Attrition extent

Some authors (e.g., Vaux and Keaims, 1980, Sishtla et al., 1989, Pis et al., 1991) define the time integral of the attrition rate as the attrition extent... 

Friability tests can be used for various purposes. They are widely used in quality control. Here, samples of produced material are subjected to a more or less arbitrary but well defined stress. The attrition extent is assessed by comparison with a standard value and a decision is reached whether the material meets the standard. Moreover, friability tests are often used for comparison of different materials to select the most attrition-resistant one. This is a usual procedure in the case of catalyst development. For example, Contractor et al. (1989) tested anew developed fluidized bed VPO-catalyst in a submerged-jet attrition test (described below). Furthermore, the specific attrition rate of a material in a certain process can be roughly estimated by friability tests. In this case the stress must be similar to that occurring in the process and the obtained degradation extent must be compared with those of other materials from which the process attrition rate is known. 

Figure 21. Attrition extent caused by a conventional cyclone and by the new cyclone design suggested by Molerus and Gliickler (1996).

A salient feature of the fluidized bed reactor is that it operates at nearly constant temperature and is, therefore, easy to control. Also, there is no opportunity for hot spots (a condition where a small increase in the wall temperature causes the temperature in a certain region of the reactor to increase rapidly, resulting in uncontrollable reactions) to develop as in the case of the fixed bed reactor. However, the fluidized bed is not as flexible as the fixed bed in adding or removing heat. The loss of catalyst due to carryover with the gas stream from the reactor and regenerator may cause problems. In this case, particle attrition reduces their size to such an extent where they are no longer fluidized, but instead flow with the gas stream. If this occurs, cyclone separators placed in the effluent lines from the reactor and the regenerator can recover the fine particles. These cyclones remove the majority of the entrained equilibrium size catalyst particles and smaller fines. The catalyst fines are attrition products caused by... 

Similarly, a variety of drier types are available to remove residual moisture eontent for whieh tests are normally required prior to final equipment seleetion. In eaeh of these operations, eare should be taken to aseertain the extent of partiele size ehange due to attrition and fragmentation, or, in some eases, granulation within the downstream units. 

The next level is that of shaped catalysts, in the form of extrudates, spheres, or monoliths on length scales varying from millimeters to centimeters, and occasionally even larger. Such matters are to a large extent the province of materials science. Typical issues of interest are porosity, strength, and attrition resistance such that catalysts are able to survive the conditions inside industrial reactors. This area of catalysis is mainly (though not exclusively) dealt with by industry, in particular by catalyst manufacturers. Consequently, much of the knowledge is covered by patents. 

Both, the mechanism and the extent of particle degradation depend not only on the process type but also on properties of the solid material, and to a large extent on the process conditions. Clift (1996) has stated that attrition is a triple-level problem, i.e., one is dealing with phenomena on three different length and time scales the processing equipment, the individual particles, and the sub-particle phenomenon such as fracture which leads to the formation of fines. The appearance of attrition can, therefore, differ very much between the various applications. For that reason, the following section deals with the various modes of attrition and the factors affecting them. 

In order to evaluate the extent of attrition and its impact on the particle size distribution, there is a need of a qualitative and quantitative characterization. This, however, is not as simple as it may seem at first. There are many different properties, parameters and effects that manifest themselves and could be measured. In addition, as will be shown, the choice of the assessment procedure is strongly connected with the definition of attrition which, on its part, depends on the degradation mechanism that is considered to be relevant to the process. Hence there are a lot of procedures and indices to characterize the process of particle attrition. Section 3 deals with those which are relevant to fluidized beds and pneumatic conveying lines. 

Fluidized Bed Tests. These tests have direct relevance to all applications where particles are subjected to conditions of fluidization. Some authors believe that these tests can also to some extent simulate the stress of pneumatic transport. Coppingeretal. (1992) found at least a good correlation with the attrition resistance in dense-phase pneumatic conveying when they tested various powders in a slugging fluidized bed. 

The extent of the attrition which is due to the presence of bubbles is conveniently described by the relative production rate of fines... 

Although the results from these methods may correlate to some extent, they simulate different essential requirements of the catalysts. Attrition loss primarily relates to handling, transport, loading and screening whereas the crush tests simulate the forces imposed on the catalyst in a fixed bed. The drop test simulates the risk of catalyst break-up during loading and pneumatic transport. 

Preliminary work involved finding the minimum impeller speed to attain a uniform suspension in the crystallizer and the extent of attrition at this minimum impeller speed. It has already been reported by Lx>h, Ang and Kirke (7) that an impeller speed of 350 rpm was sufficient to maintain a uniform suspension in the crystallizer and the bulk of attrition occurred in the first 4 hours. The extent of attrition was not very significant in any typical nucleation run. 

---