Predicting Defluidization in Fluidized Bed Conversion: From Plastics Pyrolysis to Biomass Combustion via Surface Coating Models

In fluidized bed conversion processes such as pyrolysis and combustion, defluidization mainly arises from particle agglomeration, which originates from the surface coating of primary bed materials (e.g., sand) by partially liquefied feedstock components, e.g., plastics or biomass. For reliable operation, the probability of occurrence of defluidization must be quantifiable. However, existing models are either computationally expensive or difficult to transfer across feedstocks with different rheological behaviors. Furthermore, such transferability challenges are particularly pronounced in technically relevant systems involving liquefied components, such as molten polymers and ash-derived silicate melts. In this study, we propose two new coating approaches: (i) a simplified full coating model, where a fraction of bed particles is directly assumed to be fully covered upon feed introduction, and (ii) a partial coating model, where only local surface regions of particles are coated. The proposed models are implemented within a Monte Carlo framework and validated against experimental data reported in the literature for polyethylene and polypropylene pyrolysis as well as for wheat straw combustion. Across all cases, the model predictions capture the experimentally observed defluidization behavior reported in reference studies (e.g., with coefficients of determination of R2=0.912 for the polymer series and R2=0.917 for the wheat straw series). Beyond model validation, several model-based analyses and discussions are further conducted based on the characteristics of the proposed framework. Overall, the developed methodology provides a generalized basis for analyzing coating-driven defluidization across polymers and biomass, with potential extensions to co-pyrolysis, co-gasification, and other thermochemical conversion processes.