Numerical Simulation of Fluidization Behavior and Chemical Performance for Hydrochlorination of Silicon Tetrachloride in a Fluidized Bed Reactor

Exploring the fluidization behaviors and chemical performance in silicon tetrachloride (SiCl4) hydrochlorination processes within a fluidized bed reactor (FBR) poses significant challenges. In this study, we developed an Eulerian-granular model (EGM) by integrating the Eulerian–Eulerian two-fluid model with the kinetic theory of granular flow (KTGF). The effect of fluidization velocities on the flow regime, heat transfer, and chemical reaction performance were investigated. The applicability of the simulation method and the validity of the model were confirmed through comprehensive comparisons, including the simulated values of the maximum bed expansion height (Hmax) with theoretical values derived from empirical formulas and the simulated gas temperature profile with Hsu’s experimental data. The results indicate that the present EGM can be feasible to describe the variation of the flow regime within the FBR. An increase in bed voidage over time, coinciding with transitions in the flow regime, can be observed. Particularly noteworthy was the attainment of a more uniform distribution of SiCl4 under the bubbling fluidization state. Furthermore, the FBR possess high heat transfer characteristics, and the reaction gas can reach the set temperature of the bed after entering a small distance (about 10 mm). The presence of circulating bubbles within the FBR enhances the mixing uniformity of the SiCl4 reaction gas and silicon particles, particularly in the central and upper regions of the bed under the bubbling fluidization state. As a result, the predicted highest concentration of SiHCl3 was 13.08% and the conversion rate of SiCl4 was 28.97% under the bubbling fluidization state. Our results can provide a theoretical basis for further understanding of the hydrochlorination process of SiCl4 within the FBR.