
Fluidization (or fluidisation) is a process similar to
liquefaction
In materials science, liquefaction is a process that generates a liquid from a solid or a gas or that generates a non-liquid phase which behaves in accordance with fluid dynamics.
It occurs both naturally and artificially. As an example of t ...
whereby a
granular material
A granular material is a conglomeration of discrete solid, macroscopic scale, macroscopic particles characterized by a loss of energy whenever the particles interact (the most common example would be friction when granulation, grains collide). T ...
is converted from a static
solid
Solid is a state of matter where molecules are closely packed and can not slide past each other. Solids resist compression, expansion, or external forces that would alter its shape, with the degree to which they are resisted dependent upon the ...
-like state to a dynamic
fluid
In physics, a fluid is a liquid, gas, or other material that may continuously motion, move and Deformation (physics), deform (''flow'') under an applied shear stress, or external force. They have zero shear modulus, or, in simpler terms, are M ...
-like state. This process occurs when a fluid (
liquid
Liquid is a state of matter with a definite volume but no fixed shape. Liquids adapt to the shape of their container and are nearly incompressible, maintaining their volume even under pressure. The density of a liquid is usually close to th ...
or
gas) is passed up through the granular material.
When a gas flow is introduced through the bottom of a bed of solid particles, it will move upwards through the bed via the empty spaces between the particles. At low gas velocities, aerodynamic
drag on each particle is also low, and thus the bed remains in a fixed state. Increasing the velocity, the aerodynamic drag forces will begin to counteract the gravitational forces, causing the bed to expand in volume as the particles move away from each other. Further increasing the velocity, it will reach a critical value at which the upward drag forces will exactly equal the downward gravitational forces, causing the particles to become suspended within the fluid. At this critical value, the bed is said to be fluidized and will exhibit fluidic behavior. By further increasing gas velocity, the bulk density of the bed will continue to decrease, and its fluidization becomes more intense until the particles no longer form a bed and are "conveyed" upwards by the gas flow.
When fluidized, a bed of solid particles will behave as a fluid, like a liquid or gas. Like
water
Water is an inorganic compound with the chemical formula . It is a transparent, tasteless, odorless, and Color of water, nearly colorless chemical substance. It is the main constituent of Earth's hydrosphere and the fluids of all known liv ...
in a
bucket
A bucket is typically a watertight, vertical Cylinder (geometry), cylinder or Truncation (geometry), truncated Cone (geometry), cone or square, with an open top and a flat bottom that is attached to a semicircular carrying handle (grip), handle ...
: the bed will conform to the volume of the chamber, its surface remaining perpendicular to
gravity
In physics, gravity (), also known as gravitation or a gravitational interaction, is a fundamental interaction, a mutual attraction between all massive particles. On Earth, gravity takes a slightly different meaning: the observed force b ...
; objects with a lower density than the bed density will float on its surface, bobbing up and down if pushed downwards, while objects with a higher density sink to the bottom of the bed. The fluidic behavior allows the particles to be transported like a fluid, channeled through
pipes, not requiring mechanical transport (e.g.
conveyor belt).
A simplified every-day-life example of a gas-solid
fluidized bed would be a hot-air
popcorn popper. The
popcorn kernels, all being fairly uniform in size and shape, are suspended in the hot air rising from the bottom chamber. Because of the intense mixing of the particles, akin to that of a boiling liquid, this allows for a uniform temperature of the kernels throughout the chamber, minimizing the amount of burnt popcorn. After popping, the now larger popcorn particles encounter increased aerodynamic drag which pushes them out of the chamber and into a bowl.
The process is also key in the formation of a
sand volcano and fluid escape structures in
sediment
Sediment is a solid material that is transported to a new location where it is deposited. It occurs naturally and, through the processes of weathering and erosion, is broken down and subsequently sediment transport, transported by the action of ...
s and
sedimentary rock
Sedimentary rocks are types of rock (geology), rock formed by the cementation (geology), cementation of sediments—i.e. particles made of minerals (geological detritus) or organic matter (biological detritus)—that have been accumulated or de ...
s.
Applications
Most of the fluidization applications use one or more of three important characteristics of fluidized beds:
# Fluidized solids can be easily transferred between reactors.
# The intense mixing within a fluidized bed means that its temperature is uniform.
# There is excellent heat transfer between a fluidized bed and heat exchangers immersed in the bed.
In the 1920s, the Winkler process was developed to gasify coal in a fluidized bed, using oxygen. It was not commercially successful.
The first large scale commercial implementation, in the early 1940s, was the
fluid catalytic cracking (FCC) process, which converted heavier
petroleum
Petroleum, also known as crude oil or simply oil, is a naturally occurring, yellowish-black liquid chemical mixture found in geological formations, consisting mainly of hydrocarbons. The term ''petroleum'' refers both to naturally occurring un ...
cuts into
gasoline
Gasoline ( North American English) or petrol ( Commonwealth English) is a petrochemical product characterized as a transparent, yellowish, and flammable liquid normally used as a fuel for spark-ignited internal combustion engines. When for ...
. Carbon-rich "
coke" deposits on the
catalyst
Catalysis () is the increase in rate of a chemical reaction due to an added substance known as a catalyst (). Catalysts are not consumed by the reaction and remain unchanged after it. If the reaction is rapid and the catalyst recycles quick ...
particles and deactivates the catalyst in less than 1
second
The second (symbol: s) is a unit of time derived from the division of the day first into 24 hours, then to 60 minutes, and finally to 60 seconds each (24 × 60 × 60 = 86400). The current and formal definition in the International System of U ...
. The fluidized catalyst particles are shuttled between the fluidized bed reactor and a fluidized bed burner where the coke deposits are burned off, generating heat for the
endothermic
An endothermic process is a chemical or physical process that absorbs heat from its surroundings. In terms of thermodynamics, it is a thermodynamic process with an increase in the enthalpy (or internal energy ) of the system.Oxtoby, D. W; Gillis, ...
cracking reaction.
By the 1950s, fluidized bed technology was being applied to mineral and metallurgical processes such as drying,
calcining
Calcination is thermal treatment of a solid chemical compound (e.g. mixed carbonate ores) whereby the compound is raised to high temperature without melting under restricted supply of ambient oxygen (i.e. gaseous O2 fraction of air), generally fo ...
, and sulfide
roasting
Roasting is a cooking method that uses dry heat where hot air covers the food, cooking it evenly on all sides with temperatures of at least from an open flame, oven, or other heat source. Roasting can enhance the flavor through caramelizat ...
.
In the 1960s, several fluidized bed processes dramatically reduced the cost of some important
monomers
A monomer ( ; ''wikt:mono-, mono-'', "one" + ''wikt:-mer, -mer'', "part") is a molecule that can chemical reaction, react together with other monomer molecules to form a larger polymer chain or two- or three-dimensional network in a process called ...
. Examples are the
Sohio process for
acrylonitrile and the oxychlorination process for
vinyl chloride
Vinyl chloride is an organochloride with the formula H2C =CHCl. It is also called vinyl chloride monomer (VCM) or chloroethene. It is an important industrial chemical chiefly used to produce the polymer polyvinyl chloride (PVC). Vinyl chloride is a ...
. These chemical reactions are highly exothermic and fluidization ensures a uniform temperature, minimizing unwanted side reactions, and efficient heat transfer to cooling tubes, ensuring high productivity.
In the late 1970s, a fluidized bed process for the synthesis of
polyethylene
Polyethylene or polythene (abbreviated PE; IUPAC name polyethene or poly(methylene)) is the most commonly produced plastic. It is a polymer, primarily used for packaging (plastic bags, plastic films, geomembranes and containers including bott ...
dramatically reduced the cost of this important
polymer
A polymer () is a chemical substance, substance or material that consists of very large molecules, or macromolecules, that are constituted by many repeat unit, repeating subunits derived from one or more species of monomers. Due to their br ...
, making its use economical in many new applications. The polymerization reaction generates heat and the intense mixing associated with fluidization prevents hot spots where the polyethylene particles would melt. A similar process is used for the synthesis of
polypropylene
Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is produced via chain-growth polymerization from the monomer Propene, propylene.
Polypropylene belongs to the group of polyolefin ...
.
Currently, most of the processes that are being developed for the industrial production of
carbon nanotubes
A carbon nanotube (CNT) is a tube made of carbon with a diameter in the nanometre range (nanoscale). They are one of the allotropes of carbon. Two broad classes of carbon nanotubes are recognized:
* ''Single-walled carbon nanotubes'' (''SWC ...
use a fluidized bed. Arkema uses a fluidized bed to produce 400 tonnes/year of multiwall carbon nanotubes.
A new potential application of fluidization technology is
chemical looping combustion, which has not yet been commercialized.
One solution to reducing the potential effect of
carbon dioxide
Carbon dioxide is a chemical compound with the chemical formula . It is made up of molecules that each have one carbon atom covalent bond, covalently double bonded to two oxygen atoms. It is found in a gas state at room temperature and at norma ...
generated by
fuel combustion (e.g. in
power station
A power station, also referred to as a power plant and sometimes generating station or generating plant, is an industrial facility for the electricity generation, generation of electric power. Power stations are generally connected to an electr ...
s) on
global warming
Present-day climate change includes both global warming—the ongoing increase in global average temperature—and its wider effects on Earth's climate system. Climate change in a broader sense also includes previous long-term changes ...
is
carbon dioxide sequestration. Regular
combustion
Combustion, or burning, is a high-temperature exothermic redox chemical reaction between a fuel (the reductant) and an oxidant, usually atmospheric oxygen, that produces oxidized, often gaseous products, in a mixture termed as smoke. Combustion ...
with
air
An atmosphere () is a layer of gases that envelop an astronomical object, held in place by the gravity of the object. A planet retains an atmosphere when the gravity is great and the temperature of the atmosphere is low. A stellar atmosph ...
produces a gas that is mostly
nitrogen
Nitrogen is a chemical element; it has Symbol (chemistry), symbol N and atomic number 7. Nitrogen is a Nonmetal (chemistry), nonmetal and the lightest member of pnictogen, group 15 of the periodic table, often called the Pnictogen, pnictogens. ...
(as it is air's main component at about 80% by volume), which prevents economical sequestration. Chemical looping uses a
metal
A metal () is a material that, when polished or fractured, shows a lustrous appearance, and conducts electrical resistivity and conductivity, electricity and thermal conductivity, heat relatively well. These properties are all associated wit ...
oxide
An oxide () is a chemical compound containing at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion (anion bearing a net charge of −2) of oxygen, an O2− ion with oxygen in the oxidation st ...
as a solid
oxygen
Oxygen is a chemical element; it has chemical symbol, symbol O and atomic number 8. It is a member of the chalcogen group (periodic table), group in the periodic table, a highly reactivity (chemistry), reactive nonmetal (chemistry), non ...
carrier. These metal oxide particles replace air (specifically
oxygen
Oxygen is a chemical element; it has chemical symbol, symbol O and atomic number 8. It is a member of the chalcogen group (periodic table), group in the periodic table, a highly reactivity (chemistry), reactive nonmetal (chemistry), non ...
in the air) in a combustion reaction with a solid, liquid, or gaseous fuel in a fluidized bed, producing solid metal particles from the
reduction of the metal oxides and a mixture of carbon dioxide and
water vapor
Water vapor, water vapour, or aqueous vapor is the gaseous phase of Properties of water, water. It is one Phase (matter), state of water within the hydrosphere. Water vapor can be produced from the evaporation or boiling of liquid water or from th ...
, the major products of any combustion reaction. The
water
Water is an inorganic compound with the chemical formula . It is a transparent, tasteless, odorless, and Color of water, nearly colorless chemical substance. It is the main constituent of Earth's hydrosphere and the fluids of all known liv ...
vapor is condensed, leaving pure carbon dioxide which can be sequestered. The solid metal particles are circulated to another fluidized bed where they react with air (and again, specifically oxygen in the air), producing heat and
oxidizing
Redox ( , , reduction–oxidation or oxidation–reduction) is a type of chemical reaction in which the oxidation states of the reactants change. Oxidation is the loss of electrons or an increase in the oxidation state, while reduction is ...
the metal particles to metal oxide particles that are recirculated to the fluidized bed combustor. A similar process is used to produce
maleic anhydride
Maleic anhydride is an organic compound with the formula . It is the acid anhydride of maleic acid. It is a colorless or white solid with an acrid odor. It is produced industrially on a large scale for applications in coatings and polymers.
Str ...
through the partial oxidation of n-butane, with the circulating particles acting as both catalyst and oxygen carrier; pure oxygen is also introduced directly into the bed.
Nearly 50% of the silicon in solar cells is produced in fluidized beds.
For example, metallurgical-grade silicon is first reacted to
silane
Silane (Silicane) is an inorganic compound with chemical formula . It is a colorless, pyrophoric gas with a sharp, repulsive, pungent smell, somewhat similar to that of acetic acid. Silane is of practical interest as a precursor to elemental ...
gas. The silane gas is thermally cracked in a fluidized bed of seed silicon particles, and the silicon deposits on the seed particles. The cracking reaction is endothermic, and heat is provided through the bed wall, typically made of graphite (to avoid metal contamination of the product silicon). The bed particle size can be controlled using attrition jets. Silane is often premixed with hydrogen to reduce the explosion risk of leaked silane in the air (see
silane
Silane (Silicane) is an inorganic compound with chemical formula . It is a colorless, pyrophoric gas with a sharp, repulsive, pungent smell, somewhat similar to that of acetic acid. Silane is of practical interest as a precursor to elemental ...
).
Liquid-solid fluidization has a number of applications in engineering The best-known application of liquid-solid fluidization is the backwash of granular filters using water.
Fluidization has many applications with the use of
ion exchange
Ion exchange is a reversible interchange of one species of ion present in an insoluble solid with another of like charge present in a solution surrounding the solid. Ion exchange is used in softening or demineralizing of water, purification of ch ...
particles for the purification and processing of many industrial liquid streams. Industries such as food & beverage, hydrometallurgical, water softening, catalysis, bio-based chemical etc. use ion exchange as a critical step in processing. Conventionally ion exchange has been used in a packed bed where a pre-clarified liquid passes downward through a column. Much work has been done at the University of Western Ontario in London Ontario, Canada on the use of a continuous fluidized ion exchange system, named "Liquid-solid circulating fluidized bed" (LSCFB), recently being called "Circulating fluidized ion exchange" (CFIX). This system has widespread applications extending the use of traditional ion exchange systems because it can handle feed streams with large amounts of suspended solids due to the use of fluidization.
References
External links
UBC Fluidization Research CentreICFAR
{{Authority control
Chemical processes