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Ocean Engineering 125 (2016) 203–213

Contents lists available at ScienceDirect

Ocean Engineering
journal homepage: www.elsevier.com/locate/oceaneng

Stability of vertical hydraulic transport processes for deep ocean


mining: An experimental study
J.M. van Wijk a,n, A.M. Talmon b,c, C. van Rhee b
a
IHC MTI, Smitweg 6, Kinderdijk 2961 AW, Netherlands
b
Faculty of Mechanical, Maritime and Materials Engineering, Section of Dredging Engineering, Mekelweg 2, Delft 2628 CD, Netherlands
c
Deltares, PO Box 177, Delft 2600 MH, Netherlands

art ic l e i nf o a b s t r a c t

Article history: Vertical hydraulic transport systems for deep ocean mining have lengths up to a few kilometers from
Received 27 May 2015 seafloor to sea surface. Typical ratios of particle diameter d over riser diameter D are d/D = O(10−1), and
Received in revised form the feeding of the riser is irregular. These conditions make the vertical transport operation susceptible to
9 May 2016
propagating density waves which is detrimental for the transport process. There is however few ex-
Accepted 17 August 2016
perience with hydraulic transport on this scale.
We adopt a continuum description of the transport process and use stability analysis theory from the
Keywords: field of fluidization technology. We indicate the similarities and differences between fluidization and
Vertical hydraulic transport vertical hydraulic transport to show that the theory can be extended to transport conditions as well.
Density waves
We demonstrate the applicability of the theory with a fluidization experiment using particles having
Stability analysis
d/D ≤ 0.26 , which is an extension of the d/D range in classic hindered settling theory. Our transport
Flow assurance
experiment with similar particles shows differences with the fluidization experiments, indicating that
flow stability in vertical transport might actually improve compared to fluidization.
& 2016 Published by Elsevier Ltd.

1. Introduction plug and loosing particles at the bottom. The plug flow is asso-
ciated with system instability, i.e. the density waves might actually
In deep ocean mining, the vertical hydraulic transport of grow and form large solid plugs. It is expected that similar regimes
polymetallic nodules or large rock cuttings is a key process. With can also occur in vertical transport systems. The occurrence of the
d/D = O(10−1) (particle diameter d, riser diameter D), relative par- plug flow regime in a vertical transport system will be detrimental
ticle sizes found in this industry exceed the conventional hydraulic for the operation, so this regime should be avoided.
transport parameter range by far. Different transport modes or In his review article, Di Felice (1995) reports on 26 liquid-solid
regimes are very likely to occur, so knowledge of these regimes is fluidization experiments from the period 1948–1991 in 10 of
essential for design and operation of vertical transport systems. which void waves or plugs have been observed. In a fluidized bed
Since there is a strong analogy between vertical hydraulic trans- plugs thus are a quite common feature. Studies in the field of
port and fluidization technology, we will use the latter as a starting fluidization technology that focus on stability criteria for fluidized
point for this research. beds are for instance Verloop and Heertjes (1970),Foscolo and
In fluidization theory, two extreme regimes are discerned. Gibilaro (1984,1987), Batchelor (1988) and Nicolas et al. (1994).
There is the state of homogeneous fluidization on one side, where Only few researchers however have addressed the problem of plug
all particles in the fluidized bed are homogeneously distributed, flow occurring in transport systems.
and there is the plug flow regime on the other side of the spec- The vertical transport of large particles (manganese nodules)
trum. In the plug flow regime, particles move through the fluidi- has been studied by amongst others (Clauss, 1971; Engelmann,
zation column as density waves, collecting particles on top of the 1978; Xia et al., 2004) and (Yang et al., 2011), but only the latter
shows a photograph of different flow regimes. Research at IHC MTI
in 2008, in which mono-disperse mixtures of glass beads were
n
Corresponding author. transported in a vertical water flow, showed the occurrence of
E-mail addresses: JM.vanWijk@mtiholland.com (J.M. van Wijk), plugs that propagated through the riser ( D = 100 mm ) as waves
A.M.Talmon@tudelft.nl, arno.talmon@deltares.nl (A.M. Talmon),
C.vanRhee@tudelft.nl (C. van Rhee).
with a very large volume fraction. The density waves seemed to be
URLS: http://www.royalihc.com (J.M. van Wijk), http://www.deltares.nl, dependent on particle properties. Especially the larger particles
http://www.tudelft.nl/ (A.M. Talmon), http://www.tudelft.nl (C. van Rhee). (d > 20 mm) showed propagating plugs. These experiments

http://dx.doi.org/10.1016/j.oceaneng.2016.08.018
0029-8018/& 2016 Published by Elsevier Ltd.
204 J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213

Nomenclature [Pa/m]
kr Coefficient in dynamic wave velocity equation, Eq. (4)
a Empirical coefficient, Eq. (21) [ ] [m2/s2]
A Cross section area [m2] ke Coefficient in dynamic wave velocity equation, Eq. (4)
Ap Particle projected area [m2] [ ]
Ar Archimedes number [  ] λ Linear volume fraction of solids [  ]
b Empirical coefficient, Eq. (21) [ ] ms Mass of solids in an experiment [kg]
cv Volume fraction of solids [–] μf Dynamic fluid viscosity [Pa s]
cvd Delivered volume fraction of solids [  ] n Richardson and Zaki index, Eq. (7) [ ]
c v, h High volume fraction of solids in a shock [  ] N Number of frames [  ]
c v, l Low volume fraction of solids in a shock [  ] ρf Fluid density [Kg/m3]
cv,0 Initial volume fraction of solids [ ] ρs Solids density [Kg/m3]
cv, max Maximum volume fraction of solids [ ] Rep Particle Reynolds number [  ]
d Particle diameter [m] Rep, tr Particle Reynolds number at regime transition [ ]
D Pipeline inner diameter [m] τf Fluid phase wall shear stress [Pa]
E Modulus of elasticity [Pa] τs Solid phase wall shear stress [Pa]
F Solids flux [m/s] vd Dynamic wave velocity [m/s]
FB Buoyancy force [N] vf Fluid velocity [m/s]
FD Drag force [N] vfront Front velocity of a plug [m/s]
FF Friction force [N] vf , fl Fluid velocity at fluidization [m/s]
FG Gravity force [N] vf , tr Fluid velocity at regime transition [m/s]
g Gravitational acceleration [m/s2] vk Kinematic wave velocity [m/s]
h0 Initial batch height [m] vk, s Shock front velocity [m/s]
h Batch height [m] vm Mixture velocity [m/s]
it Total hydraulic gradient [Pa/m] vs Solids velocity [m/s]
if Hydraulic gradient due to fluid phase wall friction [Pa/ vslip Slip velocity between solids and fluid [m/s]
m] Vp Particle volume [m3]
is Hydraulic gradient due to solid phase wall friction [Pa/ wt Terminal settling velocity of a single particle [m/s]
m] wt , a Terminal settling velocity of a single particle including
is, s Hydraulic gradient due to static weight of solid phase the influence of wall friction [m/s]

motivated us to conduct more experiments, which are reported in The occurrence of propagating plugs would be a serious risk for
this paper. the hydraulic transport operation as they can result in riser
Yang et al. (2011) conducted hydraulic lifting experiments in a blockage. This problem has not got much attention so far, while
setup of 30 m high and 200 mm in diameter. They provide pictures instabilities in fluidized beds have been investigated thoroughly.
showing plugs similar to those observed in the IHC MTI laboratory Therefor we start our analysis of the problem by a review of lit-
in 2008, but no information is given on the demarcation of the erature on fluidization, and from there we take the step to the
different regimes. It is however clear from these experiments that occurrence of plug flow in vertical hydraulic transport. When the
particles with d/D = O(10−1) typically show the plug flow conditions at which plugs occur are known, the design of vertical
behaviour. hydraulic transport systems can be optimized for flow stability. To
Propagating plugs have been studied more thoroughly in the this end, first a continuum model is presented to find a theoretical
field of vertical pneumatic conveying. Niederreiter and Sommer description of the propagation of disturbances through a riser.
(2004) developed a sensor for measuring the forces on pneuma- Then fluidization experiments and transport experiments are
tically conveyed plugs of solids. Their experimental facility has a presented in which the propagation velocities of disturbances are
transparent vertical pipe with D = 50 mm , in which plastic beads measured and compared with theory. Based on these results we
with d = 3 mm are transported. Camera stills given in their paper discuss the stability of the internal flow in vertical transport
display the propagation of a plug very similar to those observed in systems.
our experiments in 2008 and those shown in Yang et al. (2011). In
Strauss et al. (2006) experiments with the setup of Niederreiter
and Sommer (2004) are compared with DEM simulations. These 2. Theory
simulations again show plugs being propagated through the riser,
but no analysis is made of possible flow regime transitions. 2.1. Stability of fluidized beds
An extensive analysis of flow regimes and regime transitions
for vertical pneumatic conveying systems and fluidized beds (gas- Di Felice (1995) reports on many unstable liquid-solid fluidized
solid, liquid-solid) is given by Rabinovich and Kalman (2011). They beds, in which density waves, plugs, voidage waves etc. were ob-
differentiate between dense phase flow and dilute phase flow. served. The propagation of disturbances has been studied ex-
Within the dense phase flow, one can find the separate plugs and tensively in the literature in an attempt to explain the turbulent
plugs with particle rain, and in the dilute phase flow one finds nature of many fluidized beds, and the sometimes sudden tran-
transport of homogeneous mixtures. The plugs with particle rain sition from highly unstable to almost perfect homogeneous
or density waves are in fact the plugs that are studied by Nie- fluidization.
derreiter and Sommer (2004) and Strauss et al. (2006). For our Much of the work on stability of fluidized beds can be traced
research the regime transition from plug flow to the state of back to Wallis (1969). The essence of his stability theory of flui-
homogeneous flow is important. dized beds is the existence of two types of propagating
J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213 205

disturbances: kinematic waves (with velocity vk ) and dynamic The theory can be summarized as follows. Irrespective of the
waves (with velocity vd ). Kinematic waves are propagating dis- source of a disturbance, the disturbance will propagate through
turbances in a homogeneous fluidized bed (i.e. the propagation of the mixture at a finite velocity, which will be visible as travelling
a local increase in the volume fraction of solids cv ). Dynamic waves regions of large volume fractions of solids. Whether the amplitude
are related to the propagation of a force field. of the disturbance grows or diminishes depends on the properties
The kinematic wave velocity can be found from the solids flux of the mixture. When vd > vk the amplitudes diminish and there is
F (cv ) = cv·vs . The solids flux F is a nonlinear function in cv . It will be stable flow, while for vk > vd amplitudes grow. For assessment of
discussed in detail in Section 2.2. From the solids flux F (cv ) the the stability, simply comparing vd and vk is sufficient. If we want to
kinematic wave velocity for small perturbations can be found know whether a system is extremely unstable or just slightly in
(LeVeque, 1990): unstable, a more detailed analysis can be conducted as outlined in
∂F (cv ) Gibilaro (2001).
vk(cv ) =
∂cv (1)
2.2. A continuum description of particle transport
For dynamic waves to exist, the particle bed should behave like
an elastic medium with modulus of elasticity E . The concept of For the development of density waves we are interested in the
elasticity of a fluidized bed was used by Verloop and Heertjes axial development of the volume fraction of solids, hence the
(1970) to predict the transition from homogeneous to hetero- continuity equation can be simplified to the z direction only, with
geneous fluidization. They employed the stability criterion of z positive upwards (anti-gravity). According to our previous re-
Wallis (1969), which states that a fluidized bed is stable when search reported in Van Wijk et al. (2014), for inert (in this case
vd > vk and unstable when vd < vk . The main challenge in the work relatively large) particles the effect of axial dispersion is negligible.
of Verloop and Heertjes (1970) was to find a suitable expression This results in the transport equation for the volume fraction of
for the modulus of elasticity of the bed. They propose an expres- solids cv :
sion for E as a function of the minimum fluidization velocity. Ac-
cording to their calculations, E should be in the order 102 − 104 Pa . ∂cv ∂( cv·vs )
+ =0
In pursuit of a similar criterion for fluidized bed stability, Fos- ∂t ∂z (5)
colo and Gibilaro (1984) introduce the drag force on a particle in
The solids transport velocity vs is given by:
the fluidized bed as a function of the volume fraction of solids in
the bed and particle properties. In this way, they derive the par- vs = vf − vslip (6)
ticle phase pressure gradient ∂p/∂z = E·∂cv/∂z , so that the dynamic 2
In Eq. (6), vf is defined as 4·Q f /(π ·D ) and vslip is the solids slip
wave velocity could be computed as vd = ∂p/∂ρs = E /ρs . The
velocity. The slip velocity of solids in an upward flow of water is
particle phase pressure is due to the hydrodynamic interaction
modelled by Richardson and Zaki (1954):
between particles and fluid, not to be confused with grain stresses.
n
An extensive research program on the dynamics of fluidized beds vslip = 10−d / D ·wt ·( 1 − cv ) (7)
by research groups in Italy and the UK in the period 1984–2001 is
reported in Gibilaro (2001). The factor 10−d / D shown in Eq. (7) proves to be very significant
Foscolo and Gibilaro (1984) give for E : for relatively large solids. Note that in a fluidization experiment it
holds vf = vslip , while the actual particle slip velocity with respect
E = 3.2·g ·d·cv· ρs − ρf( ) (2) to the fluid surrounding the particle is vslip·(1 − cv )−1. The exponent
n depends on the particle Reynolds number:
so that the dynamic velocity is given by:
ρf ·wt ·d
vd = (
3.2·g ·d·cv· ρs − ρf /ρs ) (3)
Rep =
μf (8)
When the solids density and fluid density are of the same order The value of n ranges from n = 2.36 for relatively large particles
of magnitude (which could be the case for practically all relevant to n = 4.7 for relatively small particles. The exponent n is modelled
vertical hydraulic transport processes), the added mass of particles according to Rowe (1987):
should be taken into account. In Gibilaro et al. (1990) the work of
Foscolo and Gibilaro (1984) is extended to yield the following 4.7 + 0.41·Rep0.75
n=
description of the dynamic wave velocity vd : 1 + 0.175·Rep0.75 (9)

vd =
k r ·vf , fl + ( )
k e· 1 + k r − k r ·v2f , fl In Eq. (7), wt is the terminal settling velocity of a single
1 + kr (4) (spherical) particle. It is given by:

4·g ·(ρs − ρf )·d


( )(
The coefficient ke is defined as ke = 2·E / 2·ρs + ρf , with E ) wt =
3·ρf ·CD
given byEq. (2), the coefficient k r is defined as (10)
⎡ ⎤
( ) ( )( )
k r = 3·cv·ρf /⎣ 1 − cv · 2·ρs + ρf ⎦. The superficial velocity in the Typical solid's densities of deep sea deposits are in the range
system in case of fluidization is denoted vf , fl . An important initial 2000 kg/m3 < ρs < 3000 kg/m3. The drag coefficient CD is a function
observation is that inclusion of added mass as in Eq. (4) results in a of Rep as well. Cheng (2009) provides a comparison of eight rela-
smaller vd , which is detrimental for the stability of a fluidized bed. tions for CD(Rep) of spherical particles. Based on his review, the
Several authors have conducted stability analysis of fluidized equation of Brown and Lawler (2003) is used:
beds using the concept of dynamic waves relating to the particle
⎛ ⎞
phase pressure, see for instance (Foscolo and Gibilaro, 1987; 24 ⎜ 0.407
CD = ·⎜ 1 + 0.15·Rep0.681⎟⎟ +
Batchelor, 1988; Nicolas et al., 1994; Johri and Glasser, 2002). Key Rep ⎝ −1
⎠ 1 + 8710·Rep (11)
concept is the actual modelling of the particle phase pressure
because it defines the modulus of elasticity E of the mixture. Having defined the terms in Eq. (6), it can be rewritten to:
206 J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213

n
vs = vf − 10−d / D ·wt ·( 1 − cv ) (12)

Now the solids flux F (cv ) = cv·vs can be defined:


n
F (cv ) = cv·vs = vf ·cv − 10−d / D ·wt ·cv·( 1 − cv ) (13)

And the kinematic wave velocity follows from Eq. (1):


∂F (cv ) n
vk(cv ) = = vf − 10−d / D ·wt ·( 1 − cv )
∂cv
n− 1
+ 10−d / D ·wt ·cv·n·( 1 − cv ) (14)

Foscolo and Gibilaro (1984),Batchelor (1988) and many others


(Di Felice, 1995) use vk = n·wt ·cv·(1 − cv )n − 1 (omitting the factor
10−d / D ). Indeed, in the case of fluidization it holds (by definition)
vf = vslip , so then the first two terms in Eq. (14) cancel.
For n < 3 (which is the case for all glass beads used in our
experiments), Eq. (14) is a monotonically increasing function of cv
up to cv = cv, max . It can be seen that a constant fluid velocity vf only
implies a shift in kinematic wave velocity, or in other words, the
Fig. 1. The solid's contribution to the hydraulic gradient compared with the data of
kinematic wave velocity manifests itself relative to the fluid ve- Xia et al. (2004). The model gives a good estimate of the order of magnitude of
locity. This would be true in the absence of a significant influence frictional losses.
of the riser wall on the solids transport velocity. In that case the
propagation of discontinuities during fluidization and vertical
hydraulic transport are equally comparable. comparable to prototype scale. The data comprise the total hy-
dp 1
When perturbations are larger, the velocity of the front of the draulic gradient it = · = i f + is + is, s : the total gradient is given
dz ρf ·g
perturbation is given by the shock velocity vk, s . If the volume
by the carrier fluid flow gradient i f = 4·τf /D , the static contribution
fraction of the perturbation is denoted cv, h and if the volume
fraction of the mixture (which the shock runs into) is denoted cv, l , ( )
of the solids is, s = ρs − ρf /ρf and the solid's contribution due to
with cv, h > cv, l , then the shock velocity is given by: friction is = 4·τs/D . Fig. 1 shows the measured solids gradient is
compared to the gradient computed with Eq. (17). The delivered
F (cv, h) − F (cv, l )
vk, s = volume fractions of solids cvd as given in the paper
c v, h − c v, l (15) ( cvd = 0.05, 0.1, 0.2 and 0.25) have been corrected for the slip ve-
The envelope of the propagation of disturbances has an upper locity in order to arrive at the actual volume fraction of solids in
limit of vk Eq. (14), a lower limit of vs Eq. (12), and all possible vk, s (
the riser. To this end, the relation cv = cvd/ 1 − wt /vf has been used )
are in between Eq. (15). (Wilson et al., 2006), with wt = 0.71 m/s as reported by Xia et al.
(2004). The corrected volume fractions have been used to obtain
2.3. From fluidization to vertical hydraulic transport the static pressure contribution of the solids is, s . Comparison be-
tween the model of Ferre and Shook (1998) and data of Xia et al.
In order to use the stability criterion for fluidized beds vd = vk , (2004) shows good agreement as can be seen in Fig. 1.
we have to verify that the moving frame of reference (transport To assess the influence of wall friction on the slip velocity, we
versus fluidization) has no significant influence. The interaction calculate the settling velocity wt , a of a spherical particle with an
between the mixture and the riser during transport is evidently additional friction force present. We assume that the wall shear
wall friction, which is absent in the case of fluidization. stress τs as described by Eq. (17) introduces an additional force
The wall shear stress of the mixture is modelled as τm = τf + τs 4·τ
FF = − Vp· c ·Ds acting on the particle. Vp is the particle volume, which
v
(Ferre and Shook, 1998). The fluid wall shear stress is given by:
for a sphere reads Vp = 1/6·π ·d3. In deriving the equation for FF , we
f assume that a single particle is exposed to the pressure gradient
τf = ·ρ ·v2f
8 f (16) dp/dz = 4·τs/D which acts both through the fluid and between
Here, f is the Darcy-Weisbach friction factor which can be particles. The particle component reads dp/dz , the fluid compo-
found with for instance the Moody diagram. The solids shear nent reads 1/cv·dp/dz . The total force on the particle then is given
stress τs can be modelled with Ferre and Shook (1998): by FF = ( ) ( )
∫S 1 − cv /cv·dp/dz·zdS = Vp· 1 − cv /cv·dp/dz . Equilibrium
−0.36 of gravity FG = − Vp·ρs ·g , buoyancy FB = Vp·ρf ·g , drag
⎛ ρ ·v ·d ⎞ ⎛ d ⎞0.99
τs = 0.0214·⎜⎜ s
m ⎟ 1
⎟ ·⎜ ⎟ ·λ1.31·ρs ·vm
2
Fd = Ap ·CD· 2 ·ρf ·wt2, a
and the additional friction force FF , and ela-
⎝ μf ⎠ ⎝ D⎠ (17) boration for the terminal settling velocity with influence of wall
friction wt , a gives:
Note that Eq. (17) uses the mixture velocity vm , which is given
by vm = cv·vs + (1 − cv )·vf . The linear volume fraction of solids is ⎡
−1 wt, a =
4 d ⎢⎛
·

· ⎜⎜ ρs − ρf ⎟⎟·g +
( 1 − cv)4·τs ⎤⎥
(
given by λ = (cv, max/cv )1/3 − 1 ) . Measurement in D = 99.4 mm 3 ρf ·CD ⎢⎣ ⎝ ⎠ c v· D ⎥⎦
(18)
and D = 136.4 mm pipe sections with spherical glass beads in the
range d = 10 − 35 mm have shown that the maximum volume Eq. (18) has a vertical asymptote at cv = 0 which has no physical
fraction of solids takes the value cv, max ≈ 0.6. meaning since wall friction of the solid phase is not present at zero
Xia et al. (2004) report frictional losses of surrogate manganese volume fraction of solids.
nodules in an upward water flow. The nodules have d = 15 mm , In Fig. 2 we show wt , a/wt for
ρs = 2000 kg/m3 and the riser has a diameter D = 200 mm , a scale D = 154 mm, d = 25 mm, vm = 1 m/s, 2 m/s and 3 m/s. As can be
J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213 207

riser and downcomer, through which fresh water is pumped with


a centrifugal pump (Linatex type D4 , with a three bladed im-
peller). The suction side has Dsuc = 100 mm . The pump speed is
controlled with a frequency drive. The pump's outlet is connected
to a flow straightener: a bundle of small pipes suppressing rotation
of the flow. The flow straightener also provides a steel wire grid for
support of the bed of particles.
A transparent riser section is mounted on top of the flow
straightener. Two risers are employed in successive experiments.
The first has an inner diameter of 99.4 mm , with a length of
L = 2.7 m . The second has an inner diameter of 136.4 mm , with a
length L = 3.0 m .
Alongside the riser a large ruler is mounted so the vertical
position of the particles can be monitored. The ruler has a blocked
scale which measures 50 mm per block. On top of the riser, there is
a T-piece with on one end the particle inlet, and on the other end
the exit of the riser towards a buffer tank. The buffer tank contains
Fig. 2. The settling velocity of a particle including the influence of wall friction, Eq. a steel grid to catch the particles. The bottom of the tank is con-
(18), compared with the settling velocity without wall friction, Eq. (10). nected to the downcomer ( D = 150 mm ) that leads to the cen-
trifugal pump's inlet.
seen, wall friction slightly increases the effective settling velocity A flow meter (a Krohne Optiflux 4000 with an inner diameter
(i.e. wt , a/wt > 1), which has a small but stabilizing effect on the of 100 mm ) and a temperature sensor (with a calibrated range of
transport process by increasing vk , see Eq. (14). The maximum  25 °C to 100 °C and an accuracy of 0.1%) are mounted in the
effect is well within 10% increase in slip velocity.
horizontal section before the pump inlet. Temperature fluctuations
In the next sections, the validity of hindered settling theory and
were very small, and an average water temperature of T = 15 °C
the model for the kinematic wave velocity, Eq. (14) will be tested
was measured.
for fluidization of large particles. It will become clear that hin-
A CCD video camera is used to record the fluidization column
dered settling theory gives a reasonable prediction of the relation
between vslip and cv within a certain confidence interval, but it will with a resolution of 720 x 576 and a framerate of 25 fps. All sensors
also become clear that this confidence interval has a large impact are logged with a frequency of 50 Hz .
on the assessment of stability. The transport experiment test setup is a modification of the
fluidization column, see Fig. 3. The grid and flow straightener have
been removed to allow circulation of particles. The flow sensor has
3. Fluidization and transport experiments been relocated to the downcomer, together with a temperature
sensor. The riser section is equipped with a differential pressure
3.1. Test setups sensor with a range Δp = 0 − 160 kPa . The riser has a larger inner
diameter, D = 154 mm . During the experiments the water tem-
The fluidization setup, Fig. 3, consists of a loop with a single perature was about 18 °C.

Fig. 3. Main parts and dimensions of the test setups. The fluidization column has inner diameters 99.4 mm and 136.4 mm (interchangeable section) and the transport
experiment test setup has an inner diameter of 154 mm .
208 J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213

3.2. Test method 4. Results and discussion

A fluidization experiment starts with a packed bed of solid 4.1. Verification of hindered settling theory for large particles
particles on the grid. The batch typically has a mass of about 5 kg .
The initial batch height is measured. In order to assess the flow Upon fluidization, all particles first show plug flow with par-
velocity range needed for each test, the pump is started and the ticle rain, however for the particles with d = 10 mm this was
water velocity is increased slowly until a volume fraction of solids hardly visible. The larger d/D , the more pronounced the plug flow
cv ≈ 0.1 is obtained. The range between the velocity at cv ≈ 0.1 and with particle rain. Ultimately at the end of each test, at the highest
zero velocity then is divided in fifteen to twenty steps typically. For superficial flow velocity, the particle bed was at the onset of par-
a real test, the velocity is increased stepwise, and as a result of the ticle transport with no plugs present. Fig. 4 shows the two main
increased velocity the bed of solids expands. Each newly set ve- regimes encountered in the experiments.
locity is maintained for three minutes, so a new equilibrium can The fluid velocity vf , fl measured at equilibrium is compared
establish. The equilibrium bed height is measured by analysis of with the outcome of Eq. (7) using the measured volume fraction of
the camera recordings. Every frame the height is observed, the solids, Eq. (20). In a fluidization experiment (i.e. no transport of
equilibrium bed height is the average of observed bed heights over particles) vf = vslip holds by definition, see Eq. (6). Note that we use
the timespan of the flow step.
vf , fl to denote the fluid velocity during fluidization. The terminal
The initial volume fraction of solids is determined by measur-
settling velocity wt of a sphere is calculated by iteratively solving
ing the particle's density ρs, the total mass of solids ms and the
Eq. (10) with the drag coefficient given by Eq. (11). The hindered
initial bed height h0. They are related by:
settling exponent n is calculated with Eq. (9).
ms /ρs The comparison of the measured fluid velocities with the cal-
cv,0 =
0.25·π ·D2 ·h0 (19) culated fluid velocities according to hindered settling theory for all
test data is shown in Fig. 5. The lines indicate the ±25% confidence
The relation between the measured bed height h and the interval. There seems to be a minor non-linearity in the data that is
average volume fraction of solids in the riser cv(h) is given by: not covered by the model, e.g. the data show a slightly upward
h0 curve and has an asymmetric preference to the upper side of the
cv(h) = cv,0· vf , measured = vf , modelled line. The mechanism behind this deviation is
h (20)
still matter of debate. Richardson and Zaki (1954) mentioned that
The fluidization experiment primarily provides data relating for d/D > 1/9 their model failed. However, in these tests with
fluid velocity and volume fraction of solids. Next to that we 0.1 < d/D ≥ 0.26, the model seems to properly predict the hin-
measure the kinematic wave velocities associated with the plugs dered settling velocities.
by analysis of the video recordings (Section 4.2). Furthermore we
use the fluidization experiment to determine the transition from
plug flow to homogeneous fluidization, see Section 4.3.
The properties of the particles at test are summarized in Ta-
ble 1. The particles are spherical glass beads. The diameter ratio
d/D is given for D = 99.4 mm and D = 136.4 mm . The water density
at T = 18 °C is ρf = 999 kgm−3, and the water viscosity is
μf = 1.14·10−3 Pa·s.
For the transport experiment we used the d = 24.8 mm parti-
cles from Table 1. Just above the centrifugal pump, there is an
expansion piece from D = 99.4 mm to D = 154 mm pipe. Due to
continuity (i.e. F¼constant), cv increases over the expansion. This
is the main disturbance source in the experiment, inducing kine-
matic waves. We then look at the propagation of this disturbance
over the riser by visual observation and analysis of the camera
recordings.
A transport experiment consists of gradually increasing the
volume fraction of solids in the system by adding more and more
particles while operating the system at a constant fluid velocity.
We tested at several velocities in the range 0 < vf < 2 m/s to verify
that the velocity is independent of the propagation of dis-
turbances. The volume fraction of solids was varied in the range
0 < cv < 0.3 by inserting up to 50 kg of glass beads in the system.

Table 1
Properties of the glass beads used in the fluidization tests.

d [mm] d/D ρs [kg/m3]

10.0 0.100, 0.073 2520


12.8 0.129, 0.094 2530
14.0 0.141, 0.103 2570
15.7 0.158, 0.115 2490
20.0 0.201, 0.147 2510 Fig. 4. Glass beads ( d = 35 mm ) in the plug flow mode with particle rain (left) and
24.8 0.249, 0.182 2660 glass beads ( d = 10 mm ) in the homogeneously fluidized state (right) in the
35.0 0.352, 0.257 2660 D = 136.4 mm riser. Ultimately, every particle bed reached the particle transport
mode when vf → wt .
J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213 209

We analyzed the front velocities of the d = 15.7 mm and


d = 20.0 mm beads in the D = 99.4 mm fluidization column
(d/D = 0.16 and d/D = 0.20) and the d = 24.8 mm and d = 35.0 mm
beads in the D = 136.4 mm fluidization column ( d/D = 0.18 and
d/D = 0.26). In Fig. 7 the front velocities relative to the superficial
fluid velocity, vfront − vf , fl , are compared with the characteristic
velocities of the mixtures relative to the fluid, vk − vf , fl (Eq. (14)
with vf , fl the measured superficial fluid velocity during fluidiza-
tion). As can be seen the model predicts the order of magnitude
reasonably well, but the scatter is very large. There does not seem
to be a strong relation between vk and d/D , but from the data we
know that especially at larger volume fractions of solids the error
becomes large.
The next step is to look at the conditions under which the
behaviour of the fluidized bed changes from plug flow (with par-
ticle rain) to a homogeneously fluidized bed, because this would
give us insight in the validity of the vd ¼vk criterion for regime
transition. Since we found some scatter in the model predictions
Fig. 5. Velocities as measured in the fluidization column compared with model
with Eq. (14), it can be expected that the prediction of stability
predictions of Eq. (7). The particles have d/D ≤ 0.26 .
shows some uncertainty as well.
Given the fact that the data is well within the ±25% boundaries,
we are confident that hindered settling theory is a good descrip- 4.3. Regime transition from plug flow to homogeneous fluidization
tion of the slip velocities for particles with d/D ≤ 0.26. Since ty-
pical mixture velocities in vertical transport systems are an order The flow regime can be indicated during the experiments by
of magnitude larger than the slip velocities, the uncertainty of 25% visual observation. The actual fluid velocity at regime transition,
will not have a large impact on any design calculation with hin- vf , tr can thus be deduced for all particle types. In the plug flow
dered settling theory. We will however see that it has an impact on regime plugs travel upward, disintegrate and rain down again. This
the calculation of the kinematic wave velocities. results in large fluctuations in bed height. A time lapse of camera
observations of this process is shown in Fig. 6. In case of homo-
4.2. The propagation velocity of plugs geneous fluidization, the expanded bed height is much more
stable. We define the velocity at regime transition vf , tr as the fluid
Now we have verified that hindered settling theory is well velocity at which fluctuations in bed height are significantly di-
suited for describing the slip velocity of large particles in our minished. That is, height variations should drop below 10% and
fluidization test, the next step is to look at the propagation of this should be visually verified. For some experiments the fluc-
disturbances. The plugs or disturbances observed in the experi- tuations remained well above 10% , but then a clear transition was
ments manifest themselves relative to the fluid velocity, Eq. (14). still visible. In these cases only visual observation has been used.
In order to find an estimate of the propagation velocity, we One way to look at the regime transition between plug flow
tracked the front of a disturbance in time (see Fig. 6 for a typical and homogeneous fluidization is using the relation between the
situation). The camera has a frame rate of 25 fps, so counting the particle Reynolds number (at transition) Rep, tr and the Archimedes
number of frames N needed for the front to propagate the distance number Ar of the particles in the fluidized bed, as given by Rabi-
Δz gives the front velocity vfront = Δz·25/N . novich and Kalman (2011):

Fig. 6. Time lapse (Δt = 0.44 s between frames) of particles with d = 24.8 mm in plug flow mode in the D = 136.4 mm riser. The plug accelerates upward and looses particles
at the bottom upon increasing velocity.
210 J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213

Fig. 8. Rep, tr versus Ar at regime transition from plug flow to homogeneous flui-
Fig. 7. Measured front velocities compared with the kinematic wave velocity or dization. The data adheres to the general framework Rep, tr = a·Ar b .
characteristic velocity vk, relative to the superficial fluid velocity vf , fl . The order of
magnitude is predicted well, but the scatter is large.
regime transition. The associated volume fraction of solids can be
estimated with Eq. (7), letting vslip = vf , tr . The volume fraction of
Rep, tr = a·Ar b (21) solids thus found can be used as an upper limit for safe operation
of the VTS.
Eq. (21) can also be formulated in terms of the superficial fluid
We have shown that hindered settling theory is a good ap-
velocity at regime transition vf , tr :
proximation of the particle slip velocities, and we have shown that
ρf ·vf , tr ·d based on our model, we are able to give a reasonable estimate of
Rep, tr = the kinematic wave velocities vk. It is however the question
μf (22)
whether the reasonable accuracy of the model in predicting vk is
The Archimedes number Ar from Eq. (21) is given by: sufficient to give a good prediction of the stability of the system.
The intersection between vd and vk should give the volume
Ar =
( )
ρf · ρs − ρf ·g ·d3 fraction of solids at the point of regime transition. However,
μf2 (23) comparison of vd using Eq. (3) and vk = wt ·10−d / D ·cv·n·(1 − cv )n − 1
(the ideal case in Eq. (14) where the fluid velocity and hindered
The parameters a and b are used to fit the data to this settling velocity cancel out) shows that vd > vk for the fluidized
framework. beds examined in this research, so theoretically these fluidized
The fluid velocity at regime transition between plug flow and beds should show stable behaviour.
homogeneous fluidization is determined by the velocity at which This was clearly not the case and we anticipated that the ac-
fluctuations in the expanded bed height diminish by visual ob- curacy in prediction of vk is not sufficient for a stability analysis.
servation. Table 2 shows the volume fraction of solids in the flui- Therefor we tried the full Eq. (14), in which we substituted the
dized bed cv, tr and the fluid velocity vf , tr as measured at regime measured value vf = vf , tr from Table 2. The results were striking.
transition. Given the measured velocity at regime transition, the point of
The particle Reynolds number at this point is defined by Eq. intersection vd ¼ vk corresponds almost perfectly with the mea-
(22). The Rep, tr values from the experiments are plotted versus the sured volume fraction of solids at regime transition. A comparison
Ar numbers of the particles on a double log scale in Fig. 8. The line between measurements and calculations is given in Fig. 9. Inclu-
in the plot is a least square fit to the data according to Eq. (21). All sion of added mass (i.e. using Eq. (4) instead of Eq. (3) for vd) gives
data fit the general framework of Eq. (21) well, although with
coefficients different than found in Rabinovich and Kalman (2011).
Once a and b are known for a specific batch of material, Eq. (22)
can be used for engineering purposes. To this end, first Ar is de-
termined from the particle properties, with which Rep, tr can be
determined. Rep, tr gives the fluid velocity through the batch at

Table 2
Volume fraction of solids cv, tr and fluid velocity vf , tr at regime transition as mea-
sured in the fluidization experiments.

d [mm] d/D cv, tr [–] vf , tr [m/s]

10.0 0.100, 0.073 0.38, 0.39 0.20, 0.19


12.8 0.129, 0.094 0.24, 0.17 0.34, 0.40
14.0 0.141, 0.103 0.25, 0.26 0.31, 0.32
15.7 0.158, 0.115 0.22, 0.15 0.36, 0.44
20.0 0.201, 0.147 0.12, 0.11 0.48, 0.55
24.8 0.249, 0.182 0.16, 0.19 0.46, 0.52 Fig. 9. Volume fraction of solids at regime transition as calculated with vd ¼vk
35.0 0.352, 0.257 n/a, 0.13 n/a, 0.62 (using vf = vf , tr in Eq. (14), and using Eqs. (3) and (4) for vd) compared with the
measured volume fraction of solids.
J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213 211

a minor difference, and Eq. (3) gives the best result.


In this section we have shown that an accurate description of vk
is crucial in the prediction of the regime transition. This required
using the full description of Eq. (14), which only can be used if the
actual fluid velocity vf approaching the plug is accurately known.
The theoretical description vk = wt ·10−d / D ·cv·n·(1 − cv )n − 1 proved
not to work well, so for stability analysis in the design phase
fluidization tests with representative material samples are needed.

4.4. Transport experiment: kinematic wave velocities during trans-


port of solids

In the transport experiment we investigate the flow regimes


and propagation velocities of disturbances of the d = 24.8 mm
glass beads in a D = 154 mm riser. The main difference with the
fluidization experiment is the circulation of particles in a con-
tinuous loop.
The mass inserted in the loop is a measure of the volume
fraction of solids in the riser, but since a part of the material is
suspended in the return line and in the pump, the actual cv in the
riser will be smaller. We therefor use the additional information of
the Δp measurement. The pressure difference over a vertical pipe
comes from frictional losses and the static weight of the mixture.
In the latter we are interested. For a proper estimation of cv from a
Δp measurement, one should use a U-tube setup with both a Δp
sensor in the riser and return line. Furthermore, these lines should
have equal diameters without any obstructions, so one can safely
assume that the mixture wall friction is equal in both the riser and
return line and the Δp readings are associated with the static
weight only (Clift and Manning-Clift, 1981).
For our setup this unfortunately is not possible, so we will use
Fig. 10. Example of the propagation of a disturbance through the riser ( Δt = 0.43 s
the Δp readings of the riser corrected for the fluid contribution to
between frames).
wall friction. The distance between the flowline connections of the
sensor is L = 2.26 m , so we expect the pressure drop due to wall
friction in the PVC pipe to be Δpf = f ·L/D·1/2·ρf ·v 2f with f ≈ 0.01 for measurements are taken at velocities vf < 1 m/s, so for 0 < cv < 0.3
PVC (conservative estimate). At vf = 1.90 m/s (maximum velocity we expect the slip velocity to increase up to 1.2 % at maximum
in the experiments), this would give Δpf = 0.30 kPa , which is of the (Fig. 2, vf ≈ vm = 1 m /s graph at cv ¼ 0.3). From our fluidization
same order as the submerged weight at small cv. Because of the experiments it proved that we were able to predict the particle slip
water-filled impulse tubes, the Δp sensor does not measure the velocity within 25% accuracy, while the anticipated increase in slip
weight of the water, so the volume fraction of solids follows from: velocity is much smaller. We will therefor neglect the influence of
wall friction in our analysis.
Δp − Δpf 1
cv ≈ · The slip velocity vslip can either be calculated or measured in a
g ·L ρs − ρf (24) fluidization experiment. We use Eq. (7). Since the characteristic
velocity manifests itself relative to the fluid, we can track the front
The video recordings are analyzed for the occurring flow pat- of a disturbance for a few frames (with a frame rate of 30 fps) in
terns. It was observed that the fluid velocity did not influence the the same way as was done for the fluidization experiment.
observed transport regime. Up to cv ¼0.06 we observed random As an example we look at Experiment 8. Fig. 10 shows three
particle motion in the riser. From cv ¼ 0.11 towards cv ¼0.22 we video stills. The lines show the position of the front of a dis-
observed propagating disturbances, and up to cv ¼ 0.3 the dis- turbance, propagating upward. The first and last frame are 39
turbances become more and more densely packed. frames apart, in which the front has propagated over 0.60 m . This
When we look at the relation Rep, tr = 0.104·Ar 0.6 which we results in an absolute velocity of vfront = 0.60 m ·30/39 = 0.46 m/s at
found for the fluidization experiments, and if we assume that this a superficial fluid velocity of vf ≈ 0.5 m/s.
relation is also valid for the larger D = 154 mm riser, we find This method has been used for all experiments, tracking a few
Rep, tr = 9.88·103. The associated fluid flow through the solids then disturbances per experiment. In these tests close up recordings
is vf , tr = 0.45 m/s, which coincides with a volume fraction of solids were used. The front of a disturbance was tracked over a 0.30 m
at regime transition of about cv, tr = 0.22 (using our data on the distance, giving a velocity of vfront = 0.30 ·30/N m/s.
hindered settling velocity of the d = 24.8 mm glass beads). This The results are shown in Fig. 11. The measured data is pre-
number is supported by the observations in our transport ex- sented as v − vf (i.e. velocities with respect to the superficial fluid
periment. The relatively clear demarcation between flow regimes velocity). The dynamic wave velocity vd is modelled using Eq. (3),
that was found in the fluidization experiments however was not without added mass. Putting vd in the same frame of reference the
found in this transport experiment. fluid velocity through the batch needs to be known, which is ap-
The next step in the analysis is comparing the propagation proximated as wt ·10−d / D ·(1 − cv )n . The kinematic wave velocity vk is
velocity of a disturbance with Eq. (14). modelled with Eq. (14), and vf is simply subtracted. The shock
In Section 2.3 we have shown that wall friction increases the velocities according to Eq. (15) are shown for
effective slip velocity of the particles. The larger part of the cv, l = 0.1, 0.2, 0.3, 0.4 . In all graphs shown in Fig. 11 we use
212 J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213

5. Conclusions and recommendations

5.1. Conclusions

We have validated our model equations with fluidization ex-


periments. We used glass beads with diameters in the range
d = 10 − 35 mm with densities around ρs = 2500 kg/m3 and
d/D < 0.26, comparable to real deep sea deposits in prototype scale
transport systems. We have shown that for large d/D ratios, classic
hindered settling theory still predicts the solid phase slip velocity
within reasonable limits of ±25% .
The kinematic wave velocity was derived from hindered set-
tling theory. By analysis of the influence of wall friction on the
solid phase slip velocity, we have shown that wall friction has a
very small, but stabilizing effect on the vertical transport operation
because it decreases the kinematic wave velocities.
We analyzed the propagation velocity of shock-fronts as a
measure of the kinematic wave speed vk, and compared these with
the theoretical vk. The order of magnitude of the measured shock-
front velocities in the fluidization experiments is predicted well by
Fig. 11. Measured propagation velocity of the front of a disturbance in the VHT the theoretical vk, but especially at larger volume fractions of so-
tests corrected for the superficial fluid velocity. The measurements have been lids the model overestimates vk.
conducted at different fluid velocities and volume fractions of solids. Additionally,
the results of the d = 24.8 mm glass beads fluidization test are shown. The theo-
In the fluidization experiments we measured the fluid velocity
retical lines for vk − vf , vk, s − vf , vd − vf and vs − vf show how the experiments fit and volume fraction of solids at regime transition from the plug
the theoretical framework. flow regime (associated with bed instabilities) to the homo-
geneously fluidized regime. The data adheres to the general fra-
mework Rep, tr = a·Ar b , which indicates we have consistently
d = 24.8 mm and ρs = 2660 kg/m3 for the glass beads, identified the regime transitions. We were able to give a good
prediction of the volume fraction of solids at regime transition cv, tr
ρf = 1000 kg/m , μf = 1.1·10−3 Pa s for the water, in a riser with
3
with the criterion vd ¼vk, using Eqs. (3) and (14), substituting
D = 154 mm .
vf = vf , tr (the measured fluid velocity at the point of transition).
The fluidization data clearly shows that the disturbances or
Accurate prediction of vk is key for stability analysis.
density waves are propagated with shock velocities vs, k < vk (note
In the transport experiment we measured the propagation
that the fluidization tests were conducted in a D = 136.4 mm riser,
velocity of disturbances for 0 < vf < 2 m/s and cv < 0.3. We ob-
but the difference with a D = 154 mm riser is negligible). The data
served propagation of disturbances over the entire range of cv. The
is shown for the average volume fraction cv, but note that in the
associated kinematic wave velocities proved to be much smaller
case of shock velocities, the horizontal axis denotes the volume
than the theoretical kinematic wave velocity or shock velocities. It
fraction of the disturbance. A fair comparison between the test
seems like these disturbances were just advected with the particle
data and the shock velocities requires information about the axial
distribution of the volume fraction of solids, which we un- transport velocity. The much smaller propagation velocities of the
fortunately do not have. As an indication, one can assume that the disturbances points, on theoretical grounds, at an increased flow
disturbances associated with the test data have larger volume stability of the transport system compared to a fluidized bed. The
fractions than the averages depicted in the figure, so for compar- decrease in kinematic wave velocities during transport is in line
ison with the shock velocities the data should be shifted to the with the theoretical influence of wall friction on the transport
right. On average the VHT test data follows the transport velocity process, but wall friction only cannot explain the extreme reduc-
vs, which means that the observed disturbances were just ad- tion in vk.
vected with the flow. Towards cv ¼0.3 however larger wave velo-
cities are observed, which resemble actual density waves. 5.2. Recommendations
While in the fluidization experiments we found kinematic
wave velocities that matched Eq. (14) well, and we were thus able The outcome of a stability analysis is very sensitive to the
to assess the regime transition from plug flow to fluidized flow, choice of models for vk and vd, so for stability assessment of long
the vertical transport experiments show differently. The propa- distance vertical transport systems, it is advised to conduct la-
gation velocity of disturbances is much smaller than both the boratory tests with representative particle samples. A simple
theoretical velocities and the velocities found in the fluidization fluidization test would already give insight in the flow stability of
experiment. Since vk⪡vd , the stability criterion is met for all cv, so it the transport system, and thus can be used to find the upper al-
can be concluded that vertical transport of solids shows stable lowable limit of the volume fraction of solids. Using a design rule
behaviour, i.e. all disturbances will eventually diminish. of the form Rep, tr = a·Ar b can be a valuable addition to fluidization
The question which now emerges, is whether we can gen- tests.
eralize the conclusion from our transport experiment. In Section In our experiments we used mono-disperse mixtures, but in
2.3 we reasoned that wall friction only has a small effect on the practice the particle size distributions will be much wider. It
slip velocities, but if present, friction would decrease the kinematic would be interesting to investigate the influence of significant
wave velocities with respect to the superficial fluid velocity, which amounts of finer material (e.g. d < 5 mm ) in the transport system.
is in line with our experiment. The measured vk is however much We expect the stability conditions to improve, because the pre-
smaller than would be expected from friction. This observation sence of finer material would effectively decrease the particle slip
points at stability of our transport system, but extended experi- velocity.
ments in a longer test setup are needed to verify this. In the transport experiment the propagation velocities of
J.M. van Wijk et al. / Ocean Engineering 125 (2016) 203–213 213

disturbances matched the average fluid velocity. Apparently, de- Engelmann, H.E., 1978. Vertical hydraulic lifting of large–size particles a contribu-
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