A Materials
ΔP/Lg

Superficial Gas Velocity, Uo

Applying the Fundamentals
16
 Pressure Drop, ΔP 3/3
For Geldart Group B and D Materials
ΔP/Lg

Superficial Gas Velocity, Uo

Applying the Fundamentals
17
 Voidage and Minimum Velocities

Voidage
decrease
occurs because
some of the
Bed Voidage

emulsion gas
“degasses” into
ε1 the bubble
ε2 phase

ε3

Umf1 Umf2 Umf3

Gas Velocity

Applying the Fundamentals

18
 Differential pressure across bed
Minimum Bubbling
Velocity Umb 1/2 umf

• Can determine umb from the

respect to fixed bed height

% bed height change with
fluidization curve but it is not
always straightforward umb
• Better way is to determined umb
from direct bed height
measurements

Applying the Fundamentals

19
Minimum Bubbling Velocity Umb 2/2
• Behavior of bubbles significantly affects
hydrodynamics: solids mixing, entrainment, heat &
mass transfer
• Bubbles formed due to inherent instability in gas-
solid systems
• E æ e mb ö
U mb = çç ÷÷
r p è 3 - 2e mb ø
• Where E is a complex function of structure of packing,
material properties of packing particles, particle size,
particle contact, inter-particle cohesion, etc
• In practice, Umb estimated to be
d p ρ 0.06
U mb = 2.07 exp ( 0.716m f ) 0.347f

µ
• Where mf = mass fraction of fine powder < 45 μm

20
 Bubble Size 1/3

• Bubble size is dependent on particle size

• The bigger the particles, the bigger the bubbles
• Geldart Group A powders tend to have bubbles on the order of 2 to 5
cm
• Geldart Group B powders can have bubbles on the order of meters

Applying the Fundamentals

21
 Bubble Size 2/3
• In ambient bubbling fluidized beds and low velocity conditions
whereby db é as U é (Mori & Wen, 1975)
• Volume diameter of bubble diameter averaged over a cross-sectional area of the bed
• " H%
db = dbm − ( dbm − dbi ) exp $−0.3 '
# D&
• Valid for U - U mf < 0.48 m/s, 0.3m < D < 1.3m, and 60 µm < d p < 450 µm
• H = vertical distance from distributor; dbi = initial bubble size at distributor;
dbm = maximum bubble size
• & −0.2 "
0.4
$
( 1.38g # d(
A U −U mf )% for perforated plates
dbi = '
( 0.376 (U −U mf )2 for porous plates
)
• Ad = distributor plate area per orifice

• [
dbm = 1.49 D 2 (U - U mf )] 0.4

• Darton et al. (1977), for free bubbling beds without slugging and
maximum stable bubble size
d b = 0.54(U - U mf )
0.4 0.8 - 0.2
(H + 4 Ad ) g
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 Bubble Size 3/3
• At high gas velocity condition and/or elevated pressures, bubble size
may not always increase with the gas velocity
• Cai et al. (1994):
! p$
0.06 ) ! $
2 ,
0.42 p 2 p
0.8
db = 0.38H # &
" pa %
(U −U )
mf exp +−1.4 ×10 # & − 0.25 (U −U mf ) − 0.1 (U −U mf ).
+*
−4

" pa % pa .-
• Valid for 0.1 MPa < p < 7.1 MPa, Group B and smaller Group D particles
• Volume diameter of bubbles averaged over entire bed:
Hf
• 1
d bb =
Hf ò d dH
0
b

• For a single spherical cap bubble in infinite medium (db/D < 0.125)
• Davies & Taylor (1950) U = 0.71 gd
b¥ b¥

• In the bubbling bed, average bubble rise velocity (Davidson &

Harrison, 1963): U bb = U - U mf + 0.71 gd bb
• Term U - Umf added to account for multiple bubble effects

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 Expanded Bed Height, Hf 1/2

• Hf = Hem + Hbubble
• Hf = total expanded bed height caused by both emulsion phase and
bubbles
• Useful for reactor height design
• Hem = expanded bed height caused by emulsion phase
• Hbubble = expanded bed height caused by bubbles

Hbubble
Hf
Hemulsion

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 Expanded Bed Height, Hf 2/2
• Bed expansion due to (i) emulsion phase expansion and (ii)
presence of bubbles
• For emulsion phase expansion of Group A, assuming no velocity
effect on Hem, Abrahamsen & Geldart (1980):
• H 2.54 ρ 0.016 0.066
µ exp ( 0.09m f ) mf = mass fraction of particles < 45 μm
em f
= 0.118
H mf 0.1 0.118
dp g ( ρ p − ρ f ) H mf0.043
• At ambient temperature, Babu et al. (1978):
0.738
• 0.05 < dp < 2.87 mm; 257 < ρp < 3928 kg/m3 Hf 14.3 (U −U mf ) d 1.006
p ρ 0.376
p
= 1+
• 0.1 < P < 7.0 MPa H mf 0.937
U mf ρ f 0.126

• At high temperature (< 1258 K), Cai et al. (1993):

• Hf
= 1+
(
21.4 U - U mf )
* 0.738
d 1p.006 r 0p.376 wg= molecular weight of gas;
0.126 Umf*=Umf at ambient temperature
H mf æ pö
(U ) * 0.937
mf
çç wg ÷÷
pa ø
è 25
 Slugging Fluidization 1/6

• Bubbles can get very large for Geldart Group B

and D particles

Applying the Fundamentals

26
 Slugging Fluidization 2/6

Bed Diameter

Slugging
• Slugging is where the bubble nearly encompasses the bed
diameter
• Can cause significant amount of bed displacement
• Slugging starts at bubble diameters of 2/3 of the bed diameter
Applying the Fundamentals
27
 Slugging Fluidization 3/6
No Wall
Effects
Until
0.38
Wall Affects
Bubbles
No Wall
Effects Slugging

Diameter of Bed Equivalent diameter of

bubble
• For a single bubble

• However, if bubble gets too large in diameter, the wall can

affect the bubble size and velocity
Applying the Fundamentals
28
 Slugging Fluidization 4/6
• When bubbles grow in sizes comparable to the bed diameter,
slugging occurs.
• Slugging occurs only in beds with ratio of bed height to bed diameter
(H/D) > 2
• Large H/D provides enough time for bubbles to coalesce and grow
• Slugging occurs when bubble diameter ≈ ⅔ D

• Minimum gas velocity for slugging

• Stewart & Davidson, 1967
U msl = U mf + 0.07 gD
for 0.05 < D < 0.3m, 850 < ρ p < 2,800kg / m 3 , 0.055 < d p < 3.38mm

• Minimum bed height for slugging

• Baeyens & Geldart 1974 0.175
H msl =1.34D
for 0.05 < D < 0.3m, 850 < ρ p < 2,800kg / m 3 , 0.055 < d p < 3.38mm
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 Slugging Fluidization 5/6
• Different forms of slugs
• (a) Round-nosed slug: systems of fine particles;
• (b) Wall slug (also known as the half slug): beds with rough walls, large dp/D
ratios, angular particle shapes, and relatively high gas velocities
• (c) Square-nosed slug: appears in coarse particle systems where the particle
bridging effect is significant

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 Slugging Fluidization 6/6
• Rise velocity of single isolated Type (a) slug
• Hovmand & Davidson, 1971:
U sl∞,a = 0.35 gD

• Rise velocity of Type (b) slug: U sl∞, b = 2U sl∞, a

• Rise velocity of Type (c) slug: U sl∞,c < U sl∞,a

• particles will "rain" through the plug continuously àparticles are in a state of
bridging instead of truly fluidizing
• plug rising velocity is then a function of interparticle forces, internal friction of
particles, and gas velocity

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 Turbulent Fluidized Beds 1/2

• Turbulent fluidized beds

• High solid hold-ups
• 25 to 35 vol%
• Limited axial mixing
• Good heat transfer
• Good mass transfer
• Higher solids losses
• Higher attrition

Applying the Fundamentals

32
 Turbulent Fluidized Beds 2/2
• Bed surface less distinct
• The upper surface of the turbulent bed exists but becomes more diffused with a
large concentration in the freeboard
• Small bubbles
• Bubbles split and redisperse frequently and often appear in more irregular
shapes.
• Rigorous bubble movement
• difficult to distinguish the emulsion (continuous) phase from the bubble (discrete)
phase in the bed
• Random bubble motion
• enhanced interphase exchange and hence intimate gas-solid contact and high
heat and mass transfer.

33
 Transition between Bubbling and Turbulent
• If D is large and dp is small, bubbling
regime transitions directly to turbulent
without slugging
• Uc and Uk are characterization velocities
for bubbling-turbulent transition
• Uk > Uc
• Uc = when bubbles or slugs reach their
maximum diameter; largest standard
deviation of pressure fluctuation
• Uk = standard deviation of pressure
fluctuation reaches steady state

34
 Determining Uc 1/2
• Largely empirical correlations
• Uc ê when dp ê or P é or internals present
• Internals induce bubble breakup à magnitude of pressure fluctuation
reduces à smoother operation results à Uc ê

35
 Determining Uc 2/2
• For Group A and B particles within the range of 293 < T < 773 K and
0.1 < P < 0.8 MPa, Cai et al. (1989):
0.27
• 0.2 )
! µ a $ ! ρa $! ρ p − ρ f $! KD f $ ,
Uc
= # & +## &&## &&## &&. Subscript ‘a’ refers to

gd p " µ % +*" ρ f %" ρ f %" d p %.- ambient conditions

• KDf accounts for the effects of the bed geometry and internals
• Without internals and 57 < D < 475 mm 1
æ 0.211 2.42 ´10 -3 ö 0.27
KD f = Dçç 0.27 + 1.27
÷÷
èD D ø

36
 Bubbling vs Turbulent Fluidization
• At low-velocity turbulent regime, bubbling and turbulent
characteristics are similar
• At higher velocity, distinct differences, hence bubbling correlations
do not work for high-velocity turbulent regime.
• Turbulent: Bubble breakup dominant over coalescence; Bubbling: more
balanced
• Turbulent: db ê as U é ; Bubbling: db é as U é
• Similar: db ê as P é (at a constant U or constant U — Umf)
• Turbulent: smaller bubbles, lower rise velocity, longer gas residence
times, higher dense bed expansion

37
 Which regime is better? 1/2

To Bubble

Emulsion Bubbles
From Bubble

Gas in Emulsion Gas in Bubbles

• With heterogeneous reactions, you want your bubbles to be as

small and as slow as possible
Applying the Fundamentals
38
Which regime is better? 2/2

• Although smooth fluidization

has better mass transfer, its
flow rates are too low for
practical applications
• Most commercial fluidized bed
operate under bubbling or
turbulent fluidization regimes

Applying the Fundamentals

39