Jakob D. Redlinger-Pohn, Lisa M. König, and Stefan Radl ... · LIGGGHTS ® & CFDEM 20.05.2015 7...
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Towards Simulation-based Engineering of Fibre Fractionation Equipment
State of the Art Open-Source Simulation Tools
Jakob D. Redlinger-Pohn, Lisa M. König, and Stefan Radl Institute of Process- and Particle Engineering, Graz University of Technology
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Agenda
(1) Intro & State of the Art
(i) What is Simulated-Based Engineering?
(ii) Fibre Modeling
(2) A New Open-Source Fibre Simulation Code
(i) Code and Modeling Approach
(ii) Fibre Behavior in Classical Flow Situations
(3) Case study: Can we Predict Fibre Segregation in Coiled Tubes?
(4) Conclusion & Outlook
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IPPT FLIPPR team
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What is Simulation Based Engineering?
Engineering by trial and error – the 20th century approach for design
Simulation guided engineering – 21st century approach for efficient engineering
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Source: www.teslamotors.com
Why not in the pulp & paper industry?
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Multi-cylinder approach [1] Fibres are flexible and deformable Stiffness needs to be tuned to data Expensive calculation
Spheroid approach [2] Fibres are stiff Easier and cheaper calculation of fibre wall and fibre fibre interaction Used for suspension of fibres
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Fibre Modeling
Two approaches found in the literature. Multi-cylinder where fibre is modelled by joined cylinders or as stiff spheroids.
[1] J. Andric, et.al., Acta Mech. 224 (2013) 2359-2374 [2] C. Marchioli, et.al., Physics of Fluids 22 (2010) 033301-1 – 033301-14
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Code and Modeling Approach
1 – Multipurpose Continuum Solvers
o OpenFOAM®
o CFDEM®
o Palabos
o ANSYS Fluent
o AVL Fire®
2 – Multipurpose Lagrangian Solvers
o Yade / WooDEM
o LAMMPS / LIGGHTS®
o SimPARTIX®
o EDEM
o Itasca PFC
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Selection Criteria for Fibre Applications
(1) Collision handling for non-spherical particles
(2) Flexible and deformable particles
(3) Advanced coupling models (i.e., for the fluid-particle interaction forces and torques)
(4) Efficient parallelization for Euler-Lagrange co-simulations Open-source
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Code and Modeling Approach
LIGGGHTS® & CFDEM®
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Implemented into LIGGGTHS® & CFDEM®
(1) Multisphere approach to model rigid fibres (drawback: low efficiency & “rough” particles)
(2) “POEMS” package to model flexible particles (multicylinder approach)
(3) Cohesion forces (van der Walls forces, liquid bridges, etc.)
Free stream of fibre suspension,
© DCS Computing GmbH
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Code and Modeling Approach
LIGGGHTS® & CFDEM®
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Our Contribution to LIGGGHTS® & CFDEM®
(4) Fibre-wall interactions
(5) Fibre-Fibre interaction
(6) Lubrication forces between fibres and fibre-wall
(7) Surface roughness effects
(8) Implicit fibre-fluid drag and torque interaction
Rigid fibre represented as spheroid in suspension flow. Forces and torque on the
fibre are indicated in red
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Fibre Behavior in Classical Flow Situations
Case (1) – Fibre in Shear Flow (Jeffery Orbit).
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AR 2
AR 22.7
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Fibre Behavior in Classical Flow Situations
Case (2) – Fibre/Wall Interaction (fibre close to walls).
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y0 = 0.35 Dmajor
y0 = 0.15 Dmajor
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Fibre Behavior in Classical Flow Situations
Case (3) – Fibre/Fibre Interaction (formation of flocks from thin suspension).
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Case study: Can we Predict Fibre Segregation in Coiled Tubes?
Fibre suspension flow in coiled tubes is common process in any paper mill. From experimental studies with a coiled tube it is known that
fibres segregate according to their length [1].
However, the segregation mechanism is not understood.
Currently: black-box model
Hypothesis: turbulent fluctuations cause separation.
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[1] O. Laitinnen, BioResources 6 (2011) 672-685
Schematic description of tube flow fractionation [1]
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Case study: Can we Predict Fibre Segregation in Coiled Tubes?
Step 1: CFD Simulation to provide fluid flow
Step 2: Add the fibres to the flow field
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Set of Re and
Stationary and oscillating flow
behavior
Initial random orientation and
position of the fibres
Aspect ratio 160, 40, and 20
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Case study: Can we Predict Fibre Segregation in Coiled Tubes?
Preliminary simulation results using CFDEM® of fibre suspension flow in curved pipes shows:
(i) areas of preferred fibre accumulation
(ii) Preferential fibre orientation in the flow and relative to the wall
Ongoing work focuses on analysis of
(i) fibre trajectories and speed, and
(ii) fibre residence time distribution
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Conclusion & Outlook
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Fibre/wall model implemented in CFDEM® and tested.
Improved fibre-fluid coupling allows larger time steps.
Fractionation of fibres based on their length in coiled tubes was successfully simulated for the first time.
Simulations provide insight (fibre orientation / speed / residence time distributions) and allow the rational design and optimization of fractionation equipment.
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Conclusion & Outlook
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Cost: ca. 1 cent/CPUh. 32 kCores
[1] M. Stöhr, J. Zabloudil, AHPC 2015.
Modeling of fibres challenging (aspect ratio, fibre flexibility)
Dedicated high-quality open-source codes are key for wide spread use (www.cfdem.com)
Scientific computing grows rapidly in Austria
Computing speed & cost now acceptable (dcluster, VSC-3).
Efficiency and cost of Vienna HPC clusters [1].
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PROJECT MEMBERS
Scientific Partners:
Industrial partners:
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The K-Project Flippr ° is within the scope of COMET - Competence Centers for Excellent Technologies sponsored by BMVIT, BMWFJ, Province of Styria and Carinthia. The COMET program is managed by FFG
FUNDING PARTNERS
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Towards Simulation-based Engineering of Fibre Fractionation Equipment
State of the Art Open-Source Simulation Tools
Jakob D. Redlinger-Pohn, Lisa M. König, and Stefan Radl Institute of Process- and Particle Engineering, Graz University of Technology