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Abstract <p>Reactors with a fluidized bed of catalysts are used in many industries, particularly oil refining, coal gasification, petrochemistry, etc. It is known that in order to prevent the entrainment of the catalyst, the reactors are equipped with devices of particle-capture systems, i.e., cyclones. However, there are significant disadvantages, particularly the removal of the catalyst. The paper proposes to reduce catalyst losses in a fluidized bed reactor by replacing cyclones with separation devices with arc-shaped elements. The article presents the design of the proposed separator. The principle of its operation is described. It is shown that under the action of inertial and centrifugal forces, particles are knocked out of the gas–dust flow towards the arc-shaped elements. In the course of numerical studies conducted in the Ansys Fluent software package, it is found that at relatively low speeds up to 1 m/s, a high separator efficiency of more than 69.2% is achieved. At a gas–dust flow velocity of more than 1 m/s, two critical particle sizes are identified, which correspond to maximum and minimum efficiency. At a gas–dust flow velocity of 2 m/s, the value of <i>a</i><sub>cr.1</sub> = 52.4 µm (<i>E</i> = 99.9%), <i>a</i><sub>cr.2</sub>&#xa0;= 138 µm (<i>E</i> = 63.7%). At a gas–dust flow velocity of 3 m/s, the value of <i>a</i><sub>cr.1</sub> = 52.4 µm (<i>E</i>&#xa0;= 99.9%), <i>a</i><sub>cr.2</sub> = 138 µm (<i>E</i> = 25.7%). As the particle size increases to <i>a</i><sub>cr.1</sub>, the efficiency increases, since the particles can be better knocked out of the structured flow. With a particle size between <i>a</i><sub>cr.1</sub> and <i>a</i><sub>cr.2</sub> the particles bounce off the arc-shaped elements back into the current and are carried away. When the particle size is more than <i>a</i><sub>cr.2</sub>, they randomly bounce off different arc-shaped elements and fall into the hopper due to gravity. The pressure loss in the separator is less than 58 Pa at a gas–dust flow rate of less than 1 m/s. The use of separators with arc-shaped elements in fluidized bed reactors to capture catalyst particles as an alternative to cyclone separators is an appropriate measure that significantly reduces catalyst losses.</p>

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Separation Device with Arc-Shaped Elements for Capturing Catalyst Particles in a Fluidized Bed Reactor

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • V. E. Zinurov,
  • E. I. Salakhova,
  • A. V. Dmitriev,
  • A. F. Ziangirov,
  • A. M. Muginov

摘要

Abstract

Reactors with a fluidized bed of catalysts are used in many industries, particularly oil refining, coal gasification, petrochemistry, etc. It is known that in order to prevent the entrainment of the catalyst, the reactors are equipped with devices of particle-capture systems, i.e., cyclones. However, there are significant disadvantages, particularly the removal of the catalyst. The paper proposes to reduce catalyst losses in a fluidized bed reactor by replacing cyclones with separation devices with arc-shaped elements. The article presents the design of the proposed separator. The principle of its operation is described. It is shown that under the action of inertial and centrifugal forces, particles are knocked out of the gas–dust flow towards the arc-shaped elements. In the course of numerical studies conducted in the Ansys Fluent software package, it is found that at relatively low speeds up to 1 m/s, a high separator efficiency of more than 69.2% is achieved. At a gas–dust flow velocity of more than 1 m/s, two critical particle sizes are identified, which correspond to maximum and minimum efficiency. At a gas–dust flow velocity of 2 m/s, the value of acr.1 = 52.4 µm (E = 99.9%), acr.2 = 138 µm (E = 63.7%). At a gas–dust flow velocity of 3 m/s, the value of acr.1 = 52.4 µm (E = 99.9%), acr.2 = 138 µm (E = 25.7%). As the particle size increases to acr.1, the efficiency increases, since the particles can be better knocked out of the structured flow. With a particle size between acr.1 and acr.2 the particles bounce off the arc-shaped elements back into the current and are carried away. When the particle size is more than acr.2, they randomly bounce off different arc-shaped elements and fall into the hopper due to gravity. The pressure loss in the separator is less than 58 Pa at a gas–dust flow rate of less than 1 m/s. The use of separators with arc-shaped elements in fluidized bed reactors to capture catalyst particles as an alternative to cyclone separators is an appropriate measure that significantly reduces catalyst losses.