KEY STAR TECHNOLOGIES:

DISPERSED MULTIPHASE FLOW

AND LIQUID FILM MODELLING DAVID GOSMAN

EXEC VP TECHNOLOGY, CD-ADAPCO

Introduction

Atomisation modelling

Lagrangian dispersed flow modelling and validation

Wall impact modelling and validation

Liquid film modelling and validation

Further industrial application examples

Closure

CONTENTS

INTRODUCTION

KEY METHODOLOGIES AVAILABLE IN STAR-CCM+ AND STAR-CD

1. Lagrangian modelling of dispersed multiphase flow of droplets

or solid particles.

2. Modelling of droplet or solid particle impact on walls.

3. Modelling of liquid film formation, dynamics, heat/mass transfer

in all cases with full interaction with continuous phase.

• STAR-CCM+ generally applicable (e.g. aeronautical, chemical process,

oil/gas, medical, etc)

• STAR-CD specifically targeted at reciprocating internal combustion

engine (ICE) modelling

Aerospace (gas turbine combustor, blade erosion, icing….)

Automotive (engine combustion, exhaust aftertreatment, soiling….)

Chemical Process (spray driers, gas/liquid contactors, evaporators,

reactors…..)

Energy (coal furnaces, steam turbines, nuclear reactors……)

Oil and Gas (multiphase pipeline flow, pipeline erosion,

separators….)

Manufacturing Process (spray painting, coating, quenching…..)

… and many more

INDUSTRIAL APPLICATIONS

ATOMISATION MODELLING - OVERVIEW

• modelling of droplet formation by breakup of liquid stream

• provides initial conditions for Lagrangian spray simulation

• built-in models for several atomiser types

• may also include internal flow in atomiser

pressure jet atomiser

pressure swirl atomiser

range of approaches available in both STAR-CCM+ and STAR-CD:

- empirical, including user input

- phenomenological/experiment-based

- physics-based, transport equations

ATOMISATION MODELLING – OPTIONS AVAILABLE

AVAILABLE MODELS STAR-

CCM+

STA

R-CD

Typical

Application

User input – individual droplets

- distribution

✓

✓

✓

✓

general

Huh model (pressure jet) ✓ ICE

Reitz-Diwaker (pressure jet) ✓ ✓ ICE

MPI model (pressure jet) ✓ ICE

LISA model (conical spray) ✓

gas turbine

ELSA model (nozzle flow and atomisation) ✓

ICE, general

LES+VOF (high-resolution nozzle flow and

atomisation)

✓

✓

general

Liquid core

surface

nozzle

Simulation of spray atomisation by pressure jet nozzle with STAR-CD

Includes internal nozzle flow

High-resolution VOF+LES (+cavitation)

ATOMISATION MODELLING - EXAMPLES

LAGRANGIAN DISPERSED FLOW MODELLING – OVERVIEW

multiphase modelling of dynamics, heating, evaporation/condensation of

droplets or solid particles.

solve Lagrangian conservation equations for statistically representative

particles, along with Eulerian conservation equations for fluid phase

phase equations fully-coupled

urea injection in SCR system

LAGRANGIAN MODELLING – SOME DETAILS

Particle momentum

Particle mass

Particle energy

Fluid momentum

Particle location

Particle and continuum fluid conservation equations

particles

built-in models in STAR-CCM+/STAR-CD for key phenomena, including

- droplet turbulent dispersion, breakup, collision and coalescence

- interphase heat/mass transfer

- chemical reaction (coal combustion)

LAGRANGIAN MODELLING – SOME DETAILS

FEATURES MODELLED STAR-

CCM+

STAR

-CD

Particle material – fluid

- solid

✓

✓

✓

Interphase Drag ✓ ✓

Turbulent dispersion ✓ ✓

Breakup ✓ ✓

Droplet collision, coalescence ✓ ✓

Interphase heat transfer – sensible

- latent

- radiative

✓

✓

✓

✓

✓

Multicomponent mass transfer – miscible

- immiscible

✓

✓

✓

Boiling, critical point thermodynamics ✓ ✓

Electrostatic forces ✓

Particle combustion (coal) ✓

disperse

disperse

breakup

collide/coalesce

LAGRANGIAN MODELLING – VALIDATION EXAMPLE

0,000

0,005

0,010

0,015

0,020

0,025

0,0000 0,0005 0,0010 0,0015

t(s)

liqu

id p

en

etr

atio

n (

m)

calculation (90%)

EXP

0,000

0,010

0,020

0,030

0,040

0,050

0,060

0,0000 0,0005 0,0010 0,0015

t(s)

va

po

r p

en

etr

ation

(m

)

calculation (0.1%)

EXP

Pinj = 1300 Bar

liquid penetration vapour penetration

Evaporating Diesel spray simulation

WALL IMPACT MODELLING - OVERVIEW

prediction of regimes and outcomes of droplet or solid particle impact on

wall.

regime can depend on: droplet dynamics; surface temperature,

roughness, material……

outcome can include deposition, secondary breakup…….

solid particle impact can lead to wall erosion

Models available in both STAR-CCM+ (droplets, solid particles) and STAR-CD (droplets)

Strongly experiment-based

Regimes and outcomes for droplets:

WALL IMPACT MODELLING – SOME DETAILS

Senda et al model

Models for droplet and/or solid particle impact in STAR-CCM+ and STAR-CD

WALL IMPACT MODELLING - OPTIONS

FEATURE MODELLED STAR-

CCM+

STAR

-CD

particle material – fluid

- solid

✓

✓

✓

droplet impact regime identification

- dry, wet wall

- user specified

✓

✓

✓

✓

droplet impact outcome

- secondary droplet size, velocity

- liquid deposition rate

✓

✓

✓

✓

droplet-wall heat transfer ✓

droplet multicomponent evaporation and boiling

- finite rate

- instantaneous

✓

✓

user-specified particle stick/rebound/escape ✓ ✓

wall erosion rate ✓

Ice accretion rate ✓

Simulation of spray impingement on cold wall using STAR-CD

WALL IMPACT MODELLING – VALIDATION EXAMPLE

2.6ms

6.6ms

4.6ms

8.6ms

measured calculated

prediction of dynamics, heat/mass transfer, melting/solidification of thin liquid film on wall

film may be result of spray impact, condensation, melting, inlet boundary……..

interaction with adjacent fluid phase via interface boundary conditions and special deposition and stripping models.

modelled by solving Eulerian conservation equations in special way, avoiding need for fine mesh across film.

LIQUID FILM MODELLING - OVERVIEW

• assume film thin, laminar, locally smooth

• express Eulerian conservation equations in integral form across film thickness δ

in wall-normal direction n,

• assume normalised wall-tangential velocities and

temperature, concentrations vary quadratically across film

• result is two-dimensional conservation equations for film thickness δ, mean

velocity umean; temperature Tmean etc as functions of wall-tangential coordinates

and time.

• solve 2D equations by finite-volume method – fast, efficient, can accommodate

arbitrarily thin films.

LIQUID FILM MODELLING – SOME DETAILS

δ n φ

Modelling options in STAR-CCM+ and STAR-CD

LIQUID FILM MODELLING – SOME DETAILS

Features Modelled STAR

-

CCM+

STAR

-CD

Transition from isolated droplet deposition

to film

✓ ✓

interphase momentum transfer via

- interfacial drag

- interfacial deposition/stripping

✓

✓

✓

✓

internal and interphase energy transfer

- conduction/convection/boiling

- evaporation/condensation

- deposition/stripping

✓

✓

✓

✓

✓

✓

internal and interphase mass transfer

- multicomponent

- evaporation/condensation

- deposition/stripping

✓

✓

✓

✓

✓

✓

surface stripping ✓ ✓

edge separation ✓ ✓

solid particle ingestion ✓

solidification/melting ✓

Simulation of air blast atomisation using STAR-CCM+

Lagrangian, liquid film, stripping

LIQUID FILM MODELLING – VALIDATION EXAMPLES

Coarse Grid Resolution

OIL/GAS APPLICATION – PIPELINE EROSION

Simulation of undersea pipeline erosion using STAR-CCM+

Multiphase oil-water-sand mixture

Lagrangian solid particle, erosion models

AUTOMOBILE APPLICATION – RAIN MANAGEMENT

Simulation of rain impact on automobile exterior

Lagrangian droplets, liquid film, stripping

AUTOMOBILE APPLICATION – CATALYTIC CONVERTOR

Simulation of urea injection in automotive catalytic convertor

Lagrangian spray, liquid film with boiling

Simulation of automobile spray painting process with STAR-CCM+

Lagrangian spray, overset mesh

MANUFACTURING APPLICATION – SPRAY PAINTING

MEDICAL APPLICATION – METERED DOSE INHALER

Simulation of metered dose inhaler operation with STAR-CCM+

Lagrangian spray, liquid film, evaporation

AEROSPACE APPLICATION – WING ICING

Simulation of aircraft wing icing with STAR-CCM+

Lagrangian spray, ice accretion, liquid film, freezing/melting

AEROSPACE APPLICATION – ENGINE NACELLE ICING

Simulation of aircraft engine icing with STAR-CCM+

Lagrangian spray, ice accretion, mesh morphing

Powerful, unique methodologies in STAR-CCM+ for simulating

dispersed multiphase and liquid film flows, separately or in

combination

Extensive and continuing validation and refinement

Many industrial applications already – but potential for much more

Further extensions envisaged, e.g.:

- combined Lagrangian ⇔VOF

- combined Liquid Film ⇔ VOF

- fast conjugate heat transfer + Liquid Film

SUMMARY

CLOSURE