Study of hydrodynamic characteristics in a circulating fluidized bed gasifier for plastic waste by computational fluid dynamics modeling and simulation

For designing an efficient circulating fluidized bed reactor, understanding the complex hydrodynamic characteristics in the reactor is required. Hence, in the present study, the modeling and simulation of the circulating fluidized bed gasifier using plastic waste were carried out with Eulerian-Granular approach. Several cases were investigated as changing superficial gas velocities or sizes of plastic waste particle. Firstly, cases were examined with four different velocities when the particle diameter is 1 mm. At the gas velocity of 6 or 8 m/s, gas volume fraction is more than 95 % throughout the reactor and particle velocity has positive value overall. Therefore, a circulating fluidized bed seems to be formed in both cases. Comparing those two cases, better solid mixing can be expected considering the mass fraction and solid velocity at the superficial gas velocity of 6 m/s. Thus this case was further studied for the effect of particle size. As the diameters of plastic waste particle are 1 or 3 mm, it is considered that a circulating fluidized bed is formed. And plastic waste and sand particles are well mixed throughout the reactor. However, the particle diameter increases over 3 mm then, it is very hard to maintain circulating fluidization condition.     

Evaluation of waste pyrolysis characteristics in a pressurized fluidized bed reactor

To obtain the distribution of fuel components to gas, tar and char in a pressurized fluidized bed waste pyrolyzer, experiments were conducted with a laboratory scale fluidized bed reactor. Waste samples were fed batchwise from the top of the reactor into the fluidized bed of silica sand and pyrolyzed by nitrogen/nitrogen-O2 gas and the effects of pressure, particle size, heating rate and oxygen addition were investigated. In the case of rubber, the char yield tended to increase a little and the tar yield decrease over the pressure of 304-709 kPa. In comparison with the thermogravimetry data it was clearly demonstrated that the char yield from fluidized bed pyrolysis is much lower. A small amount of oxygen addition decreased both tar and char yields but its further increase did not affect them very much.     

Elutriation characteristics of fine particles from bubbling fluidized bed incineration for sludge cake treatment

In this study, measurements of elutriation rate were carried out in a bench scale bubbling fluidized bed incinerator, which was used to combust sludge cake. The particle size distribution and ignition loss were analyzed to study the elutriation characteristics of bubbling fluidized bed incineration. Drawn from the experimental data, the elutriation rate constant K(i)* for fine particles were obtained and correlated with parameters. It was found that most of the solid particles (about 95%) elutriated came from the fluidized medium (inorganic matters), but few came from unburned carbon particles or soot (about 5%). Finally, this paper lists a comparison of K(i)* between this study and the published prediction equations derived or studied in non-incineration modes of fluidized bed. A new and modified correlation is proposed here to estimate the elutriation rate of fine particles emitted from a bubbling fluidized bed incinerator. Primary operation variables (superficial gas velocity and incineration temperature) affecting the elutriation rate are also discussed in the paper.     

Investigation of hydrogen generation from municipal solid waste incineration fly ash

Hydrogen generation from municipal solid waste incineration fly ash was investigated to understand the influences of contacting method, kinds of contact solution, liquid to solid ratio, and particle size distribution of materials. Redox properties of materials and hydrogen generation were also studied. The largest quantity of gas generated in contact with water was 29.1 ml/g-ash, most of which was hydrogen. Fluidized bed fly ash generated more gas than stoker fly ash. In order to calculate the hydrogen generation potential (the maximum quantity of gas generated in contact with water), a novel system using a Y-shaped test tube and NaOH was utilized. This method gives values which are related to the quantity of generated gas in contact with water. A relationship between the aluminum content and hydrogen generation potential was observed, especially for fluidized bed fly ash. The reducing potential of fluidized bed fly ash was higher than that of stoker fly ash. Only fluidized bed fly ash showed a positive correlation between aluminum content and reducing potential, and between reducing potential and hydrogen generation potential. These results suggest that fluidized bed fly ash contains more Al⁰ than stoker fly ash. Received: September 11, 1998 / Accepted: March 19, 1999     

Tar removal during the fluidized bed gasification of plastic waste

A recycled polyethylene was fed in a pilot plant bubbling fluidized bed gasifier, having an internal diameter of 0.381 m and a maximum feeding capacity of 90 kg/h. The experimental runs were carried out under various operating conditions: the bed temperature was kept at about 850 degrees C, the equivalence ratio varied between 0.2 and 0.35, the amount of bed material was between 131 and 215 kg, the fluidizing velocity was between 0.5 and 0.7 m/s, quartz sand and olivine were used as bed material, and air and steam were used as fluidizing reactants. The results confirm that the tar removal treatments applied inside the gasifier (primary methods) can eliminate or strongly reduce the need for a further downstream cleanup of the syngas. In particular, the utilization of a natural olivine as an in situ tar reduction agent remarkably improves the quality of the product gas, in terms of both high hydrogen volumetric fraction and larger syngas yield.     

The influence of fly ash load and particle size on the formation of PCDD,PCDF, PCBz and PCB in a pilot incinerator

A laboratory-scale, fluidized bed reactor fuelled by a synthetic fuel was used to study the influence of fly ash load, particle size, temperature and residence time on the low-temperature formation of chlorinated aromatic compounds. Large fly ash particles were removed from the flue gases by means of a cyclone at the entrance to the cooling section of the reactor. The experimental variables were varied according to an experimental plan of full factorial design. Polychlorinated dibenzo-p-dioxins, dibenzo-furans, polychlorinated benzenes and biphenyls were analysed in the collected flue gas samples. Despite the fact that most of the fly ash load was removed by the cyclone, formation of chlorinated aromatics occurred to the same extent as in earlier experiments, without the cyclone. These results demonstrate the importance of small fly ash particles in the post-combustion formation of chlorinated aromatics.     

臭氧氧化—包埋菌流化床生物处理组合工艺深度处理煤气化废水

采用臭氧氧化—包埋菌流化床生物处理组合工艺对煤气化废水进行深度处理。实验结果表明：当臭氧的质量浓度20 mg/L、臭氧进气流量1.5 L/min、臭氧通气时间30 min、包埋菌流化床水力停留时间24 h时，臭氧氧化工序的COD去除率达到30.0%~40.0%，总酚去除率达到100.0%；包埋菌流化床工序的COD去除率达到60.0%以上，氨氮的去除率大于95.0%；经组合工艺处理后，出水COD<60 mg/L，ρ（氨氮）<1.0 mg/L，ρ（总酚）未检出，色度小于50倍，达到GB8978—1996《污水综合排放标准》中的一级排放标准。     

Limitations for heavy metal release during thermo-chemical treatment of sewage sludge ash

Phosphate recycling from sewage sludge can be achieved by heavy metal removal from sewage sludge ash (SSA) producing a fertilizer product: mixing SSA with chloride and treating this mixture (eventually after granulation) in a rotary kiln at 1000 ± 100 °C leads to the formation of volatile heavy metal compounds that evaporate and to P-phases with high bio-availability. Due to economical and ecological reasons, it is necessary to reduce the energy consumption of this technology. Generally, fluidized bed reactors are characterized by high heat and mass transfer and thus promise the saving of energy. Therefore, a rotary reactor and a fluidized bed reactor (both laboratory-scale and operated in batch mode) are used for the treatment of granulates containing SSA and CaCl₂. Treatment temperature, residence time and - in case of the fluidized bed reactor - superficial velocity are varied between 800 and 900 °C, 10 and 30 min and 3.4 and 4.6 m s⁻¹. Cd and Pb can be removed well (>95 %) in all experiments. Cu removal ranges from 25% to 84%, for Zn 75-90% are realized. The amount of heavy metals removed increases with increasing temperature and residence time which is most pronounced for Cu.In the pellet, three major reactions occur: formation of HCl and Cl₂ from CaCl₂; diffusion and reaction of these gases with heavy metal compounds; side reactions from heavy metal compounds with matrix material. Although, heat and mass transfer are higher in the fluidized bed reactor, Pb and Zn removal is slightly better in the rotary reactor. This is due the accelerated migration of formed HCl and Cl₂ out of the pellets into the reactor atmosphere. Cu is apparently limited by the diffusion of its chloride thus the removal is higher in the fluidized bed unit.     

High efficiency chlorine removal from polyvinyl chloride (PVC) pyrolysis with a gas–liquid fluidized bed reactor

In this research a gas–liquid fluidized bed reactor was developed for removing chlorine (Cl) from polyvinyl chloride (PVC) to favor its pyrolysis treatment. In order to efficiently remove Cl within a limited time before extensive generation of hydrocarbon products, the gas–liquid fluidized bed reactor was running at 280–320 °C, where hot N₂ was used as fluidizing gas to fluidize the molten polymer, letting the molten polymer contact well with N₂ to release Cl in form of HCl. Experimental results showed that dechlorination efficiency is mainly temperature dependent and 300 °C is a proper reaction temperature for efficient dechlorination within a limited time duration and for prevention of extensive pyrolysis; under this temperature 99.5% of Cl removal efficiency can be obtained within reaction time around 1 min after melting is completed as the flow rate of N₂ gas was set around 0.47–0.85 Nm³ kg^?1 for the molten PVC. Larger N₂ flow rate and additives in PVC would enhance HCl release but did not change the final dechlorination efficiency; and excessive N₂ flow rate should be avoided for prevention of polymer entrainment. HCl is emitted from PVC granules or scraps at the mean time they started to melt and the melting stage should be taken into consideration when design the gas–liquid fluidized bed reactor for dechlorination.     

流化床反应器处理高浓度含氟废水的效率和稳定性

采用小试规模的流化床反应器处理氟质量浓度为500~1 400 mg/L的模拟高浓度含氟废水。以氟化钙颗粒为晶种,以氯化钙溶液为沉淀剂（流量25 L/h）,考察了流化床连续运行过程中沉淀除氟的效率和稳定性。实验结果表明：氟化钙的沉淀反应在30.7 s内即可完成;在废水流量为11~23 L/h、反应pH为7.0~9.0、上升流速为0.005 9~0.013 0 m/s、钙与氟的摩尔比为0.85~1.00的条件下,出水清液中氟质量浓度低于10 mg/L,达到《污水综合排放标准》（GB 8978—1996）要求。连续运行过程中,流化床沉淀除氟高效稳定,操作条件范围较宽。流化床出水中细颗粒沉淀物的存在会导致氟浓度显著升高,应采取有效措施减少其产生或溢出,以保证沉淀除氟效率。     

Thermal valorization of post-consumer film waste in a bubbling bed gasifier

The use of plastic bags and film packaging is very frequent in manifold sectors and film waste is usually present in different sources of municipal and industrial wastes. A significant part of it is not suitable for mechanical recycling but could be safely transformed into a valuable gas by means of thermal valorization. In this research, the gasification of film wastes has been experimentally investigated through experiments in a fluidized bed reactor of two reference polymers, polyethylene and polypropylene, and actual post-consumer film waste. After a complete experimental characterization of the three materials, several gasification experiments have been performed to analyze the influence of the fuel and of equivalence ratio on gas production and composition, on tar generation and on efficiency. The experiments prove that film waste and analogue polymer derived wastes can be successfully gasified in a fluidized bed reactor, yielding a gas with a higher heating value in a range from 3.6 to 5.6 MJ/m³ and cold gas efficiencies up to 60%.     

Batch separation of shredded bulky waste by gas-solid fluidized bed at laboratory scale

A gas-solid fluidized bed separator using various bed materials was used to separate shredded municipal bulky waste (SBW). Using 290 microm glass beads as the bed material, the apparent density of the fluidized bed was 1.5 g/cm(3) and the SBW could be separated into combustibles such as wood, paper and plastics and incombustibles such as metals and glass. The overall efficiency (Newton's efficiency) of the separation was calculated to be 0.93. In order to obtain high efficiency, the superficial velocity must be adjusted so that the fluidized bed is agitated moderately and at the same time there is no weak fluidized region. Using a mixture of particles of nylon shot and 68 microm glass beads, the apparent density of the fluidized mixture bed could be varied between 0.63 and 0.99 g/cm(3) by changing the mixing ratio of the two materials. In the case of a mixing ratio of 20% for glass beads, an apparent density of 0.65 g/cm(3) was produced, in which wood and paper components were recovered while plastics remained in the bed to give a final overall efficiency of 0.88.     

Element associations in ash from waste combustion in fluidized bed

The incineration of MSW in fluidized beds is a commonly applied waste management practice. The composition of the ashes produced in a fluidized bed boiler has important environmental implications as potentially toxic trace elements may be associated with ash particles and it is therefore essential to determine the mechanisms controlling the association of trace elements to ash particles, including the role of major element composition. The research presented here uses micro-analytical techniques to study the distribution of major and trace elements and determine the importance of affinity-based binding mechanisms in separate cyclone ash particles from MSW combustion. Particle size and the occurrence of Ca and Fe were found to be important factors for the binding of trace elements to ash particles, but the binding largely depends on random associations based on the presence of a particle when trace elements condensate in the flue gas.     

Mathematical modelling of MSW incineration on a travelling bed

The rising popularity of incineration of municipal solid waste (MSW) calls for detailed mathematical modelling and understanding of the incineration process. In this paper, governing equations for mass, momentum and heat transfer for both solid and gaseous phases in a moving bed in a solid-waste incineration furnace are described and relevant sub-models are presented. The burning rates of volatile hydrocarbons in the moving bed of solids are limited not only by the reaction kinetics but also the mixing of the volatile fuels with the under-fire air. The mixing rate is averaged across a computation cell and correlated to a number of parameters including local void fraction of the bed, gas velocity and a length scale comparable to the particle size in the bed. A correlation equation is also included to calculate the mixing in the freeboard area immediately next to the bed surface. A small-scale fixed bed waste incinerator was built and test runs were made in which total mass loss from the bed, temperature and gas composition at different locations along the bed height were measured. A 2-D bed-modelling program (FLIC) was developed which incorporates the various sub-process models and solves the governing equations for both gases and solids. Thermal and chemical processes are mainly confined within a layer about 5-9 times in thickness of the averaged particle size in the burning bed. For a large part of the burning process, the total mass loss rate was constant until the solid waste was totally dried out and a period of highly rising CO emission followed. The maximum bed temperature was around 1200 K. The whole burning process ended within 60 min. Big fluctuations in species concentration were observed due to channelling and subsequent 'catastrophic' changes in the local bed conditions. Reasonably good agreement between modelling and measurements has been achieved. Yet the modelling work is complicated by the channelling phenomenon in the bed. Numerical simulations without consideration of the channelling effect produced very good agreement with experiments concerning the total mass loss, but significant discrepancy exists for temperature and gas composition profiles. Transient phenomena such as the breaking of waste particles and the "catastrophic" creation of new burning channels occurring during waste incineration is a vital area requiring further investigation at the fundamental level. The underlying theory of bed behaviour must be extended to include these transient events.     

Valorisation of waste tyre by pyrolysis in a moving bed reactor

The aim of this work is to assess the behaviour of a moving bed reactor, based on a screw transporter design, in waste tyre pyrolysis under several experimental conditions. Waste tyre represents a significant problem in developed countries and it is necessary to develop new technology that could easily process big amounts of this potentially raw material. In this work, the influence of the main pyrolysis process variables (temperature, solid residence time, mass flow rate and inert gas flow) has been studied by a thorough analysis of product yields and properties. It has been found that regardless the process operational parameters, a total waste tyre devolatilisation is achieved, producing a pyrolytic carbon black with a volatile matter content under 5 wt.%. In addition, it has been proven that, in the range studied, the most influencing process variables are temperature and solid mass flow rate, mainly because both variables modify the gas residence time inside the reactor. In addition, it has been found that the modification of these variables affects to the chemical properties of the products. This fact is mainly associated to the different cracking reaction of the primary pyrolysis products.     

Remediation of petroleum-contaminated soils by fluidized thermal desorption

A novel type of fluidized bed desorber was developed for the remediation of petroleum-contaminated soils at low temperature with high efficiency. Cahn balance® was utilized to investigate the thermal desorption behavior of soils contaminated by various hydrocarbons. The performance of the fluidized-bed desorber was investigated at different operating modes. Batch operation of the fluidized-bed desorber exhibited 99.9% desorption efficiency at temperatures of ca. 300°C within a half hour. Continuous operation of the fluidized-bed indicated that Q/F (the ratio of the mass flow rate of fluidizing gas to feeding rate of contaminated soils) is less important at higher temperature (>300°C), if proper fluidization is ensured. The periodic operation of the fluidized bed desorber shows the possibility to reduce off-gas volume significantly.     

Co-combustion of agricultural residues with coal in a fluidized bed combustor

Power generation from biomass is an attractive technology that utilizes agricultural residual waste. In order to explain the behavior of biomass-fired fluidized bed incinerator, biomass sources from agricultural residues (rice husk and palm kernel) were co-fired with coal in a 0.15m diameter and 2.3m high fluidized bed combustor. The combustion efficiency and carbon monoxide emissions were studied and compared with those for pure coal combustion. Co-combustion of a mixture of biomass with coal in a fluidized bed combustor designed for coal combustion increased combustion efficiency up to 20% depending upon excess air levels. Observed carbon monoxide levels fluctuated between 200 and 900 ppm with the addition of coal. It is evident from this research that efficient co-firing of biomass with coal can be achieved with minimal modifications to existing coal-fired boilers.     

钡渣用于三相流化床烟气脱硫

提出了在三相流化床内用钡渣进行烟气脱硫的方法。分析了钡渣湿法脱硫原理，并进行了工艺改进实验，对两种不同溶渣方式工艺进行了静态和动态模拟实验，考察了两种方式的离子浓度和吸收容量等因素。实验表明，将渣先和水混合再用脱硫废水调整水质、脱硫塔进水pH在7．5左右时有利于系统的稳定运行。当液气比为2．88、气速为9．5m／s时，脱硫效率可以达到85％以上。这种方法可大大降低脱硫成本，实现以废治废。     

Waste tyre pyrolysis: Modelling of a moving bed reactor

This paper describes the development of a new model for waste tyre pyrolysis in a moving bed reactor. This model comprises three different sub-models: a kinetic sub-model that predicts solid conversion in terms of reaction time and temperature, a heat transfer sub-model that calculates the temperature profile inside the particle and the energy flux from the surroundings to the tyre particles and, finally, a hydrodynamic model that predicts the solid flow pattern inside the reactor. These three sub-models have been integrated in order to develop a comprehensive reactor model. Experimental results were obtained in a continuous moving bed reactor and used to validate model predictions, with good approximation achieved between the experimental and simulated results. In addition, a parametric study of the model was carried out, which showed that tyre particle heating is clearly faster than average particle residence time inside the reactor. Therefore, this fast particle heating together with fast reaction kinetics enables total solid conversion to be achieved in this system in accordance with the predictive model.