Three-dimensional simulation of the particle distribution in a downer using CFD–DEM and comparison with the results of ECT experiments

A three-dimensional numerical model of the down-flow fluidized bed (Downer) with a newly designed distributor was applied to investigate the particle distribution profiles using combined computational fluid dynamics (CFD) and the discrete element method (DEM). A realistic model of DEM, which calculates the contact force acting on the individual particles, is used to monitor the movement of individual particles in the bed. The contact force is calculated using the concepts of the spring, dash-pot, and friction slider. The flow field of gas is predicted by the Navier–Stokes equation. This CFD–DEM model provides information regarding the particle movement and distribution, the particle velocity, and the gas velocity in the bed under different air-particle mixture conditions. The results demonstrate that the air supply conditions directly influence the particle distribution uniformity. Furthermore, the numerical predictions for the axial and radial profiles of the particle distribution were found to agree well with the experimental results obtained by electrical capacitance tomography (ECT).     

On the particle–particle contact effects on the hole cleaning process via a CFD–DEM model

ABSTRACT

The accurate and precise computational models in order to predict the hole cleaning process is one of the helpful assets in drilling industries. Besides the bulk properties such as the flow velocity, particles average size, cleaning fluid properties, etc., that will affect the cleaning process, there is an unanswered question about the microscopic properties of the particles, particularly those which determines the contact characteristics: Do those play a major role or not? The rudimentary answer is not. The first purpose of the present work is to answer this question via a developed computational fluid dynamics coupled with discrete element method (CFD–DEM) in which the six unknown rolling and sliding friction coefficients of particle–particle contact, particle–wall contact, and particle–drill contact are considered as the main microscopic properties of the contacts. The second purpose is to search for optimum values of these coefficients in order to calibrate the CFD–DEM model with the experimental data for a near horizontal well cleaning available in the literature. The verification of the calibrated CFD–DEM model is checked by simulation of the hole cleaning process for different inclination angles of the deviated well. The results indicate the pivotal role of the microscopic properties of the particles on the characteristics of the particle transport mechanism.     

Resolved CFD–DEM coupling simulation using Volume Penalisation method

A resolved CFD–DEM coupling model for the simulation of particulate flows is proposed in this work. The Volume Penalisation (VP) method, which is a family of the continuous forcing Immersed Boundary (IB) method, is employed to express the particle–fluid interaction. A smooth mask function is used to avoid sharp transition between the solid (particle) and fluid domains that may cause numerical oscillation with moving particles. Optimal permeability is employed to reduce the model error associated with the VP method. It is determined as a function of only the interface thickness and fluid kinematic viscosity. The proposed model is accurate, easy to implement with any discretisation scheme, and only requires small computational overhead for particle–fluid interaction. Several simulations are performed to test the validity of the proposed model in various systems, i.e. from dilute to relatively dense flows, and the results show good agreement with the exact solution or empirical correlation. It is found that the error can be scaled with the ratio between the gap and interface thickness. The proposed model is also applied to predict the relative viscosity of suspensions and the density segregation in fluidised beds.     

Direct measurement of particle–particle interaction using micro particle interaction analyzer (MPIA)

Direct particle–particle contact force measurement was successfully conducted for realistic parameter determination to support discrete element method (DEM) simulation by using a newly developed force measurement of micro particle interaction analyzer (MPIA). In this system particle-to-particle distance and deformation can be controlled by nanometer accuracy. The system can be used for measuring not only short-distance deformation but also long-distance deformation that was validated by both elastic contact and liquid bridge interaction including rupture distance, respectively. Then, the system was applied to obtain plastic normal deformation characteristics such as coefficients of restitution of the spherical granules at low loading force less than 0.5 mN. Granules were prepared from two-stage pressure swing granulation (PSG) technique in a fluidized bed.     

Simulation of the pressure drop across granulated mixtures using a coupled DEM – CFD model

The sinter process converts mixtures of iron ore, iron ore fines and fluxes into a fused aggregate (sinter) that is used as burden material in the blast furnace. The rate of this process is predicted by measuring the pressure drop across the green granulated mixture before ignition. A lower pressure drop corresponds with a higher permeability resulting in a higher sinter rate. The addition of fine material, such as concentrate or concentrate agglomerated into micropellets, to the sinter mixture affects the pressure drop. This study numerically predicts the pressure drop over several granulated mixtures in order to reduce the number of experimental measurements. The pressure drop was studied both experimentally using a pot grate and by coupled DEM (Discrete Element Method) – CFD (Computational Fluid Dynamics) simulations. The validation of the model was performed by comparing the measured and numerical values of the pressure drop across glass beads 3 and 6?mm in diameter respectively. The simulation of the pressure drop was extended to granulated mixtures that contain 0–40% concentrate or micropellets. DEM was also used to numerically simulate iron ore granules and relate their mechanical behaviour to particle size distribution, shape, friction coefficient, Young’s modulus and adhesion force.     

Hydrodynamic predictions of dense gas–particle flows using a second-order-moment frictional stress model

Based on the Eulerian–Eulerian two-fluid continuum approach, an improved unified second-order-moment two-phase turbulence model combining with the kinetic theory of particle collision frictional stress model is developed to simulate the dense gas–particle flows in downer, where the effective coefficient of restitution is incorporated into the particle–particle collision. The interaction term between gas and particle turbulence is fully taken into account by the transport equation of two-phase stress correlation. Hydrodynamics of high density particle flow, measured by Wang et al. [27] are predicted and the simulated results are in good agreement with experimental data. On the conditions of considering the realistic energy dissipation due to frictional stress, particle concentration and particle axial averaged velocity are closely the measured and they are better than without frictional stress model. Furthermore, the particle Reynolds stress is redistributed and the particle temperature is reduced. Effect of frictional stress leads to increase obviously the collision frequency at the outlet and inlet regions and the magnitude of frequency of particle collisions is 10².     

Study of sedimentation of non-cohesive particles via CFD–DEM simulations

The sedimentation process of granular materials exists ubiquitously in nature and many fields which involve the solid–liquid separation. This paper employs the coupled computational fluid dynamics and discrete element method (CFD–DEM) to investigate the sedimentation process of non-cohesive particles, including the hindered settling stage and the deposition stage. Firstly, the coupled CFD–DEM model for sedimentation is validated by the hindered settling velocity at different solid volume concentrations of suspension \(\phi _{0} \), i.e., \(\phi _0 =\) 0.05–0.6. Two typical modes of sedimentation are also presented by the concentration profiles and the equal-concentration lines. Then, the comparisons between mono- and poly-dispersed particle system are detailed. In the sedimentation of the poly-dispersed particle system, the segregation phenomenon is simulated. Furthermore, this segregation effect reduces with the increase of the initial solid concentration of suspension. From the simulations, the contact force between every pair of particles can be obtained, hence we demonstrate the “effective stress principle” from the view of the particle contact force by giving the correspondence between the particle contact force and the “effective stress”, which is a critical concept of soil mechanics. Moreover, the deposition stage can be simulated by CFD–DEM method, therefore the solid concentrations of sediment bed \(\phi _{\mathrm{max}} \) on different conditions are studied. Based on the simulation results of \(\phi _{\mathrm{max}} \) and the theory of sedimentation, this paper also discusses a method to calculate the critical time when sedimentation ends of two typical modes of sedimentation.     

An investigation of the effect of SiC particle size on Cu–SiC composites

In this study mechanical properties of copper were enhanced by adding 1 wt.%, 2 wt.%, 3 wt.% and 5 wt.% SiC particles into the matrix. SiC particles of having 1 μm, 5 μm and 30 μm sizes were used as reinforcement. Composite samples were produced by powder metallurgy method and sintering was performed in an open atmospheric furnace at 700 °C for 2 h. Optical and SEM studies showed that the distribution of the reinforced particle was uniform. XRD analysis indicated that the dominant components in the sintered composites were Cu and SiC. Relative density and electrical conductivity of the composites decreased with increasing the amount of SiC and increased with increasing SiC particle size. Hardness of the composites increased with both amount and the particle size of SiC particles. A maximum relative density of 98% and electrical conductivity of 96% IACS were obtained for Cu–1 wt.% SiC with 30 μm particle size.     

Microstructural investigation of a silica fume–cement–lime mortar

Several additions, minerals and organic, are used in mortars, such as pozzolanic materials, cementicious materials and polymers. Literature about the use of additions in masonry mortars (cement/lime/sand mixes) is scarce; usually, studies are about concrete mortars. The purpose of this work is to study the microstructural effects of the substitution of 10% of Portland cement by silica fume in a 1:1:6 (cement/lime/sand mix proportion by volume) masonry mortar. Scanning electron microscopy with energy dispersive X-rays analysis (SEM/EDX) shows that, with silica fume, the C–S–H formed is type III at early ages and that type III and type I coexist at later ages. Silica fume lowers the total porosity and increases compressive strength only at later age and, as expected, the pore structure of mortar with silica fume is found to be finer than of non-silica fume mortar.     

An investigation of a solid–liquid phase-change-cooled mirror

This article details a new design for a laser-reflecting mirror utilizing phase-change-cooling technology, which is innovative in using spiral cooling ducts filled with solid-liquid phase-change material to maintain a constant temperature inside the reflecting mirror in a positive-branch telescopic, virtually confocal unstable resonator. The structure no longer needs the 45° scraper plate that is always utilized in a positive-branch telescopic, virtually confocal unstable resonator for coupling the output and provides a high-quality coaxial laser output. The numerical calculation results show, that when phase-change cooling is utilized, the localized maximum temperature dropped from 44 to 33°C. Experiments show that the total surface deformation of a copper mirror dropped from 1.4?µm to 0.27?µm when using phase-change cooling, after continued laser exposure for 10?s and, under the same conditions, that of a silicon mirror dropped from 1.1?µm to 0.4?µm.     

CFD modeling of dilute phase pneumatic conveying in a horizontal pipe using Euler–Euler approach

ABSTRACT

Computational fluid dynamics simulations were performed to investigate the behavior of dilute phase pneumatic conveying of plastic pellets in a horizontal circular pipe. The pellets are 200?µm in diameter and 1000?kg/m³ in density. A parametric study was performed to investigate the effects of turbulence model and model collision parameters on pressure drop, solid’s volume fraction and velocity profiles. Among model collision parameters, specularity coefficient has considerable effect on the pressure drop. Moreover, the results from simulations carried out for different solid loadings and velocities were compared with experimental data found in the literature. The air velocities range from 6 to 15?m/s and solids to air mass flow ratios range from 1 to 3. At higher air velocities, the pressure drops predicted by the standard k-omega turbulence model are higher than the pressure drops predicted by the standard k-epsilon model. In contrast, at lower gas velocities, the standard k-epsilon model predicts higher pressure drops compared to the standard k-omega turbulence model. However, no significant difference in solids and air velocity profiles is observed for the two different turbulence models.     

Theoretical study of Ni–Al nanoalloy clusters using particle swarm optimisation algorithm

Abstract

The global structural optimisations for Ni–Al nanoalloy clusters at different compositions have been investigated using particle swarm optimisation combined with simulated annealing method. The second moment approximation of the tight binding potential has been used in describing the interatomic interactions. Some stable structures were obtained for Ni_xAl_x(x=1–8), Ni_3xAl_x(x=1–4) and Ni_xAl_3x(x=1–4) nanoalloy clusters. The simulation results show that the lowest energy isomers of nanoalloy clusters with the approximate composition 'NiAl, Ni₃Al and NiAl₃' generally have structures based on icosahedral packing. It is confirmed that segregation is favoured for Ni–Al nanoalloy clusters, with the surface becoming richer in Al and the core becoming richer in Ni.     

Development of a procedure for spherical alginate–boehmite particle preparation

Herein we describe a versatile new strategy for producing spherical solid particles with 2 mm in size using integrated gelling process. The method involves the formation of spherical droplets by using a peristatic pump device and shaping the droplets in a liquid calcium chloride solution. The shape and size of these calcium alginate macroparticles depend strongly on the calcium solution concentration. The shaping mechanism of the macroparticles and the impact of the experimental conditions on particle shape and size are investigated. This method has the following features: (1) A new level of control over the shapes of the particles is offered. (2) The procedure can be scaled up to produce large numbers of particles. (3) The final porous structure of the developed particle can be designed for a specific application (adsorption, catalysis).     

Failure behavior investigation of a unidirectional carbon–carbon composite

The failure behavior and morphology of a carbon–carbon composite (C–C composite) manufactured by isothermal chemical vapor infiltration was studied by three-point bending tests, polarized light microscope and scanning electron microscope, respectively. The C–C composite was reinforced by PAN-based carbon fiber aligned in only one direction. Flexural strength and modulus of the composite were 200.9 MPa and 50.5 GPa, respectively. Failure behavior of the unidirectional C–C composite can be described as three stages including brittle fracture behavior at beginning, quasi-ductile behavior finally, and fluctuation behavior between them. Two main kinds of cracks, namely cracks parallel and perpendicular to loading direction alternately resulted in deformation evolution of the composite. The strength of interfacial bonding and cracks orientation played key roles to failure behavior of C–C composite.     

CFD–DEM Model for Simulation of Non-spherical Particles in Hole Cleaning Process

During the well drilling process, particles are produced in different shapes. The shape of particles can influence the characteristics of particles transport process. The aim of this work is to analyze the effects of particle shape on the transportation mechanism. For this purpose, a three-dimensional model is prepared for simulation of particle transportation with spherical and non-spherical shapes, during deviated well drilling. The motion of particles and the non-Newtonian fluid flow are simulated via discrete element method and CFD, respectively. The two-way coupling scheme is used to incorporate the effects of fluid–particle interactions. Three different samples of non-spherical shapes are constructed using multi-sphere method. The interactions of particle–particle/wall/drill pipe are taken into account via Hertz–Mindlin model. Simulations are carried out for some laboratory-scale configurations and fair agreements with the experimental data available in the literature are established.     

Performance analysis of an air rock thermocline TES tank for concentrated solar power plants using the coupled DEM–CFD approach

Clean Technologies and Environmental Policy - One of the most common solutions currently available to meet future energy needs in the world is concentrated solar power (CSP) plants combined with...     

Detailed analysis of particle–substrate interaction based on a centrifugal method

The interaction between particles and inclined substrates in a centrifuge was investigated theoretically and experimentally. First, the balance of the force acting on a particle adhering to the substrate, with an inclination angle from 0 to 90° to the horizontal, was formulated separately in the normal and tangential directions. The adhesion force was then derived based on the point-mass model as a function of the angular velocity. Next, the balance of the moments of the forces acting on a particle adhering to the substrate was formulated; theoretical equations for the adhesion force and the effective contact radius were then derived from the angular velocities, obtained at any two inclination angles, based on the rigid-body model. Finally, the removal fraction curves of spherical/nonspherical particles with median diameters of less than 10 µm were experimentally obtained by increasing the angular velocity at each inclination angle. The experimentally obtained angular velocities were substituted into the theoretical equations to compare the point-mass and rigid-body models. The effects of the particle shape on the adhesion force and effective contact radius and that of the inclination angle on the removal fraction curves based on the theoretical equation were also investigated.     

Penetration behaviour of individual hydrophilic particle at a gas–liquid interface

The penetration behaviour of a hydrophilic particle impacting on a gas–liquid interface was studied both experimentally and mathematically. The aim of this study was to determine the critical impact velocity below which a falling hydrophilic particle would remain on a horizontal liquid surface. A model to predict the critical velocity has been developed based on energy balance of both the particle and liquid volume in the vicinity of the impact zone. The model also includes the effect of hydrophobicitiy (contact angle) of the particle as well as the change in potential energy of the impacted liquid. Experiments were performed using spherical glass beads of diameter 0.97–1.66 mm, and using liquids with varying density (1000–1182 kg/m³), viscosity (1.002–4.796 mPa s) and surface tension (50.31–87.42 mN/m). High speed video camera was used to obtain the particle impact velocity, cavity profile and velocity of the three-phase contact line (TPCL) at the critical conditions. The TPCL line velocity and cavity profile were used as inputs for the model. The fitted advancing contact angle was employed in the model. It was found that the model was in good agreement with the experimental observations, and the fitted advancing contact angle agreed with the combined molecular-hydrodynamic model well.     

Experimental investigation of a novel hybrid metal–composite joining technology

An integrative joining technology between steel and carbon fibre-reinforced plastics (CFRP) is presented for lightweight design applications in aviation industries. Small spikes are welded onto metal surfaces via “cold-metal transfer” which then build up a fibre-friendly fixation through form-closure with co-cured composites. Manufacture of such reinforced hybrid specimens and results of static tensile testings are discussed. Video-extensometry is applied to characterize the hybrid joints in terms of strength and failure history. Comparisons with epoxy bonded references show improvements in ultimate load, maximum deformation and energy absorption capacity.     

Strategical parametric investigation on manufacturing of Al–Mg–Zn–Cu alloy surface composites using FSP

Friction stir processing (FSP) is a unique approach being presently researched for composite fabrication. In the present investigation, Al-B₄C surface composite was fabricated through FSP by incorporating B₄C powder particles into Al–Mg–Zn–Cu alloy (AA 7075) matrix. The influence of varying powder particle reinforcement strategies on the microstructure, powder distribution, microhardness, and wear resistance of the surface composite is reported. In addition, AA 6061/B₄C composites were prepared using the same parameter set and the powder distribution in the composite was compared to that in the AA 7075/B₄C composite. More homogeneous dispersion of B₄C powder was observed in AA 6061 as compared to AA 7075 substrate. Among the prepared AA 7075/B₄C composites, the best B₄C powder distribution was detected in samples processed using fine powder and incorporating the change in stirring direction between passes. The hardness and wear resistance of the prepared composites were almost doubled attributing to several strengthening mechanisms and B₄C powder distribution in the AA 7075 matrix.