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Volume 108
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Influence of fluidization dynamics and liquid evaporation on particle growth in a top-spray fluidized bed
Han Pu, Jiliang Ma *, Jialiang Cai, Yi Wang, Xiaoping Chen, Cai Liang, Daoyin Liu, Meng Liu
Southeast University, Key Laboratory of Energy Thermal Conversion and Control of Ministry of Education, School of Energy and Environment, Nanjing, 211102, China
10.1016/j.partic.2025.11.013
Volume 108, January 2026, Pages 280-292
Received 19 May 2025, Revised 12 November 2025, Accepted 17 November 2025, Available online 29 November 2025, Version of Record 5 December 2025.
E-mail: jlma@seu.edu.cn
Highlights

• Relationship between particle growth, fluidization, and evaporation is studied.

• Agglomeration closely relates to liquid viscosity, temperature and spraying rate.

• Liquid evaporation significantly correlates with dynamics of bubbles in the bed.

• Particle growth mode is categorized into nucleation growth and shell growth.

• A regime map is constructed to distinguish agglomeration and fluidization failure.


Abstract

The phenomenon of particle agglomeration in a liquid-containing fluidized bed is closely associated with the interactions between gas and solid phases, as well as the evaporation of the liquid component. This study performs an experimental investigation to examine the interactions among particle growth, fluidization behavior, and droplet evaporation within a continuous top-spray fluidized bed system. The research indicates that increased drying air temperatures generate severe drying conditions that promote the conversion of liquid bridges to solid bridges between particles. This conversion significantly decreases the nucleation time and encourages a more consistent distribution of agglomerate sizes. Additionally, a rise in the spraying rate and binder viscosity, strengthen the cohesive forces among particles, resulting in the development of larger agglomerates. The evaporation of the liquid binder exhibits a substantial correlation with the behavior of bubbles within the bed, which in turn affects particle growth and the chaotic dynamics of the fluidized bed system. The process of particle growth is delineated into two separate phases: nucleation growth and shell growth. Notably, the duration of nucleation growth phase exceeds that of the shell growth phase. Ultimately, a regime map has been developed to evaluate the feasibility of the spray granulation process concerning fluidization and drying parameters. The findings suggest that excessively low fluidization numbers, coupled with inadequate drying conditions, could lead to the failure of the liquid-containing fluidization process.

Graphical abstract
Keywords
Top-spray fluidized bed; Liqiud bridge force; Particle agglomeration; Drying; Pressure fluctuation
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