MECHANICAL

OPERATION OF
FLUIDIZATION
 Prepared by:
Prakhar Bhatnagar 23112051
Sarthak Maheshwari 23112063
Samikasha Targotra 23112061
Lokesh Joshi 23112040
Vedant Kumar Sharma 23112076
Katravath Srikanth 23112033
 WHAT IS FLUIDIZATION?

Fluidization (or fluidisation) is a process

similar to liquefaction whereby a granular
material is converted from a static solid-like
state to a dynamic fluid-like state. This
process occurs when a fluid (liquid or gas)
is passed up through the granular material.
Key Characteristics of Fluidization:
• Suspension of Particles: The solid particles become suspended in the
fluid, allowing them to flow and mix freely

• Enhanced Mixing: The fluidized state leads to better mixing and uniform
temperature distribution, making fluidization useful in industrial
applications.

• Increased Contact Surface: The process increases the contact area

between the solid and fluid, improving reaction rates in processes such
as combustion, catalysis, and chemical reactions.
 Conditions for Fluidization
Certain conditions need to be fulfilled for fluidization to occur which are listed as
follows. Note that these are the particle and fluid properties.

• Size and Shape: Uniform, spherical particles are easier to fluidize compared
to
irregularly shaped particles.
• Density: Heavier particles require a higher fluid velocity to achieve
fluidization.
• Cohesiveness: Highly cohesive particles may form clumps and resist
fluidization, leading to issues like channelling.
• Density and Viscosity: A fluid with low viscosity and appropriate density
helps achieve stable fluidization.
• Flow Rate: The flow rate of the fluid should be controlled to reach and
maintain the minimum fluidization velocity without surpassing it significantly
unless desired for a specific process
 Conditions for Fluidization
Pressure and Temperature:
• High-Pressure Systems: Higher pressure can improve fluidization
in gas-solid systems, particularly for processes that require
higher gas densities.
• Temperature: Elevated temperatures can affect both the fluid
properties (e.g., viscosity, density) and particle behavior (e.g.,
thermal expansion, softening).

Bed Height and Diameter:

• Aspect Ratio: The height-to-diameter ratio of the bed impacts
how the particles behave during fluidization. A bed that is too
shallow or too narrow may not fluidize uniformly.
• Packing: The initial packing of the particles affects the pressure
drop and fluid distribution.
MINIMUM FLUIDIZATION VELOCITY

Definition: The minimum fluidization

velocity is the lowest velocity at which
the fluid can lift and suspend the
particles, transitioning the bed from a
fixed state to a fluidized state.

Condition: The upward drag force from

the fluid must be equal to or exceed the
downward gravitational force acting on
the particles.

Factors: ​depends on the particle size,

shape, density, and the viscosity of the
fluid.
 FORMULA:
The minimum fluidization velocity can be calculated using the
Ergun equation for pressure drop in a packed bed and setting it
equal to the weight of the particles. The simplified form is:
 Types of FLUIDIZATION

Fluidization can generally be

classified into two main types:
1. Particulate Fluidization
2. Aggregative (or Bubbling)
Fluidization.

Each type has distinct

characteristics and applications
based on the behavior of
particles and fluid flow.
 Particulate Fluidization

Particulate fluidization is a type of fluidization where particles are

uniformly suspended in a fluid, resulting in a stable and evenly mixed
bed without significant bubbling or clustering. Commonly observed in
liquid-solid systems, although it can also occur in some gas-solid
systems with very fine particles.
Characteristics:
• Mostly occurs in liquid-solid systems
• Uniform suspension, smooth flow
• Moderate mixing, suitable for controlled processes
• Application in Water treatment, catalytic reactions in liquid phase
 Aggregative Fluidization
Aggregative fluidization, also known as bubbling fluidization, occurs
when the fluid flow rate through a bed of solid particles is high
enough to create bubbles or clusters within the bed. This type of
fluidization is typically seen in gas-solid systems, where the gas
moves through the bed with sufficient velocity to form bubbles,
leading to a dynamic, turbulent system.
Characteristics:
• Mostly occurs in gas-solid systems
• Turbulent with bubble formation
• High mixing, suitable for high heat and mass transfer
• Application in Combustion, drying, catalytic cracking, biomass
gasification
Bubbling Fluidization
Bubbling fluidization is a type of fluidized bed behavior where
a gas or liquid passes upward through a granular medium (like
sand, catalyst particles, or other solid particles) at a velocity
that causes the particles to become suspended or "fluidized."

In bubbling fluidization, the gas flow rate is higher than the

minimum fluidization velocity but not so high that it
transitions to turbulent or fast fluidization.
The key characteristics are:

Formation of Bubbles:
Gas bubbles form within the bed, creating regions of high and low
particle density. These bubbles rise through the bed, much like
bubbles in a liquid.

Solid Particle Behavior:

The particles in the bed move and mix as the bubbles pass
through, resulting in a well-mixed system. However, some
regions may remain stationary or less active compared to the
bubbles.
Advantages:
• Excellent heat and
mass transfer due
to intense mixing .
• Uniform
temperature
distribution within
the bed.
• Flexibility in
handling particles
of diff erent sizes
 EXPANSION OF FLUIDIZED BEDS
With both types of fluidization the
bed expands as the superficial
velocity increases, and since the
total pressure drop remains
constant, the pressure drop per
unit length decreases as e
The expansion
increases. of a fluidized
bed is a key factor in
understanding and
controlling the behavior of
the system. By adjusting
parameters like gas velocity,
particle size, and bed
geometry, the expansion can
be optimized for specific
industrial applications,
 Particulate
fluidization
For particulate fluidization the expansion is uniform, and the Ergun
equation, which applies to the fixed bed, might be expected to hold
approximately for the slightly expanded bed. Assuming the flow
between the particles is laminar.
now is the independent variable
the dependent
variable to Vo for values
is proportional
greater than
The expanded bed height may be obtained from and the values of L and
at incipient fluidization, using the equation
 Data for the
• fluidization
of small glass beads (510
micrometer) in water.

the pressure drop depends partly on the kinetic energy of the fluid,
and a greater increase in is needed to offset a given percentage
increase in V0.

Eqn-
1
Data for two sizes of glass beads are plotted in Fig. 7.12, and although the
data do not fit Eq. 1 exactly, a straight line is adequate for engineering
estimates of the bed expansion. Data from many investigations show that
the slopes of such plots vary from about 0.22 in the laminar region to 0.4
at high Reynolds numbers.
These slopes equal 1/m. A correlation for m given by Leva is shown in
Fig. 7.13. To predict the bed expansion, In is estimated using the
Reynolds number at the minimum fluidization velocity, and Eq. (7.59) is
applied directly or in ratio form. An alternate method is to determine
and ut, and draw a straight line on a plot such as Fig.7.12.
 Applications of Fluidization
• Petroleum Industry: Initially used for fluid-bed
catalytic cracking in petroleum refining. Fluidization is
used in catalytic cracking to maximize the contact
between the catalyst particles and the hydrocarbon
gases. Nowadays, catalyst regeneration happens in
large fluid-bed reactors, reaching diameters of up to 30
feet.
• Other Applications:
⚬ Fluidization is used in other catalytic processes,
such as the synthesis of acrylonitrile, and for
carrying out solid-gas reactions.
⚬ Fluidized-bed combustion is explored to reduce
boiler costs and pollutant emissions.
⚬ Fluidized beds are also used for roasting ores,
drying fine solids, and adsorption of gases.
 Advantages and Disadvantages of
Fluidization
Advanta Disadvanta
ges • ges
Most gas forms bubbles, directly
• Fluid passing through the bed contacting only a thin shell of solid
agitates the solid vigorously. (the bubble cloud).
• Excellent mixing of solids, • Lower overall gas reactant
eliminating temperature gradients, conversion than in ideal plug-flow
even in exothermic/endothermic reactors.
reactions.
• Bubble size and axial mixing may
• The motion of solids ensures vary with vessel diameter, leading
efficient heat transfer to vessel to scale-up uncertainty.
walls or cooling tubes in the bed.
• Vessel internals may experience
• The fluidized state allows easy erosion, and solids may suffer
transfer of solids between vessels. attrition, requiring proper design
 CONTINOUS
FLUIDIZATION
CONTINUOUS FLUIDIZATION OCCURS WHEN THE FLUID VELOCITY THROUGH A
BED OF SOLID PARTICLES REACHES A LEVEL WHERE ALL PARTICLES ARE LIFTED
AND TRANSPORTED BY THE FLUID FLOW. IN THIS STATE, THE PARTICLES ARE NO
LONGER JUST SUSPENDED BUT ARE CONTINUOUSLY CARRIED ALONG WITH THE
FLUID, ACHIEVING A STEADY MOVEMENT.

KEY
POINTS
Continuous fluidization
Fluid Velocity: provides efficient
The velocity This principle is
transport, minimizes
must be high mainly used to
enough to the risk of clogging, and
transport solid
overcome the can be advantageous
weight of the particles in industrial for uniform mixing and
particles and processing plants. rapid heat and mass
entrain them
in the fl uid. transfer.
 Hydraulic or Slurry Transport
Slurry transportation is the process of moving a
mixture of solids and water, called a slurry, through a
pipeline.

Mechanism: In slurry transport, small particles (less than

50 μm) are easily suspended in a moving liquid, while
larger particles (over 0.25 mm) require greater velocity to
remain suspended, especially in horizontal pipes.

Critical Velocity (vc): Below this velocity, particles settle

out of suspension. The critical velocity depends on factors
like the density difference between the solids and liquid,
particle size, slurry concentration, and pipe size.
 pneumatic conveying
In pneumatic conveying systems, gas
(usually air) moves solid particles through
pipes at high velocities, typically between
15 and 30 m/s. Pneumatic systems are
designed as either negative-pressure
(vacuum) systems or positive-pressure
systems, each serving distinct purposes
Pneumatic conveying
based on intake systems
and delivery use a pressure differential
requirements.
to move materials through pipelines. The air is drawn
from a storage unit and the pressure created when the
air is drawn into an enclosed space moves the materials.

Pneumatic conveying works best with fine, dry powders

that can easily “fly” through the conveying line. Typical
materials include flour, cement powder, carbon black,
sugar, plastic pellets, and small food particles
Key Concepts of Pneumatic Conveying
• System Types:
⚬ Vacuum (Negative-Pressure) Systems: Used for transporting solids
from multiple points to a single delivery point, with a solid-to-gas
mass ratio typically below 5.
⚬ Positive-Pressure Systems: Suitable for conveying from a single
intake to multiple delivery points, using a blower or compressor
that supplies air (or sometimes nitrogen) at pressures from 1 to 5
atm. This setup allows for a higher solids-to-gas ratio than vacuum
systems, and closed systems may recycle the gas to reduce costs
or control emissions.
Key Concepts of Pneumatic Conveying
• Critical Velocity:
In vacuum systems, the critical velocity can be calculated with an
formula:

where Dp is the diameter of the largest particle to be conveyed and the

units are in meter-kilogram-second (MKS) for consistency.
• Pressure Drop and Energy Requirements:
The pressure drop required to pass air alone through a pneumatic
conveying system is small, but it is greatly augmented when additional
energy must be supplied to lift and move the solids. The additional
energy is given by a mechanical energy balance :
where r = mass ratio of solids
to gas Vsa = velocity of solids
at inlet
Vsb = velocity of solids at
outlet
 Key Concepts of Pneumatic Conveying
Bernoulli Equation for Pneumatic Conveyors:
• Simplifying the Bernoulli equation for a nearly incompressible air flow, the
pressure drop across the system
(Pa -Pb) accounts for elevation changes, solid velocities, and frictional
losses:
r is the mass ratio of solids to gas,
V is the velocity of solids,
ρ and ρs are the densities of gas
and solids
hf​represents frictional losses.

The problem of simultaneous flow of two phases is complex, and the friction
loss can rarely be calculated with high accuracy. it’s often a minor component
compared to the energy needed for lifting and accelerating solids. The
equation above typically provides a reliable estimate of total pressure drop.
Thank YOU