Powder Technology: Xin Mo, Peining Wang, Hairui Yang, Junfu LV, Man Zhang, Qing Liu
Powder Technology: Xin Mo, Peining Wang, Hairui Yang, Junfu LV, Man Zhang, Qing Liu
                                                                       Powder Technology
                                                  journal homepage: www.elsevier.com/locate/powtec
A hydrodynamic model for circulating fluidized beds with low riser and
tall riser
Xin Mo, Peining Wang, Hairui Yang ⁎, Junfu Lv, Man Zhang, Qing Liu
Key Laboratory for Thermal Science and Power Engineering of Ministry of Education, China
Beijing Key Laboratory of CO2 Utilization and Reduction Technology, China
Department of Thermal Engineering, Tsinghua University, Beijing 100084, China
a r t i c l e i n f o a b s t r a c t
Article history:                                          Based on different flow regimes classified by the saturation carrying capacity in the riser, a comprehensive
Received 4 September 2014                                 hydrodynamic model for circulating fluidized beds was proposed and validated with experimental data. The
Received in revised form 4 January 2015                   model can describe the different axial solids distributions or regimes in previous literatures, especially the
Accepted 12 January 2015
                                                          boundaries among them. The calculation of model shows good agreement with experiments not just for gas
Available online 17 January 2015
                                                          solids behavior in riser, but also for that in standpipe.
Keywords:
                                                          The influences of the riser height on the axial solids distribution in riser were discussed. With the increase of the
Circulating fluidized beds model                           distance between the upper end of dense phase and the bottom of riser, the axial solids distribution in low riser
Transport detached height                                 appears as the exponential profile, the quasi exponential profile and the quasi S-shaped profile continuously. For
Saturation carrying capacity                              the tall riser, the quasi exponential profile is replaced by the S-shaped profile due to the dilute phase in the upper.
                                                          In addition, the saturation carrying capacity prevails in the tall riser, and with greater inventory solids circulation
                                                          rate would exceed the saturation carrying capacity to form the quasi S-shape profile.
                                                                                                                                              © 2015 Published by Elsevier B.V.
1. Introduction                                                                             when the opening of butterfly valve is great, while the variation of
                                                                                            inventory has no impact on the distribution when the opening is
    Hydrodynamic model is a useful tool to describe the gas solids flow                      small, similarly found by Xu et al. [8]. If a screw feeder exists in the
in circulating fluidized beds (CFB) reactors, especially in the riser, and is                external loop, the variation of pressure drop across standpipe had
of significant importance for design and performance of CFB reactors.                        no effect on the pressure drop across riser [8]. In Rhodes and
The hydrodynamic model integrates the pressure balance and the                              Lasussmann's experiments [14], it was found the difference of pressure
material mass balance around the whole loop, and the most difficult is                       drop between the standpipe and the butterfly valve was almost the
the proper identification of axial solids distribution in the riser.                         constant during the variation of inventory. The opening of mechanical
    The axial solids distribution is influenced by many factors. Except for                  valve was reduced to keep the constant of Gs. Therefore the increased
material properties [1], the influencing factors include the height and                      pressure drop in standpipe was offset by the increased pressure drop
diameter of the riser [1], inlet and outlet restrictions [1–5], and operating               of butterfly valve, which led to no variation in the pressure drop across
conditions (fluidizing gas velocity, solids circulating rate and material                    riser.
inventory) [1,6–14]. At certain fluidizing gas velocity and solids circula-                      The circulating fluidized bed boiler is widely used in the coal
tion rate, the effect of inventory is still a controversy. Weinstein et al.                 combustion and electric generation, which belongs to the type B CFB
[10], Mori et al. [11] and Li et al. [13] found that the interface between                  due to the following characteristics [15].
the dense phase and the dilute phase moves up with the increase of
inventory; however Hirama et al. [9,12], Rhodes and Lasussmann [14]                            (1) There is no hopper or screw feeder in the external loop, and the
did not observe this phenomenon. The controversy may result from                                   loop satisfies pressure balance. The variation of inventory influ-
the differences of experimental structures, especially the discrepancies                           ences axial solids distribution in the riser.
in external loop including the standpipe and the mechanical valve. Bai                         (2) The diameter of standpipe is small; therefore unit mass of mate-
et al. [1] found that the axial solids distribution is related to inventory                        rial in standpipe produces greater pressure drop.
                                                                                               (3) The butterfly valve is replaced by loop seal. Loop seal has small
  ⁎ Corresponding author at: Key Laboratory for Thermal Science and Power Engineering
                                                                                                   flow resistance and good gas sealing ability.
of Ministry of Education, China. Tel.: +86 10 62773384.                                        (4) The solids circulation rate is influenced by fluidizing gas velocity,
    E-mail address: yhr@mail.tsinghua.edu.cn (H. Yang).                                            aeration rate in loop seal and material inventory.
http://dx.doi.org/10.1016/j.powtec.2015.01.022
0032-5910/© 2015 Published by Elsevier B.V.
                                                         X. Mo et al. / Powder Technology 274 (2015) 146–153                                                 147
ΔP sp ¼ ΔP r þ ΔP c þ ΔP ls ð1Þ
                                                                                     Mt ¼ M r þ Mls þ M sp                                                   ð2Þ
   Saturation carrying capacity, Gssat, is one of the important
parameters to distinguish gas solids flow regimes in the riser [16].
Li et al. [13] classified the flow condition in the riser into three                   2.1. Hydrodynamic model in riser
cases, i.e. Gs b G ssat , G s = Gssat and G s N G ssat , in which the case of
Gs = Gssat prevails in the tall risers. With respect to the riser with                   As mentioned above, the gas solids distributions in different cases
weak restriction, Xu et al. [8] found saturation carrying capacity is                classified by comparing Gs with Gssat are different.
easy to keep in low fluidizing gas velocity for the riser of certain
height. By neglecting the acceleration region in the bottom of riser
and solids back-mixing influence near the exit, the relation between                  Case 1. Gs b Gssat
148                                                        X. Mo et al. / Powder Technology 274 (2015) 146–153
Table 1
Characteristics of different axial solids distributions.
   When neglecting the effects of solids acceleration, gas solids friction,             limited, and the deviation between the value calculated by Eq. (3) and
the axial solids distribution is uniform, which is defined as the dilute                 the measured value is small [27].
pneumatic conveying. Solids holdup calculated by the Eq. (3) is the
terminal solids concentration [26], and it is more acceptable for the                                G
                                                                                        ξdil ¼      s                                                     ð3Þ
CFB with low solids circulation rate. For the low solids circulation rate
                                                                                                 ρp U g −U t
and high fluidizing gas velocity, the formation of clusters would be
                                                                                                  If ξ − ξdil is smaller than 1% of ξdil, assume that the gas solids flow is
                                                                                              at the dilute state. Therefore the length of transition state, namely the
                                                                                              transport detached height, is expressed as
                                                                                                                            Z              !
                                                                                                                                Hr
                                                                                              ΔP r ¼ ρp g ξden Z d þ                 ξdZ                                          ð10Þ
                                                                                                                                Zd
                                                                                              Case 3. Gs N Gssat
                                                                                                  The characteristic of the case of Gs N Gssat is the disappearance of
                                                                                              dilute phase in the upper of riser. The solids holdup in dense phase
                                                                                              changes little with solids circulation rate when Gs N Gssat [8,29], and it
                                                                                              is assumed as Eq. (6). We assume that the dilute phase is beyond the
                                                                                              top of riser, and its solids holdup is set as Eq. (3).
                Fig. 2. Schematic diagram of circulating fluidized beds.                           The solids holdup at the riser exit is expressed as Gs / (ρp(Ug − Ut))
                                                                                              and substitutes it for ξ in Eq. (7); the relation between Zd and Gs is
                                                                                              expressed as
   The exit structures influences the axial solids holdup distribution,
especially the solids holdup in the upper of riser. The back-mixing                                             00                             1              1
would be intensive with high fluidizing gas velocity and high solids                                                             Gs
                                                                                              Z d ¼ H r þ ln @@            −ξdil A=ðξden −ξdil ÞA=α                              ð11Þ
circulation rate [3,28], and the axial solids holdup distribution is                                           ρp U g −U t
the so-called C-shaped distribution. Because the gas velocity and
the solids circulating rate in this paper is not much high, therefore
                                                                                                 If Zd is positive, the axial solids distribution is the quasi S-shaped
the effect of abrupt exit should be not much obvious. Moreover, the
                                                                                              profile; otherwise it would be the quasi exponential profile.
back-mixing especially in the low riser could confuse the relation
between the axial solids holdup distribution and the saturation carrying
                                                                                              2.2. Hydrodynamic model in cyclone
capacity; therefore the effect of abrupt exit is not considered.
   The pressure drop across riser and the material mass can be calculated
                                                                                                  Inlet dust loading at the inlet of cyclone significantly influences the
with Eqs. (4) and (5) respectively.
                                                                                              pressure drop of cyclone [31–34]. The pressure drop at first shows a
ΔP r ¼ ρp gH r ξdil                                                                 ð4Þ       descending trend with the increase of inlet dust loading, then increases
                                                                                              gradually after a turning point. Therefore the effect of solids concentration
                                                                                              could not be ignored during the calculation of pressure drop of cyclone.
Mr ¼ ΔP r Ar =g                                                                     ð5Þ
                                                                                                  Few correlations could properly reflect the effect of inlet solids load-
                                                                                              ing on the cyclone pressure drop. Chen and Shi [31] analyzed the
                                                                                              pressure drop and proposed a model based on the cyclone structures;
Case 2. Gs = Gssat                                                                            however the model is complicated, which limits its application. A
                                                                                              more universal model as Eq. (12) shown was first proposed by Baskakov
   The solids holdup in dilute phase can be calculated with Eq. (3), and
                                                                                              et al. [32]. Then it was adopted to fit the variation of pressure drop with
the solids holdup of dense phase [29] is set as
                                                                                              the inlet solids loading by others [33,34], and the results showed good
                                                 !−0:013 !                                    agreement between the measured pressure drop and the calculated
                         
                    U g ρp 1:13         ρp −ρg                       G                        pressure drop in different inlet solids loadings.
ξden ¼    1 þ 0:103                                               s             ð6Þ
                     Gs                   ρg                     ρp U g −U t                                                                   !
                                                                                                                     2       1
                                                                                              ΔP c ¼ 0:5kρg U g                   a þ a3 C i                                       ð12Þ
                                                                                                                         1 þ a1 C i 2
    The solids holdup in transition state exponentially decays with the
increase of height. The decay factor is influenced by operating conditions,
                                                                                                 The coefficients of k, a1, a2 and a3 depend on the cyclone structures.
design parameters, and properties of material and gas [19,20,23].
                                                                                              For the cyclone in this paper, the coefficients are calculated according to
Although numerous empirical correlations for predicting decay
                                                                                              the experiment data conducted in the same cyclone [34]. In addition,
factor have been proposed, there are great deviations among them
[23]. In this paper, the decay factor is adjusted to better predict the
variation in pressure drop across riser. Given the decay factor, the                          Table 2
                                                                                              Material properties.
solids holdup in the transition state is calculated by [30]
                                                                                                                     Real density      Particle diameter   Bulk      Minimum
                                                                                                                     (kg/m3)           (μm)                voidage   fluidizing voidage
 ξ−ξdil
           ¼ expð−α ðZ−Z d ÞÞ                                                       ð7Þ         Quartz sands         2600              160                 0.52      0.56
ξden −ξdil
150                                                                 X. Mo et al. / Powder Technology 274 (2015) 146–153
                                                                                                                                           
                                                                                                Mls ¼ ρp H rc Arc 1−εm f þ ρp Lpas Apas 1−εpas :                    ð17Þ
                                                                                                             G      Qv
                                                                                                U sl ¼      s þ                                                   ð18Þ
                                                                                                         ρp 1−εsp εsp Asp
                                                                                                                  U sl               
                                                                                                ε sp ¼ εpb þ                εm f −εpb                               ð19Þ
   Fig. 3. Variation of solids circulation rate with aeration rate in the supply chamber.                      U m f =εm f
                                                                                                                  ε −ε
due to the great voidage of gas solids mixture in cyclone, the material                          ΔP                     sp    pb
                                                                                                       ¼ ρp g 1−εm f                                               ð20Þ
mass in cyclone is assumed to zero.                                                              ΔL sp                 εm f −εpb
2.3. Hydrodynamic model in loop seal                                                                The material mass in standpipe is expressed as
                                                                                                                
    The loop seal consists of the supply chamber connecting the bottom                          Msp ¼ Ls ρp 1−εsp Asp                                               ð21Þ
of standpipe, the recycle chamber connecting the riser and the horizontal
passage between the two chambers. Compared with the minimum fluid-
                                                                                                where Ls is the solids height in standpipe.
ization, the voidage of the mixture and the solids height in the recycle
chamber would increase with the increase of fluidizing gas velocity in
                                                                                                2.5. Calculation procedure
the bubbling regime; however it is difficult to predict the increased solids
height. Assuming the minimum fluidization and the solids height equal
                                                                                                    Fig. 1 shows the calculation procedures for different cases classified
to the height of recycle chamber would not cause great deviation of
                                                                                                by Gssat. For all cases, gas solids behaviors in the riser, the standpipe
pressure drop for the recycle chamber with low height. For the industrial
                                                                                                and the passage of loop seal are the variables of hydrodynamic model,
CFB boilers, the height of the recycle chamber is much high, and the
                                                                                                and the pressure balance and material balance are the controlling
hypothesis of minimum fluidization may lead to great deviation.
                                                                                                equations. Three variables and two controlling equations make the
Therefore the pressure drop in the recycle chamber is simply
                                                                                                direct solution impossible. We adopt an indirectly way to calculate
assumed as
                                                                                                the gas solids flow in CFB. The first step ignores the effects of passage
                                                                                              to obtain the gas flux and solids flux in the passage, then the pressure
ΔP rc ¼ ρp gH rc 1−εm f :                                                             ð13Þ      drop and material mass in the passage could be calculated. The calculated
                                                                                                pressure drop and material mass in the passage are input to conduct the
    The pressure drop in passage influences the solids circulation                               second step. If the pressure drop of passage approaches the constant,
especially in the CFB boilers with long passage. Although the inclined                          the calculation is finished. The differences among the three cases are
passage has been proposed to reduce the flow resistance in the loop
seal, the majority of loop seal adopt the horizontal passage due to the
simple structure. The gas solids behaviors in the horizontal passage
are different from that in the inclined passage due to the different
effects of gravity. Kim et al. [21] fitted the experimental data conducted
in the loop seal with horizontal passage, and proposed an empirical
correlation for the pressure drop across the horizontal passage.
              0      0 0                    10:43 11 = 1
                                                      3
           1 B                μρp U pas
ε pas   ¼     @0:4 þ @4@                  A A C       A                             ð14Þ
          2:1           d2p ρg ρp −ρg φ2p g
 
 ΔP              0:51 2:01 −0:97 −0:76
        ¼ 0:0056Gs;pas ρbulk dp Dpas                                                  ð15Þ
 ΔL pas
    Assume that the gas solids behavior in supply chamber is the same
to that in standpipe, the pressure drop of supply chamber is normally
considered as the part of pressure drop of standpipe. The pressure
drop and material mass in loop seal are set as
the identification of axial solids distribution. For the case of Gs b Gssat, the        the results of calculation, and dots with different shapes are the
axial solids distribution is uniform, and the solids holdup depends upon               experimental data. Due to the increase of solids circulation rate,
Gs. For the case of Gs N Gssat, Zd could be obtained according to Eq. (11);            more materials are suspended in the riser. At low aeration rate,
however Zd should be given for the case of Gs = Gssat.                                 the calculation has good agreement with the experiments. After
                                                                                       3.7 m3/h of aeration rate, the pressure drop of loop seal drops; however
3. Experiments                                                                         the calculated values by Eq. (16) do not show a decreasing trend.
                                                                                       Actually the gas solids mixture in the upper of lateral passage is dilute;
    As Fig. 2 showed, the circulating fluidized bed for calculation consists            however it is dense in the bottom [37]. The voidage in Eq. (14) is the
of a riser with weak exit restriction to avoid solids back-mixing, a                   average value in the passage, which may lead to the deviation of
cyclone, a standpipe and a loop seal. More details about the circulating               pressure drop between calculation and experiments.
fluidized bed can be found in the previous study [25]. The riser height                     Fig. 5 shows the gas solids behaviors in standpipe. With the increase
and standpipe height are adjusted to calculate the axial solids distribution           of solids circulation rate, the pressure drop across riser is increased. In
in the CFB with low riser and tall riser.                                              order to keep the pressure balance with less material, the pressure
    The bed material is quartz sand, of which properties are listed in                 drop gradient in standpipe is increased with decreasing solids height,
Table 2. The superficial fluidizing gas velocity in riser is 6 m/s, and the              which leads to the increase of voidage in standpipe. The voidage calcu-
total inventory is 11 kg. The aeration rate in loop seal is adjusted to                lated is lower than that of experiments, which is deduced from the
change solids circulation rate.                                                        pressure drop gradient according to ERGUN model [36]. The deviations
                                                                                       in sphericity and diameter of solid particles may cause the deviation of
4. Model validation                                                                    voidage. The material mass in elbow and cyclone are ignored for calcu-
                                                                                       lation, which makes the calculated solids height always higher than the
    Yao et al. [25] investigates the gas solids flow in a riser with a height           experimental value. When the gas solids flow in standpipe is at the stick
of 4.5 m. Due to the very high fluidizing gas velocity (6 m/s), TDH is                  slip state, the gas flows downward, and the gas flux increases with
almost 9.76 m. Therefore the gas solids flow in riser is at the case of                 solids circulation rate. When the aeration rate is greater than 4.7 m3/h,
Gs N Gssat. As Fig. 3 showed, the solids circulation rate increases with               the solids in standpipe would be fluidized. In the fluidization state, the
the aeration rate in bottom of supply chamber. The variation of pressure               gas bypassing upward was found, while the calculation cannot simulate
drop of each section is shown in Fig. 4. Curves with different colors mark             such phenomenon.
152                                                         X. Mo et al. / Powder Technology 274 (2015) 146–153
Fig. 6. Axial solids distributions in low riser and tall riser. (a. low riser, b. tall riser.)
5. Axial solids distribution in low riser and tall riser Lower boundary in case of
    Li and Kwauk [24] regarded the exponential profile and the state of                       Gs ¼ Gssat : Z d ¼ −TDH; Gs ¼ Gssat                                        ð27Þ
Gs N Gssat as the S-shaped profile by assuming the dense phase under
the bottom of riser or the dilute phase above the top respectively. The                           Upper boundary in case of
assumptions proposed by Li and Kwauk [24] are adopted in this paper.
                                                                                             Gs ¼ Gssat : Z d ¼ H r −TDH; Gs ¼ Gssat                                    ð28Þ
The distance between the upper end of dense phase and bottom of
riser, Zd, is adopted to reflect the change of axial solids distribution.
    At fixed solids circulation rate in the state of Gs N Gssat, the pressure                      The axial solids distributions in a low riser and in a tall riser are
drop across riser does not change with the variation of total inventory                      summarized as Fig. 6. The axial solids distribution of dilute pneumatic
[6,38], which indicates that Zd depends upon solids circulation rate.                        conveying is uniform and it is not shown here. Fig. 6a corresponds to
    Axial solids distribution in case of                                                     the distributions in a low riser, while Fig. 6b shows the distributions in
                                                                                             a tall riser. The curves indicate boundaries to distinguish different
Gs N Gssat : F ðGs Þ                                                            ð22Þ         solid distributions, and the dash curves represent the assumed section
                                                                                             that is beyond the top or under the bottom. With the increase of Zd,
where Gs is related to the total inventory and gas solids behavior in                        the axial solids distribution in a low riser firstly presents as the expo-
standpipe [6,25]                                                                             nential profile, then changes to the quasi exponential profile and finally
                                                                                             evolves to the quasi S-shaped profile. For the tall riser, the quasi expo-
               
                                                                                             nential profile is replaced by the S-shaped profile due to the dilute
Gs ¼ G M t ; εsp :                                                              ð23Þ
                                                                                             phase in the upper of riser.
                                                                                                  The saturation carrying capacity prevails in the tall riser according to
   The lower boundary for state of G s N Gssat corresponds to the                            Fig. 6. The range for saturation carrying capacity in the low riser is very
disappearance of dilute phase in the upper of riser, and it is set as                        limited, which indicates that it is hard to keep saturation carrying capac-
Eq. (24). The maximum of solids circulation rate corresponds to the                          ity. For the tall riser, over the limited range of pressure drop provided by
maximum of Z d which is restricted by the maximum of pressure                                the external loop, there exists the dilute phase in the upper of riser, and
drop across standpipe.                                                                       Gs is equal to Gssat. If the total inventory is greater than a critical value at
   Lower boundary in case of                                                                 which Zd is Hr − TDH, Gs would be greater than Gssat to form the quasi
                                                                                             S-shaped profile.
Gs N Gssat : Z d ¼ H r −TDH; Gs ¼ Gssat                                         ð24Þ
                                                                                             6. Conclusions
      Upper boundary in case of
                                                                                               A comprehensive model is proposed based on the pressure balance
Gs N Gssat : Gsmax ¼ Φ H sp                                                     ð25Þ         and material balance for circulating fluidized beds. The sub-model for
                                                                                             axial solids distribution in riser is classified by the saturation carrying
                                                                                             capacity. The model is verified with experiments conducted in a low
   For the case of Gs = Gssat, Zd depends upon the total inventory and
                                                                                             riser, which shows good agreement not only for the pressure drop of
gas solids behaviors in standpipe. Greater total inventory and greater
                                                                                             each section in the circulating fluidized bed, but also for gas solids
voidage in standpipe lead to the increase of pressure drop across riser
                                                                                             behaviors in standpipe.
[18].
                                                                                                 The riser height has a significant influence on the axial solids distri-
   Axial solids distribution in case of
                                                                                             bution in CFB riser. With the increase of Zd, the axial solids distribution
                                                                                             in low riser appears as the exponential profile, the quasi exponential
                                                                                           profile and the quasi S-shaped profile continuously. For the tall riser,
Gs ¼ Gssat : F Mt ; ε sp                                                        ð26Þ
                                                                                             the quasi exponential profile is replaced by the S-shaped profile due
                                                                       X. Mo et al. / Powder Technology 274 (2015) 146–153                                                                    153
to the dilute phase in the upper of riser. In addition, the saturation                             [16] J. Li, G. Xu, W. Ge, The coexistence of two different steady states in circulating fluidized
                                                                                                        beds, in: J. Werther, M. Kwauk, J. Li (Eds.), Abstracts for WorkshopIIon Modeling and
carrying capacity prevails in the tall riser, and with greater inventory                                Control of Fluidized Bed Systems, Beijing, 1996, p. 14.
Gs would exceed the Gssat to form the quasi S-shaped profile.                                       [17] D. Bai, K. Kato, Saturation carrying capacity of gas and flow regimes in CFB, J. Chem.
                                                                                                        Eng. Jpn 28 (1995) 179–185.
                                                                                                   [18] N. Hu, H. Zhang, H. Yang, S. Yang, G. Yue, J. Lu, Q. Liu, Effects of riser height and total
Acknowledgments                                                                                         solids inventory on the gas–solids in an ultra-tall CFB riser, Powder Technol. 196
                                                                                                        (2009) 8–13.
   Financial support of this work by the Key Project of the National                               [19] D. Kunii, O. Levenspiel, Fluidization Engineering, Second ed. Butterworth-
                                                                                                        Heinemann, U.S.A., 1991
twelve-Five Year Research Program of China (2012BAA02B01)                                          [20] J. Adanez, P. Gayan, F. Garcia-Labiano, L.F. de Diego, Axial voidage profiles in fast
and the National Basic Research Program of China (973 Program)                                          fluidized beds, Powder Technol. 81 (1994) 259–268.
(2014CB744305) are gratefully acknowledged.                                                        [21] S.W. Kim, S.D. Kim, D.H. Lee, Pressure balance model for circulating fluidized beds
                                                                                                        with a loop-seal, Ind. Eng. Chem. Res. 41 (2002) 4949–4956.
                                                                                                   [22] P. Basu, L. Cheng, An analysis of loop seal operations in a circulating fluidized bed,
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