Modeling and Computational Fluid Dynamics simulation of a bubbling fluidized bed process at different scales

A reliable design and scale-up approach for a bubbling fluidized bed process requires a very detailed model based on the fundamentals of multiphase transport phenomena. The present works address the simulation and scale-up of rather complex gas-solid flow behavior in bubbling beds using Computational Fluid Dynamics (CFD) approach. The CFD model developed in this study which is based on two fluid model was used to optimize the performance and utilized as a scale-up tool for an isothermal and a non-isothermal bubbling fluidized bed process.;For isothermal case, 2-Dimensional and 3-Dimensional simulations of bubbling beds for both PSRI laboratory and large scales fluidized beds using a kinetic theory approach were performed. Our simulation results were validated and refined by comparing them with the laboratory-scale experimental data of PSRI. Then, our modified 2-D and 3-D CFD models were used to predict the large-scale PSRI bubbling fluidized bed performance at different operating conditions. In our 3-D simulations, we used exactly the same bed dimensions and inlet configurations (such as air distributor) as the experimental one to predict the characteristics of gas-solid flow patterns in the PSRI large-scale bubbling fluidized bed. The numerical simulation results compared well with both PSRI large scale experimental data on pressure drop and time-averaged void fraction near the wall, which could be a very good proof for demonstrating the capability of CFD as a tool to be used in the design and scale-up of bubbling fluidized bed systems.;For non-isothermal case, CFD simulations were performed to investigate the characteristics of pharmaceutical particle drying process in bubbling fluidized beds at three different scales (e.g., lab, kilo, and 10-kilo scales). The results of CFD simulation were compared with the experimental data obtained at laboratory-scale (Duquesne University experiments), to validate and refine our CFD model. The modified model was used to simulate the drying of the same material in Abbott laboratory kilo and 10-kilo scale units. This also could be a very good proof for demonstrating the capability of CFD as a tool to be used in the design and scale-up of non-isothermal bubbling fluidized bed processes.