2005 SIAMUF Hamill - CFX-5.7 / ANSYS CFX 10.0 Eulerian & Lagrangian • Applications ......
Transcript of 2005 SIAMUF Hamill - CFX-5.7 / ANSYS CFX 10.0 Eulerian & Lagrangian • Applications ......
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MULTIPHASE FLOWSMULTIPHASE FLOWSRecent Advances & Applications
Ian Hamill, ANSYS Europe Ltd., UK
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Presentation Outline
• Recent Advances– CFX-5.7 / ANSYS CFX 10.0 Eulerian &
Lagrangian• Applications
– Fuel spray (droplet break-up)– Suspension polymerisation (chemistry & MUSIG)– Slug catcher (free surface flows)– TWISTER supersonic separator (ASM)– Boiling
• Questions & answers
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New Features
• Eulerian multiphase– Non-drag Forces– Algebraic Slip Model– Boundary Conditions– Interphase Transfer– Numerics Improvements– Mass Transfer Improvements– MUSIG Model
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New FeaturesEulerian Multiphase
• Non-drag Forces– Lift force– Wall lubrication force– Virtual mass force– Favre-averaged turbulence dispersion
force
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Solids DistributionNew FeaturesEulerian Multiphase
– Validation from OPTIMUM project
– Experimental data of King’s College
– 600-710µm glass in water
– 800 rpm
Favre-averaged turbulent dispersion example
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normalised particle volume fractions
Solids DistributionNew FeaturesEulerian Multiphase
Favre-averaged turbulent dispersion example
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Validation
Solids DistributionNew FeaturesEulerian Multiphase
Favre-averaged turbulent dispersion example
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New Features
• Eulerian multiphase– Non-drag Forces– Algebraic Slip Model– Boundary Conditions– Interphase Transfer– Numerics Improvements– Mass Transfer Improvements– MUSIG Model
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New FeaturesEulerian Multiphase
• Algebraic Slip Model– Drag force balance or slip velocity
specification– Turbulent dispersion via gradient diffusion
hypothesis– Energy drift flux is also included– Wall deposition
• Walls can be set as deposition walls• Deposition rate available for post-processing
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New FeaturesEulerian Multiphase
• COPHIT project– Drug deposition in
upper airways– Bronchial tree
geometries:• constructed from
MRI data (Mainz)• resolved to 8th
generation
Algebraic Slip Model example
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New FeaturesEulerian Multiphase
Lagrangian
50 µm
ASM
10 µm
Algebraic Slip Model example
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New Features
• Eulerian multiphase– Non-drag Forces– Algebraic Slip Model– Boundary Conditions– Interphase Transfer– Numerics Improvements– Mass Transfer Improvements– MUSIG Model
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New FeaturesEulerian Multiphase
• MUSIG– Multiple Size Group model– Accounts for coalescence and break-up in
polydispersed phases using population balance approach
– Status• Built-in solver model in CFX-5.7• GUI in ANSYS CFX 10.0
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New Features
• Lagrangian particle tracking– Non-drag particle forces– Multi-component particles– Heat and mass transfer– Reacting particles– Particle/wall interaction and particle
absorption– Particle User Routines– Transient particle tracking– Secondary break-up
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Transient ParticleTracking
New Features
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New Features
• Transient particle tracking– Compatible with transient
grids (e.g. fuel sprays in I.C. engines)
– Example• Transient bubble plume
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Secondary DropletBreak-up
Applications
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New Features
• Secondary break-up models– Reitz & Diwakar– TAB– ETAB– CAB– Schmehl
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Droplet Break-Up Mechanisms
• Bag break-up
• Multimode break-up
• Shear break-up– most important in cross-flow rig
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Break-Up Regimes
Schmehl, Maier and Wittig,
ILASS 2000, Pasedena, CA
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Spray rig and Nozzle Detail
Traversible back wall to allow adjustment of distance of nozzle from measurement area.
Traverse Motor
Rig mount location
Fuel Nozzle
Close up of back wall with nozzle detail
Fuel Nozzle
Air flow supplyPressure
[PSI]
Honeycomb section to act as flow straightener
30mm x 30mm cross section size
10mm gap to allow unobstructed optical access
Trough to avoid fuel splashing
Flow outlet
Plenum Chamber with wire gause to smooth flow
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Effect of Droplet Break-up
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Comparison of Spray Shape
Experiment LSICFD
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D30 - 25mm Plane
Expt.
CFD
66 m/s 53 m/s 40 m/s
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Volume Flux - 25mm Plane
Expt.
CFD
66 m/s 53 m/s 40 m/s
N.B. Absolute level of volume flux in experiment not reliable
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Batch SuspensionPolymerisation
Applications
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Background
• Project OPTIMUM– Funded by the European Commission under
the ‘Competitive & Sustainable Growth’ Programme (1998-2002)
– Optimisation of Multiphase Mixing– G1RD-CT-2000-00263– Two processes studied:
• Suspension Polymerisation (Dow Benelux)• Particle Coating (Merck)
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Background
• ANSYS Europe Ltd.– Christiane Montavon– Jane Pearson– Ian Hamill
• Dow Benelux BV– Gerrit Hommersom
• Dow Olefinverbund GmbH– Rolf-D. Klodt
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Process Flowsheet:general process
Suspending agent
Water
Initiator
Reactor
Batchmixer
WasteWater
MaturationHopper
DewateringDrying
Screening
SiloHopper
PackingCar
Transport
MonomerAdditives
MaturationHopper
®
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Batch Process Sequence
Temperature
Time
Tf
Tr
Ti
charging 1. h
eatin
g up
2. h
eat in
g up
1. polymerization step(Particle formation)
2. polymerization step(finishing - full
conversion)
3. c
ool in
g do
wn
Optimum focus
®
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Reactor Process Characteristics
• Creation of oil-water suspension• Polymerisation of the dispersed oil phase
– polymer structure• Issues:
– control of the particle size (quality)• stabilization of phase interface• hydrodynamics
– control over particle growth (safety)• qualitative and local
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• Physical features of process:– large volume fraction loading (~50:50)– order of magnitude range of droplet sizes– coalescence & break-up of droplets– range of disperse-phase viscosities– buoyant flow incl. evolution of density– reacting– turbulent– large range of timescales (O(s)-O(hrs))
Reactor Process Characteristics
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• Chemical kinetics• Particle size distribution (population
balance model)
Model Implementation
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Suspension Polymerisation –Chemical Kinetics
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Reaction Scheme
i) Initiation
ii)
iii) Propagation
iv) Chain transfer to monomer
v) to polymer
vi) Termination combination
vii) disproportionation
*2II dk→
1* RMI ik→+
1RPMR nk
nf +→+
mnk
mn RPPR c +→+
mnk
mn PRR kt+→+ ,
mnk
mn PPRR dt +→+ ,
1+→+ nkp
n RMR
Process Simulation -Chemical Kinetics
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• Low conversion rates
• High conversion rate during the Gel/Trommsdorff Effect
• Slowing down of conversion due to the Cage and Glass Effects
Three Stages of Conversion
Process Simulation -Chemical Kinetics
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Batch PolymerizationKinetic Phases
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Six transport equations:• monomer, YM
• 2 initiators, YI ,YI2
• dead polymer, YP
• 0th & 2nd moments of dead polymer, µ0, µ2
Four algebraic equations:• 0th, 1st & 2nd moments of polymer radicals, λ0, λ1, λ2
• 1st moment of dead polymer, µ1
Process Simulation -Chemical Kinetics
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Verification Against Kinetic Model
• Isothermal.
• Zero-dimensional.
• Two sets of time-steps:1. Uniform 1 minute.2. Refinement to 1 second near Gel Point
followed by steps of 15 seconds.
Process Simulation -Chemical Kinetics
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Monomer Concentration
Model ValidationChemical Kinetics
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Number-averaged molecular weight of dead polymer & polymer radicals
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Model ValidationChemical Kinetics
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Conclusions
• Good agreement with kinetic model and experimental results for consumption of monomer.
• Slight under-prediction of final average molecular weight compared with kinetic model. Both produce lower values than experimental measurements.
• Small sensitivity to size of time step.
Process Simulation -Chemical Kinetics
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Suspension Polymerisation –Population Balance Model
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Why PopulationBalance Modelling?
Suspension polymerisation: suspended monomer droplets polymerise in time to solid polymer particles
Initial Final
polymerisation
How to model?
Population balance: particle identity followed in time
Here only one key parameter: particle volume(or diameter)
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Population Balance Modelling
),,,(),,,(),,(),,(),,( tYrxDtYrxBtrxFvtrxFxttrxF
prx−=⋅∇+⋅∇+
∂∂ •
PBE in most general form*:
growth-rate convection birth death
Birth into volume x Death into volume x
* Ramkrishna, Rev. Chem. Eng. 1(3), 1985
x
Break-up
x
Coalescence
xBreak-up
xCoalescence
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Population Balance
• Modification to implementation– Equations for size groups solved in a fully coupled
way– New type of discretisation– Lyon-Tobolski model for viscosity– One additional tuning constant to Maxwell
• Validation– Time evolution of PSD and Sauter mean diameter
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Particle Size Evolution
• Samples from reactor, diluted and stabilized
0.25 batch time 0.5 batch time 0.75 batch time 0.875 batch time
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CFD 3-D Model: Initial Condition
Velocity field Oil volume fraction
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CFD 3-D model:Volume Fractions
Oil volume fraction: identity point Oil volume fraction: end
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CFD 3-D model: Validation of Process Evolution
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t/tgrowth=0.75
Model Validation –Population Balance
t/tgrowth=1.0
t/tgrowth=0.25 t/tgrowth=0.5
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CFD Modelling Evaluation
• Kinetics implementation excellent• Model predicts correct trends for PSD• Runtime efficiency strongly dependent on model
size (grids/MUSIG groups) => improvement in CFX-5.7
• Some additional tuning required• Other process applications possible
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Free Surface Flows
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Free Surface Flows
• Compressive differencing in space & time• Surface tension effects (normal & Marangoni)• Homogeneous or multifluid treatment• Transient mesh adaption• Compatible with all physical models, e.g.
chemistry, interphase mass transfer
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Free Surface Flows
• Small-scale, incl. surface tension…
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Free Surface Flows
• Large-scale, e.g. Hannibal Slug Catcher
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Free Surface Flows
• Background– Gas pipeline from off-
shore field to land-based Hannibal terminal
– Slug catcher separates residual liquid from gas at end of pipeline
– Plan to increase pipeline capacity to supply new power station
– Question: Does capacity of slug catcher also have to be increased?
Inlet from pipeline
Gas outlet
Liquid outlets
Estimated cost of modifying slug catcher $25M
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Free Surface Flows
• CFX Model– Inhomogeneous multiphase
free surface transient flow– Use centre plane symmetry -
only model half the system– Hex mesh with transient mesh
adaption– Every few days a sphere is
passed along the pipeline to remove residual liquid
– Analyse ‘worst case’ scenario when sphere has just arrived
• Inlet conditions from OLGA 1-D pipeline calculation
Initial coarse mesh
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Free Surface Flows
Initial Mesh Adapted Mesh
• Transient mesh adaption in Inlet Header
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Free Surface Flows
• Current operation– No liquid carry-over to gas outlet
• first separation finger (nearest symmetry plane) partially fillswith liquid
• other fingers receive less liquid
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Free Surface Flows
Liquid carry-overFlow rates
Peak Level• High flow operation
– Can slug catcher cope with increase in capacity?
– Yes!– Liquid carry-over
only in form of fine aerosol
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Free Surface Flows
• Test to overflow– Linear increase of liquid
flow rate until overflow occurs
– Liquid enters gas header first through third separation finger
– Large safety margin demonstrated for current and future operational conditions
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TWISTER Supersonic Separator
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TWISTER Supersonic Separator
• Founded May 2001– Shell owned– Independent company
• Delivers– Equipment – Services on
• process engineering• flow simulations
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Typical mid Twister conditions:
30 bar, -45 degC
Schematic RepresentationSaturated Gas
Liquid / Gas Separation
Dry Gas
LiquidsTypical inlet conditions:
100 bar, 25 degC
Typical outlet conditions:
70 bar, 15 degC
Supersonic Wing (Mach 1-3)
Throat (Mach 1)
Acceleration to Mach 1 cools gasFurther cooling from acceleration to Mach > 1Cooling causes condensation
Axial velocityHigh
Low
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CFX simulations
• High speed compressible flow up to Mach = 2• High pressure and low temperature (real gas properties)• Multi component
– hydrocarbons, water, etc. • Multiphase
– liquid droplets and film– coalescence and break-up (MUSIG)
• Non-equilibrium phase transitions– nucleation and condensation
• Strong swirl• Turbulent flow with flow separation
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Nucleation and Droplet Growth
0.00E+00
1.00E-08
2.00E-08
3.00E-08
4.00E-08
5.00E-08
6.00E-08
-5.00E-02 0.00E+00 5.00E-02 1.00E-01 1.5
x (m)
Dro
plet
Rad
ius
(m)
2.20E+02
2.30E+02
2.40E+02
2.50E+02
2.60E+02
0.00E+00 5.00E-02 1.00E-01
x (m)
Tem
pera
ture
(K)
1-D model
T Rd
CFX CFX
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Hunter experiment
Hunter simulation
Shock-Boundary Layer Interaction
Twister simulation
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Radial Humidity Distribution
-0.02
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0.01
0.02
-0.02 -0.01 0.00 0.01 0.02z
y
Measured humidity distribution at VF=0
Particle distribution at VF=0 (CFX)
dry
wet
• Sample probe as Vortex Finder (at V.F. position = 0) • Measure RH, T and P of sample
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Bulk Boiling
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Bulk Boiling
• Example case– 2-D– 105Wm-2 heat flux at base– Adiabatic side walls– 3-fluid
• continuous water• disperse steam bubbles• continuous gas above surface
– Standard thermal phase change model– Constant bubble 1mm bubble size
• Continuing research & development in collaboration with FZ Rossendorf
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Bulk Boiling
Temperature
[c]
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Questions & Answers