Simulation of a Spray Dryer Fitted with a Rotary Disk Atomizer Using a Three-Dimensional Computional Fluid Dynamic Model

Abstract

Spray dryers fitted with a rotary disk atomizer are widely used in many industries requiring high throughputs to produce powders from liquid streams. The interaction between droplets or particles and the drying medium within the drying chamber is still not well understood and hence difficult to model reliably. In this article CFD results are presented to describe the behavior of the performance of a spray dryer fitted with a rotary disk atomizer in a cylinder-on-cone chamber geometry. Four different turbulence models, i.e., standard k ? ε, RNG k ? ε, Realizable k ? ε, and Reynolds stress models were tested and compared to simulate the swirling two-phase flow with heat and mass transfer in the chamber. The results of this investigation can provide further insight into turbulent swirling flow modeling. The predicted results, such as, air flow patterns, air velocity and temperature, distributions, particle/droplet trajectories, drying performance etc., are obtained using the CFD code FLUENT6.1. Comparison with available limited experimental data shows that CFD results display reasonable agreement. Predicted results also show that the RNG k ? ε model performs better in this specific case.     

Penetration of Particles into Buildings and Associated Physical Factors. Part I: Model Development and Computer Simulations

The PM_2.5 standard proposed by the U.S. Environmental Protection Agency (EPA) has stimulated research on the relationships between particulate matter concentrations and the exposures and subsequent health responses of sensitive subpopulations, such as the elderly. Since individuals in these subpopulations may spend more than 90% of their time indoors, understanding the relationship between outdoor particle concentrations and those found in indoor microenvironments is critical. This research resulted in a time-dependent indoor air quality model incorporating all potential particle sources and loss mechanisms. Monte Carlo simulations of the model identified the mechanisms, such as particle loss during penetration through the building envelope, that modify the outdoor particle size distribution during transport into the interior of a building, calculated indoor-to-outdoor (I/O) concentration ratios, and estimated penetration factors as a function of particle size. Indoor particle generation and transport of outdoor particles through the HVAC system were the most important contributors to the indoor concentration in residential and commercial buildings, respectively. The most significant removal mechanisms included ventilation through and particle removal by the HVAC filter if an HVAC system was present, or particle deposition on indoor surfaces if an HVAC system was not present. The modeled I/O concentration ratios varied between 0.05 and 0.5, depending on particle size and type of ventilation system, and agreed well with published experimental results. Penetration factors less than unity were calculated for particles with aerodynamic diameters larger than 0.2 θ m if the air exchange rate and steady-state I/O concentration ratio were correlated during the simulations. An additional correlation between the air exchange rate and particle deposition velocity is required if penetration factors less than unity are to be modeled for particles with aerodynamic diameters smaller than 0.2 θ m. These results     

Use of Numerical Calculations to Simulate the Sampling Efficiency Performance of a Personal Aerosol Sampler

Numerical calculations were conducted to simulate air and particle behavior near and into the inlet of an aerosol sampler in order to determine sampling efficiency performance. This was done with the pre-verified commercial computational fluid dynamics (CFD) software package, FLUENT (Fluent, Inc., Lebanon, NH, US). Air flow behavior was calculated for steady-state conditions approaching and flowing into 3D geometries of an aerosol sampler free in the air that was similar in dimension to two commercial samplers, namely the Gesamtstaubprobenahme sampler (GSP) and the conical inhalable sampler (CIS). Particle trajectories were calculated in a Lagrangian reference frame on the resulting velocity fields. Based on the particle trajectories, sampling efficiencies were calculated and compared to those reported in the literature for a CIS aerosol sampler. They were found to have similar overall trends for particle sizes up to 21 μ m. Using a correction factor, agreement was observed to be very good for smaller particles, but less so for larger particles.     

Design and Performance of a Low-Cost Micro-Channel Aerosol Collector

Aerosol sampling and identification is vital for assessment and control of particulate matter pollution, airborne pathogens, allergens and toxins, and their effect on air quality, human health, and climate change. Assays capable of accurate identification and quantification of chemical and biological airborne components of aerosol provide very limited sampling time resolution and relatively dilute samples. A low-cost micro-channel collector (μCC) which offers fine temporal and spatial resolution, high collection efficiency, and delivers highly concentrated samples in very small liquid volumes was developed and tested. The design and optimization of this μCC was guided by computational fluid dynamics (CFD) modeling. Collection efficiency tests of the sampler were performed in a well-mixed aerosol chamber using aerosolized fluorescent microspheres in the 0.5–6 μm diameter range. Samples were collected in the μCC and eluted into 100 μL liquid aliquots; bulk fluorescence measurements were used to determine the performance of the collector. Typical collection efficiencies were above 50% for 0.5 μm particles and 90% for particles larger than 1 μm. The experimental results agreed with the CFD modeling for particles larger than 2 μm, but smaller particles were captured more efficiently than predicted by the CFD modeling. Nondimensional analysis of capture efficiencies showed good agreement for a specific geometry but suggested that the effect of channel curvature needs to be further investigated.

Copyright 2014 American Association for Aerosol Research     

Deposition efficiency and uniformity of monodisperse solid particle deposition in the Vitrocell® 24/48 Air–Liquid-Interface in vitro exposure system

Abstract

A key to understanding biological response due to cell exposure to chemical constituents in aerosols is to accurately be able to determine the delivered dose. Deposition efficiency and uniformity of deposition was measured experimentally in the Vitrocell^® 24/48 air–liquid-interface (ALI) in vitro exposure system using monodisperse solid fluorescent particles with mass median aerodynamic diameters (MMAD) of 0.51, 1.1, 2.2 and 3.3?µm. Experimental results were compared with computational fluid dynamics (CFD; using both Lagrangian and Eulerian approaches) predicted deposition efficiency and uniformity for a single row (N?=?6) of cell culture inserts in the Vitrocell^® 24/48 system. Deposited fluorescent monodisperse particles were quantified using fluorescent microscopy and Image J software. Experiments were conducted using a suspension of two particle MMADs with each experiment being conducted a total of three times on different days. The average experimentally measured deposition efficiency ranged from a low of 0.013% for 0.51?µm MMAD particles to a maximum 0.86% for 3.3?µm MMAD particles. There was good agreement between the average experimentally measured and the CFD predicted particle deposition efficiency (regardless of approach) with agreement being slightly better at the smaller MMADs. Experimentally measured and CFD predicted average uniformity of deposition was >45% of the mean and within 15% of the mean for 0.51?µm and 2.2 MMAD µm particles, respectively. Experimentally measured average uniformity of deposition was between 15 and 45% of the mean while CFD predictions were within 15% of the mean for 1.1 and 3.3?µm MMAD particles. The deposition efficiency and uniformity across the cell culture inserts for solid particles should be considered when designing exposure regimens using the Vitrocell^® 24/48 ALI in vitro exposure system.

Copyright © 2019 American Association for Aerosol Research     

Considerations for Modeling Particle Entrainment into the Wake of a Circular Cylinder

The objective of this work is to evaluate the performance of the steady state Reynolds Averaged Navier-Stokes (RANS) computational fluid dynamics (CFD) models for estimating concentration of low Stokes number aerosols (Stk = O(10^?4)) in the wake of a bluff body. These simulations are compared with experimental data. In the simulations and experiments, particles are released upstream of the body and convected downstream, where some are entrained into the wake. The air velocity is computed using a steady state renormalized group k ～ ? model. Lagrangian particle trajectory simulations are performed in conjunction with each airflow model to calculate concentrations. The experiments are performed in an aerosol wind tunnel in which phase Doppler velocimetry measurements are obtained for the velocity field and aerosol concentration.

The RANS model yields a wake concentration deficit that extends downstream past x/D = 10, while the experiments produce elevated concentrations immediately downstream of the near wake. It is postulated that the concentration peak is at least in part attributed to particle interaction with the boundary layer by the following mechanism. Particles are transported into the boundary layer by turbulent diffusion, turbophoresis, and/or inertial forces. Particles then separate from the cylinder with the airflow and travel in a sheath around the periphery of the near wake to converge at the downstream edge of the near wake. Underestimation of the wake concentration by the RANS model is potentially due to inadequacy in the boundary layer approximation used in the model.     

Airflow and Deposition of Nano-Particles in a Human Nasal Cavity

A 3D computational model was developed to study the flow and the transport and deposition of nano-size particle in a realistic human nasal passage. The nasal cavity was constructed from a series of MRI images of coronal sections of a nose of a live human subject. For several breathing rates associated with low or moderate activities, the steady state flows in the nasal passage were simulated numerically. The airflow simulation results were compared with the available experimental data for the nasal passage. Despite the anatomical differences of the human subjects used in the experiments and computer model, the simulation results were in qualitative agreement with the experimental data.

Deposition and transport of ultrafine particles (1 to 100 nm) in the nasal cavity for different breathing rates were also simulated using an Eulerian-Lagrangian approach. The simulation results for the nasal capture efficiency were found to be in reasonable agreement with the available experimental data for a number of human subjects given typical anatomical differences. The computational results for the nasal capture efficiency for nano-particles and various breathing rates in the laminar regime were found to correlate well with the ratio of particle diffusivity to the breathing rate especially for the particles smaller than 20 nm. Based on the simulated results, a semi-empirical equation for the capture efficiency of the nasal passage for nano-size particles was fitted in terms of Peclet number.     

The Filtration of Fibrous Aerosols

Fibrous particles constitute an important class of aerosols that are potential human health hazards. Filters can remove aerosols from the air. The capture of spherical and fibrous aerosols by fibrous filters was investigated in this study. The governing equations of motions for translation and rotation of fibrous particles are derived for airflow over a cylindrical object. Only impaction and interception losses were considered in this study. Transport and deposition of fibrous particles were found to depend on Stokes number, fibrous particle aspect ratio, and ratio of the fibrous particle diameter to the diameter of fibrous filters. Using the Kuwabara flow field, transport and single-fibrous filter capturing efficiency of spherical and fibrous particles were calculated numerically, and these calculations were compared with available data in the literature. The calculated results compared favorably with the results of Yeh and Liu (1974) for spherical particles. Good agreement for losses by interception for both spherical and fibrous particles was observed between our results and those of Lee and Liu (1982). Further experimental data are needed to verify the predicted losses of fibrous aerosols by impaction.     

Measurement of Electrical Charge on Diesel Particles

Nanoparticles (D _p < 50 nm), which are formed as diesel engine exhaust cools and dilutes, constitute minority of total particle mass but majority of total particle number. There are several different theories to explain the nucleation of nanoparticles from diesel exhaust. The two main theories are homogeneous binary nucleation of sulfuric acid and water, and ion-induced nucleation. This study examined the ion-induced nucleation theory. In order to test the ionic nucleation theory, the charged fraction of the diesel particles were measured as a function of particle size using regular diesel fuel in this study. A very small amount of charge was found for the diesel nanoparticles in the nuclei mode, whereas there was a large charged fraction for the diesel particles in the accumulation mode. If ion-induced nucleation were the dominant mechanism for the nucleation of nanoparticles from diesel exhaust, one would expect a significant charge on the nuclei mode particles. The results from this study suggest that ion-induced binary nucleation is at least not a dominant mechanism for the nucleation of diesel exhaust when using regular diesel fuel.

This study also examined the influence of metal additives on nucleation and particle charging. The metal additives examined are of the type used to enhance particle oxidation in diesel particulate filters. When used, the additives led to a large increase in the concentration of solid particles in the nuclei mode, and significantly raised the level of particle charge for particles of all sizes. When additives were used, some of the solid particles in the nuclei mode carried a charge. We believe that these metal related particles form early enough in the combustion process to be charged by ions present during and shortly after combustion.     

A Three-Dimensional Simulation of a Spray Dryer Fitted with a Rotary Atomizer

Abstract

Spray dryers fitted with rotary atomizers are commonly used in diverse industries to produce engineered powders on a large scale. Scale-up of such units is still largely empirical and based on prior experience and know-how. In the present study, a three-dimensional spray dryer with rotary atomizer is investigated numerically with a commercial CFD code. Continuous-phase, i.e., air, conservation equations are formulated in the Eulerian model while the droplet or particle equations are set up in the Lagrangian model. Two-way coupling between the continuous and dispersed phases is taken into account in the governing equations. The stochastic approach is used to predict the particle trajectories. The RNG k ? ? turbulence model was used. Typical results, viz. air velocity, temperature, humidity profiles, and particle trajectories are presented and discussed. Compared with the pressure nozzle spray dryer, more volume of drying chamber is used effectively by the rotating disc type spray dryer. It is found that evaporation and drying take place mainly in the region and in the vicinity of first contact between air and spray. A parametric study is presented and, where appropriate, comparison is made with experimental data obtained with the simulated spray dryer.     

Penetration of Ambient Fine Particles into the Indoor Environment

Several recent studies have indicated significant health risks associated with exposure to fine particles as measured outdoors. However, much of the exposure is believed to have occurred indoors. Consequently, there is considerable interest in the relationship between indoor and outdoor fine particles. This paper describes some results from a study in which the processes of particle removal from infiltrating air by building envelopes are simulated in a chamber. The chamber consists of two compartments, each having a volume of 19 m³. Particles with aerodynamic diameters in the range of 0.05 to 5     

Numerical simulation of the flow in a rotating disk filtration module

The characterization of the flow inside an experimental flat membrane module with a smooth rotating disk was performed. The module consists of a disk rotating at speeds up to 3000 rpm inside a cylindrical housing equipped with a stationary circular flat membrane. The characterization was carried out by using a finite volume CFD software with the κ-omega turbulence model and results of the range of rotation speeds 300 ≤ Ω ≤ 20000 rpm were compared with experimental and theoretical data reported in previous studies. The simulations suggest high permeate fluxes for the device due to large average shear stresses on the membrane and the absence of stagnant zones inside the module, which are desirable features to avoid membrane fouling processes. The simulations show an overall good agreement with theoretical results based on the main assumption that the wall shear stress on the membrane and on the disk can be predicted using modified correlations for rotating flow over a stationary wall and for flow induced by a rotating disk, respectively and with experimental pressure measurements. It has been found that the flow rate imposed at the inlet of the module has an important effect on the pressure distribution. At the membrane some discrepancies were found between the results obtained with the simulations and with the theoretical approach because of the limitations of the assumptions, especially at low rotating speeds for which the effect of the flow through the module becomes important. The correlations relating the disk rotation rate with the surface averaged pressure and the shear stress on the membrane were determined.     

Field Comparison of P-Trak and Condensation Particle Counters

The P-trak ultrafine particle counter is a portable version of a condensation particle counter (CPC). Both instruments detect particle number concentrations in real time but have different detection limits. The P-trak has been widely used for indoor air quality evaluation and aerosol research. However, there is very limited information about the reliability and precision of this instrument and its comparability with other similar instruments. The purpose of this study was to compare a P-trak ultrafine particle counter with a standard CPC and evaluate its applicability to ambient air monitoring.

This study was carried out near the Interstate 405 freeway (I-405) in Los Angeles. Measurements were made at increasing distances from the freeway on both sides at night as well as inside and outside of two 2-bedroom apartments located near the freeway. A CPC and a Scanning Mobility Particle Sizer (SMPS) were collocated with two P-traks and measurement results compared.

In general, higher correlations were observed between P-trak and CPC data for indoor measurements than outdoor. The highest P-trak and CPC correlation ( r ² = 0.9385) was detected inside Apartment 2, which is located farther away from the freeway than Apartment 1. The poorest correlation occurred at 30 m downwind from the freeway. In that case, the P-trak reported about 25% of ultrafine particle concentration that CPC did. A sigmoid (S-shape) function was fitted to observed P-trak to CPC ratios and geometric mean diameters of the corresponding ultrafine particle size distributions. Overall, we concluded the P-trak worked reasonably well when sampled indoor air. However, it has significant limitations in detecting freshly emitted ultrafine particles from vehicles. The P-trak underestimated ultrafine particles especially for particles smaller than its activation size which was found to be approximately 25–30 nm. Caution must be given in interpreting data collected by P-trak monitors near combustion sources.     

Computational Fluid Dynamic Predictions and Experimental Results for Particle Deposition in an Airway Model

An area identified as having a high priority by the National Research Council (NRC 1998) relating to health effects of exposure to urban particulate matter is the investigation of particle deposition patterns in potentially-susceptible subpopulations. A key task for risk assessment is development and refinement of mathematical models that predict local deposition patterns of inhaled particles in airways. Recently, computational fluid dynamic modeling (CFD) has provided the ability to predict local airflows and particle deposition patterns in various structures of the human respiratory tract. Although CFD results generally agree with available data from human studies, there is a need for experimental particle deposition investigations that provide more detailed comparisons with computed local patterns of particle deposition. Idealized 3-generation hollow tracheo-bronchial models based on the Weibel symmetric morphometry for airway lengths and diameters (generations 3-5) were constructed with physiologically-realistic bifurcations. Monodisperse fluorescent polystyrene latex particles (1 and 10 mu m aerodynamic diameter) were deposited in these models at a steady inspiratory flow of 7.5 L /min (equivalent to heavy exertion with a tracheal flow of 60 L /min). The models were opened and the locations of deposited particles were mapped using fluorescence microscopy. The particle deposition predictions using CFD for 10 mu m particles correlated well with those found experimentally. CFD predictions were not available for the 1 mu m diameter case, but the experimental results for such particles are presented.     

Passive Filtration of Airborne Particles from Buildings Ventilated by Natural Convection: Design Procedures and a Case Study at the Buddhist Cave Temples at Yungang,China

Air exchange between interior spaces and the outdoor atmosphere can occur due to a variety of processes, including wind-driven flows and natural convectiondriven flows. As air is exchanged with the outdoors, airborne particles can be brought inside. Depending on the use of the indoor space, the presence of particles in indoor air could be a nuisance to the occupants or could be damaging to materials kept indoors. While one obvious solution to such problems is to install a mechanical air filtration system, that is not always practical. In particular, the character of some historical houses and some archaeological sites would be degraded by the presence of a mechanical air distribution system, and in some parts of the world the reliable electrical power supply needed for such a filtration system may not be available. In the present paper we consider principles for the design of passive filtration systems in which air motion through the filter material is induced by a natural convection flow rather than by a mechanical fan. A fluid mechanical model first is described for predicting the air flow through an interior space that acts as a thermal siphon. The effect of placing filter material in the path of such air flows is examined next. The indoor-outdoor air quality model of Nazaroff and Cass (1989a) is matched to the natural convection air exchange model, and calculations are performed to determine the relationship between the outdoor particle size distribution and indoor particle size distributions and particle deposition rates given a passive filtration system. Example calculations are worked for the case of a passive particle filtration system that could be installed to protect the interior of the Buddhist cave temples at Yungang, China. These are a collection of manmade cave temples dating from the 5th century AD, now situated in the middle of one of China's largest coal-mining regions with its accompanying air pollution problems.     

Performance of ventilation filtration technologies on characteristic traffic related aerosol down to nanocluster size

Near traffic routes and urban areas, the outdoor air particle number concentration is typically dominated by ultrafine particles. These particles can enter into the nearby buildings affecting the human exposure on ultrafine particles indoors. In this study, we demonstrate an aerosol generation system which mimics the characteristic traffic related aerosol. The aerosol generation system was used to determine the size-resolved particle filtration efficiencies of five typical commercial filters in the particle diameter range of 1.3–240 nm. Two different HEPA filters were observed to be efficient in all particle sizes. A fibrous filter (F7) was efficient at small particle sizes representing the nucleation mode of traffic related aerosol, but its efficiency decreased down to 60% with the increasing particle size. In contrast, the filtration efficiency of an electrostatic precipitator (ESP) increased as a function of the particle size, being more efficient for the soot mode of traffic related aerosol than for the nucleation mode. An electret filter with a charger was relatively efficient (filtration efficiency >85%) at all the observed particle sizes. The HEPA, F7 and electret filters were found to practically remove the particles/nanoclusters smaller than 3 nm. All in all, the filtration efficiencies were observed to be strongly dependent on the particle size and significant differences were found between different filters. Based on these results, we suggest that the particulate filter test standards should be extended to cover the ultrafine particles, which dominate the particle concentrations in outdoor air and are hazardous for public health.

Copyright © 2017 American Association for Aerosol Research     

Effects of the impeller blade geometry on the performance of a turbo pneumatic separator

Abstract

This paper mainly presents an analysis of the effects of the impeller blade geometry on the performance of a turbo pneumatic separator based on the CFD simulations by using Fluent 14.5.0. The simulation results indicate that the air vortex can be eliminated by using the positive bending arc blades with a remarkably small impacting angle. Furthermore, the optimum installation angle range for the positive bending arc blades was studied. The material classification experiment results show that for the positive bending arc blades with the optimum installation angles, the fishhook depth is decreased, the classification accuracy is increased, and the particle size distribution of fine powders is narrowed, especially under the design condition, compared to the straight blades. This suggestion of impeller blade geometry for the turbo pneumatic separator is the important basis for designing this type of separators and improving its classification performances.     

Experimental Investigation of Particle Removal from Surfaces by Pulsed Air Jets

This work presents an experimental study of particle removal from surfaces by means of a pulsed air jet directed toward the particle-laden surface. During the experiments, solid particles were dispersed over the surface, forming a layer of particles that did not touch each other. Under these conditions, resuspension of an individual particle was independent of the number of particles and their location. We attempt to explain the observed phenomena by analogy to heat transfer enhancement by pulsed jets. It is expected that since pulsed jets are effective in surface cooling, their application to improved surface cleaning should be promising. For a pulsed jet, we investigated the effect of pulse frequency on particle removal. It was found that particle removal efficiency could be significantly affected by the frequency of the jet. In particular, for a fixed jet velocity, the efficiency increases with frequency, reaches a maximum, and then decreases.     

CFD Study on the Effect of Hydrocyclone Structure on the Separation Efficiency of Fine Particles

Abstract

Effects of geometric structure parameters of 10 mm-diameter hydrocyclones on the particle separation efficiency are studied using computational fluid dynamics (CFD). The fluid velocity profiles and particle trajectories are simulated using RFLOW software with a standard isotropic k-ε turbulent model. The JIS standard CaCO₃-17 particles are adopted as a particulate sample in simulations and experiments. Comparing the simulated results with experimental data, a maximum deviation about 20% in partition curves occurs for 5–10 µm particles. However, fairly good agreements for the cut-size predictions and the fish-hook phenomenon are obtained. The simulated cut-size d ₅₀ is only 2 µm larger than that measured in experiments, while the value of d ₁₀₀ can be accurately predicted. An increase in overflow diameter or a decrease in underflow diameter leads to a lower separation efficiency but a clearer separation sharpness due to lower fluid underflow rate. A short-and-wide rectangular inlet is more efficient for particle separation than a tall-and-narrow one. An inclined inlet conduit plays an inessential role on the efficiency improvement but gains a 2 µm reduction in d ₁₀₀. Comparing the simulated results, the hydrocyclone used in the experiments of this study exhibits a higher separation sharpness than the Rietema type and a higher efficiency than the Bradley type based on the same operation capacity and hydrocyclone size.     

Continuous Drying of Slurry in a Jet Spouted Bed

ABSTRACT

he performance of a laboratory scale jet spouted bed (JSB) for drying rice flour slurry was studied. The bed consisted of ceramic balls (5028 mm diameter) and the rice flour slurry was sprayed onto the moving particle surface near the inlet part. All the experiments were carried out at the jet spouting regime. This regime has high bed void fraction and violent movement and collision of bed particles. As a result, the dried product layer is attrited from particle surface as a fine powder and entrained from the bed by the spouting air. The experimental result were presented to show the effects of static bed height, inlet air flow rate and temperature, and feed concentration and flow rate on the outlet air temperature, thernal efficiency, and mean particle size and moisture content of the product. Asimple mathematical model, which is based on the conservation of mass and energy equations, was developed. Predicted results agreed well with those obtained from the experiment.