Case Study
Case Study
Case Study
Case Study
Case Study

Fluidized Bed for the FAU University in Erlangen

A unit capable of testing multiple metal coupons with various novel coatings
The task

The goal of this project was to develop a unit capable of testing multiple metal coupons with various novel coatings under similar shear conditions to those found in commercial FCC reactors and using realistic FCC feedstocks.

Corrosion and erosion occur in reactors of all types. FCC reactors are recycle fluidized bed systems, which have highly-abrasive zeolite catalysts moving at extremely high linear velocities. Especially in areas where pipe-bends or hindrances are present, significant material loss of the reactor walls can occur. This presents a serious operational and safety problem for FCC reactor operators.
The ILS solution

This project is an excellent example of the ILS approach to reactor design.

The client initially approached ILS with a design, where she/he wished to generate the necessary shear by pumping the liquid at high flow rates over metal coupons with narrow gaps capable of generating the required flow velocities. ILS performed initial calculations on this proposal using Reynolds numbers and rheological properties provided by the client. ILS came to the conclusion that this approach would be mechanically extremely difficult to produce and generate a huge pressure drop. ILS proposed a novel reactor, where we basically turned the concept from our client on its head. Instead of pumping the liquid, we developed a novel rotating drum reactor, where an internal rotating drum with a narrow annular gap generates the required shear for 4 samples located symmetrically around the drum. The high temperatures required would result in oil cracking and coke formation under normal conditions. ILS was able to minimize this problem by continuously recycling the FCC feedstock through the annular gap, insuring a short residence time at high temperatures and immediately cooling the oil and storing in a lower-temperature reservoir.

The result

This project was extremely successfully and set a new milestone for materials testing for this client. It has been in operation for nearly 6 years now.

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