Dynamic Flowsheet Simulation Of Solids Processes And Its Application To Fluidized Bed Spray Granulation

This book presents the latest advances in flowsheet simulation of solids processes, focusing on the dynamic behaviour of systems with interconnected solids processing units, but also covering stationary simulation. The book includes the modelling of solids processing units, for example for comminution, sifting and particle formulation and also for reaction systems. Furthermore, it examines new approaches for the description of solids and their property distributions and for the mathematical treatment of flowsheets with multivariate population balances.

Focusing Mesoscales of Multiscale Problems in Chemical Engineering, a volume in the Advances in Chemical Engineering series provides readers with the personal views of recognized authorities who present assessments of the state-of-the-art in the field and help readers develop an understanding of its further evolution. Subjects covered in the book are not limited to the classical chemical engineering disciplines. Contributions connecting chemical engineering to related scientific fields, either providing a fundamental basis or introducing new concepts and tools, are encouraged. This volume aims to create a balance between well developed areas such as process industry, transformation of materials, energy, and environmental issues, and areas where applications of chemical engineering are more recent or emerging. Contains reviews by leading authorities in their respective areas Provides up-to-date reviews of the latest techniques in the modeling of catalytic processes Includes a broad mix of US and European authors, as well as academic/industrial/research institute perspectives Provides discussions on the connections between computation and experimental methods

Fluidized bed spray granulation is a process that facilities particle size enlargement by injecting solids in the form of a suspension, solution or melt. The produced particles are often of high value due to their highly specific, functionalized nature. This work provides a method for utilizing particle-scale simulations method like the coupled Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) to predict the properties of particles produced in scaled-up apparatuses based on laboratory-scale experiments by correlating the conditions that particle experience to the properties they develop. Furthermore, a method for calibrating DEM models of weakly wetted particle systems by utilizing a novel, probabilistic liquid bridge state model is proposed.

In this Ph.D. thesis a system of coupled fluidized bed reactors is modelled and simulated dynamically. Chemical Looping Combustion was used as an exemplary process in both the numerical and the experimental part of this work. For the simulation purpose a novel flowsheeting software was used and models for the needed process units developed and integrated into this software. The needed unit models were three interconnected fluidized bed reactors in circulating and bubbling operation conditions, a cyclone for gas-solid separation and loop seals, which ensured solids transport and gas separation between the reactors. Additionally, lab scale experiments on the reactivity of the used solids, oxygen carrier and solid fuels, were conducted and kinetic parameters extracted. All unit models were connected to a process flowsheet and simulated dynamically. The simulation results were compared to experimental data from a 25 kWth pilot plant operated at the university by the author. It could be shown that a detailed and dynamic simulation of the whole process can be carried out over a time period of more than 45 minutes and the experimental results from start-up, steady state operation and shutdown of the plant were predicted accurately.

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Fluidized bed dryers are the prime choice when it comes to drying of heat sensitive products, commonly processed in the pharmaceutical and food industry. As many products in these industries are fine and cohesive, mechanical vibration of the dryer is used to enable or improve fluidization. Thus, the goal of this thesis is the development of a fluidized bed drying model that accounts for the influence of mechanical vibration of the dryer, as well as its implementation in an open-source flowsheet simulation framework. Continuously operated fluidized bed dryers under steady-state conditions are the focus of this thesis. The aim during model development and implementation is the broadest possible application range of the model. A custom-built vibrated fluidized bed dryer is designed and constructed for comprehensive investigations of fluidized bed hydrodynamics and drying kinetics. Based on experimental investigations, a semi-empirical model for hydrodynamics of fine and cohesive powders is developed. The new model is combined with established models to allow for the flowsheet simulation of fluidized bed dryers for particles of all Geldart groups. Additionally, the influence of vibration is accounted for. Comprehensive validation experiments are performed for particles of different Geldart groups, different dryer geometries and a variety of process parameters, including mechanical vibration. Comparison of model predictions with experimental data attributes high accuracy of predicted particle and gas properties. Furthermore, sensitivity analyses are conducted to identify potential weaknesses in underlying model assumptions. Hereby, the validity of underlying assumptions is confirmed and potential optimization parameters for different applications are identified. The proposed model is unprecedented in terms of range of process parameters, variety of particle properties and dryer geometries, tested and found valid for.

Process Systems Engineering for Pharmaceutical Manufacturing: From Product Design to Enterprise-Wide Decisions, Volume 41, covers the following process systems engineering methods and tools for the modernization of the pharmaceutical industry: computer-aided pharmaceutical product design and pharmaceutical production processes design/synthesis; modeling and simulation of the pharmaceutical processing unit operation, integrated flowsheets and applications for design, analysis, risk assessment, sensitivity analysis, optimization, design space identification and control system design; optimal operation, control and monitoring of pharmaceutical production processes; enterprise-wide optimization and supply chain management for pharmaceutical manufacturing processes. Currently, pharmaceutical companies are going through a paradigm shift, from traditional manufacturing mode to modernized mode, built on cutting edge technology and computer-aided methods and tools. Such shifts can benefit tremendously from the application of methods and tools of process systems engineering. Introduces Process System Engineering (PSE) methods and tools for discovering, developing and deploying greener, safer, cost-effective and efficient pharmaceutical production processes Includes a wide spectrum of case studies where different PSE tools and methods are used to improve various pharmaceutical production processes with distinct final products Examines the future benefits and challenges for applying PSE methods and tools to pharmaceutical manufacturing