Quasi-1D and 3D TPOX porous media diffuser reformer model

This paper focuses on the numerical simulations of methane thermal partial oxidation reforming process within inert porous media and their comparison with experiments. In order to produce hydrogen rich mixtures and for the sake of reaction stability, the reformer consists on a diffuser filled with porous media. The validity of using a quasi-1D approach to model this system is explored based on 3D simulations of the isothermal fluid flow through the porous solid structure. Several fluid flow cases were taken into account as well as two different porous materials, Al₂O₃ fiber lamellae and SiSiC foam. The detailed fluid flow information obtained from the 3D study was used to provide the realistic cross-sectional area variation of the quasi-1D model. The quasi-1D 12-steps reduced chemistry model predictions are in very satisfactory agreement with the temperature and concentration fields measured within the diffuser porous reformer.     

Numerical simulation of moving free surface problems in polymer processing using volume‐of‐fluid method

We have developed a numerical algorithm based on 2D/3D finite element method for solving non‐Newtonian fluid flow with the moving free surface encountered in polymer processing. The power law model is considered as a rheological constitutive equation. The standard Galerkin finite element formulation/penalty formulation are applied to discrctize the governing equations, the volume‐of‐fluid (VOF) scheme is used to track the moving free surface, and the donor‐acceptor model introduced by Hirt and Nichols is modified and implemented on FEM. We applied the numerical scheme to simulate fountain flow and viscous buckling problems. For fountain flow, the numerical prediction of this study is in good agreement with the experimental results of other investigators. For viscous buckling, both 2D and 3D numerical simulations show that the shear thinning effect retards buckling. As this algorithm is very effective in treating moving free surface problems and requires less memory than previous algorithms, it may help solve challenging problems in polymer processing such as transient visroelastic flow simulations with moving free surfaces.     

CPFD在细颗粒料仓下料中的应用

借助计算颗粒流体力学(CPFD)的数值模拟方法,研究了细颗粒玻璃微珠在不同结构料仓内的下料特性,获得了料仓出口直径和半锥角对颗粒下料流动的影响。在实验室可视化下料平台开展了验证实验,模拟结果与实验结果吻合较好。模拟结果表明:下料流率与料仓出口直径2.5次方呈正比;料仓半锥角增大,下料流型从质量流过渡至漏斗流。CPFD模拟给出了料仓下料过程的细节信息,并获得了料仓结构对颗粒流动形态转变的临界面相对高度的影响。     

CPFD flow pattern simulation in downer reactors

This study contributes with a computational fluid dynamic simulation based on the numerical solution of continuity and momentum balance equations in a three‐dimensional (3‐D) framework. The proposed down flow gas–solid suspension model includes a unit configuration and C_D drag coefficients recommended for these units. Computational particle fluid dynamics (CPFD) calculations using suitable boundary conditions and a Barracuda (version: 14.5.2) software allow predicting local solid densification and asymmetric “wavy flows.” In addition, this model forecasts for the conditions of this study higher particle velocity than gas velocity, once the flow reaches 1 m from the gas injector. These findings are accompanied with observations about the intrinsic rotational character of the flow. CPFD numerical 3‐D calculations show that both gas and particle velocities involve the following: (a) an axial velocity component, (b) a radial velocity component (about 5% of axial velocity component), and (c) an angular velocity component. The calculated velocity components and the rotational flow pattern are established for a wide range of solid flux/gas flux ratios. © 2012 American Institute of Chemical Engineers AIChE J, 59: 1635–1647, 2013     

2D and 3D simulations of an internal airlift loop reactor on the basis of a two-fluid model

Two- and three-dimensional (2D and 3D) simulations of an airlift reactor under steady state conditions at low gas flow rates are presented. The simulations are based on a two-fluid model with a k–ε model for the turbulence and as little as possible ad hoc closure terms. The results are compared with an one-dimensional mechanical energy balance and are found to be in good agreement. The 2D results show sensitivity to the gas inlet geometry: whether or not the gas is partially sparged into the liquid directly next to a wall affects the liquid velocity distribution and thereby the gas disengagement at the top of the airlift. The three-dimensional calculations make a more realistic geometry possible. The friction in the system is found to be about a factor of two larger in the 3D case at the same gas inlet conditions. For a given gas flow rate, the mean gas fraction in the riser is the same for the 2D and 3D simulations, the liquid circulation rate is about 30% higher in the 2D case than in the 3D one. A comparison is made with experimental data obtained in an airlift of the same dimensions. The simulated overall gas fraction is in agreement with the experimental findings. The simulated superficial velocity in the riser is compared to LDA data. For the lowest superficial velocities the LDA data coincide with the results from the 2D simulations, for higher gas flow rates the LDA results switch over towards the 3D results.     

塑料斜齿平带管内三维流动及强化传热的数值模拟

利用Fluent 6.2及辅助软件对传热管内置带旋流口的塑料椭圆斜齿平带的流体流动及强化传热进行了计算机三维数值模拟,分析并比较了光管与有内置椭圆斜齿塑料平带的情况下管内流速、湍流度以及对流传热系数的分布改善情况。结果表明：平带管内流体的流动是以螺旋流动为主的复杂的三维流动;由于平带的扰流作用,使得平带管内流速、湍流强度得到了很大程度的提高,有效抑制了管内壁污垢的沉积,强化了传热,平带管内侧的平均传热系数较光管提高了45%,平带所带来的管路压降在工程许可的范围内,适用于流速低于0.8 m•s^-1的换热器中。     

New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

The simulation of three-dimensional (3D) non-isothermal, non-Newtonian fluid filling process is an extremely difficult task and remains a challenging problem, which includes polymer melt flow with free surface coupled with transient heat transfer. This paper presents a full 3D non-isothermal two-phase flow model to predict the complex flowinmelt filling process,where the Cross-WLFmodel is applied to characterize the rheological behavior of polymer melt. The governing equations are solved using finite volume method with SIMPLEC algorithm on collocated grids and the melt front is accurately captured by a high resolution level set method. A domain extension technique is adopted to dealwith the complex cavities, which greatly reduces the computational burden. To verify the validity of the developed 3D approach, the melts filling processes in two thin rectangular cavities (one of them with a cylindrical insert) are simulated. The predicted melt front interfaces are in good agreement with the experiment and commercial software prediction. For a case with a rather complex cavity, the dynamic filling process in a hemispherical shell is successfully simulated. All of the numerical results show that the developed numerical procedure can provide a reasonable prediction for injection molding process.     

Fast and efficient simulation of 3D creeping flow in ducts using a space‐marching algorithm

In this paper, an alternative solution algorithm for the creeping, 3D viscoelastic flow simulation is offered. It is based on the Parabolized Navier‐Stokes Equations formulation (PNSE), which reduces the 3D problem to a sequence of 2D problems marched along a preferred direction (the dominant flow in the duct). This algorithm is extended to the limit Re approaching 0 (creeping flow) and the viscoelastic component of the extra‐stress tensor that appears in the momentum equation is treated as a body force. The numerical results obtained with Criminale‐Ericksen‐Filbey (CEF) and Modified Phan‐Thien Tanner (MPTT) models are compared against previous numerical and experimental data. As an application of the code, prediction of viscoelastic developing flow in channels is studied, since it is a common feature in many polymer processing applications, such as extrusion coating, film blowing, injection molding, and others in which there are confined flow in ducts after metering in extruder screw. The present algorithm offers a fast and efficient solution approach to the complex problem of 3D viscoelastic flow, allowing the detailed visualization of flow phenomena that would otherwise require significant computational resources. POLYM. ENG. SCI. 45:249–259, 2005. © 2005 Society of Plastics Engineers.     

Simulation of saturated fluid flow in packed particle beds—The lattice-Boltzmann method for the calculation of permeability from XMT images

Cone beam X-ray microtomography (XMT) instrumentation is a state-of-the-art non-invasive technology now used for several years to describe important characteristics of packed particle beds in three-dimensional (3D) detail. Many process engineering operations involve the transport of fluid in porous media. It is well known that the flow in porous media depends on the geometric properties of the pore network structure and in this regard X-ray microtomographic imaging captures the porous network structure of opaque packed particle beds which is later used for fluid flow analysis. The coupling of XMT 3D imaging with a novel fluid flow simulation method, known as the lattice-Boltzmann model (LBM), allows for direct local flow determination and micro-permeability calculations for complex porous structures. In this paper the methodology is briefly explained, implementations for some practical problems are addressed, the application of the technique from results for packed particle beds of interest are presented, and a comparison with experimental data is made.     

A simple numerical approach for the optimal design of an extrusion die

A simple numerical approach that is based on the lubrication approximation is developed for the optimal design of a linearly tapered coat-hanger die. This approach does not require the analytic pressure drop / flow rate equations for flow in the manifold and in the slot section, therefore any generalized Newtonian fluid model can be easily incorporated. Example calculations have demonstrated that the predictions based on this approach are reasonably accurate as compared with those from the complete 3-D finite element simulations.     

三螺杆挤出机端面二维流场混沌混合拉格朗日拟序结构分析

三螺杆挤出机是一种新型的聚合物流体加工设备,其独有的中心区呈现出几何结构和受力状态的周期性变化,混合机理非常复杂。区别于传统的线性混合分析,从拉格朗日体系的新视角对三螺杆挤出机混沌混合进行拉格朗日拟序结构分析,利用有限时间Lyapunov指数（FTLE）、拉格朗日拟序结构（LCS）,结合Poincaré截面和粒子可视化技术研究三螺杆挤出机二维流场的流体输运和混沌混合机理,讨论了中心区动态结构特性对FTLE和LCS分布的影响,并与单螺杆挤出机和双螺杆挤出机进行了对比分析。结果表明,LCS将三螺杆挤出机流域划分为近螺杆区、远螺杆区和中心区3个具有不同运动特性的区域,扭结是连接近螺杆区、远螺杆区和中心区物质交换的桥梁。随着混合时间的增加,扭结的弯曲和折叠程度逐渐增大,增强了3个区域的物质交换,强化了三螺杆流场的混沌混合。三螺杆挤出机啮合区附近存在3个双曲固定点,混合能力较好。Poincaré截面中椭圆周期点的出现说明在流域中心有非混沌区存在,因此三螺杆挤出机的中心区混合能力相对较弱。     

Using CFD and Ultrasonic velocimetry to Study the Mixing of Pseudoplastic Fluids with a Helical Ribbon Impeller

A commercial CFD package was used to simulate the 3D flow field generated in a cylindrical tank by a helical ribbon impeller. The study was carried out using a pseudoplastic fluid with yield stress in the laminar mixing region. Ultrasonic Doppler velocimetry (UDV), a noninvasive fluid flow measurement technique for opaque systems, was used to measure xanthan gum velocity. From flow field calculations and tracer homogenization simulations, power consumption and mixing time results were obtained. The torque and power characteristics remain the same for upward and downward pumping of the impeller, but the mixing times are considerably longer for the downward pumping mode. Overall, the numerical results showed good agreement with experimental results and correlations developed by other researchers. From the power and mixing time results, two efficiency criteria were utilized to determine the best pumping mode of the impeller.     

Flow distribution and pressure drop in 2D meshed channel circuits

The present paper investigates some families of simple 2D circuits or grids of intersecting tubes or channels (thus forming meshes) from the point of view of the fluid distribution and hydraulic characteristics in slow laminar flow. Square grids with a single inlet and a single outlet, and comprising from 4 to 100 meshes are considered, either with all channels identical, or with different channels along the borders of the circuit. Analytical resolution of the mesh and node relations to obtain the steady flow distributions are convenient up to 5×5 meshes, and formal computation furnishes numerical solutions for higher order circuits. This paper discusses some details of the flow and pressure distributions, in particular the symmetries, and also the behavior of some global properties such as overall or internal resistance and flow heterogeneity, as a function of the ratio of resistances of the two types of channels.     

微通道内屈服应力型流体的流变特性及多相流研究进展

屈服应力型流体（YSFs）是一种典型的非牛顿流体,因其丰富的流变特性被广泛关注。屈服应力是高浓度的粒子分散系统和凝胶状物质（多相乳液、微胶囊、3D打印复杂结构、药物输送凝胶等）的基本特征。本文对微通道内简单屈服应力型流体的流动特征和流变行为,及其流变性对多相流系统的影响进行了综述,剖析了受限空间内流体流动与流体流变性,及多相流动力学和界面现象的耦合机制,并对亟需推进的研究方向进行了展望。为微通道内屈服应力型流体的数值模拟、实验研究和应用提供参考。     

Slip effects in tapered dies

Approximate analytical equations are derived for the calculation of pressure drop of power‐law fluids for viscous flow through tapered dies for a wide range of wall‐slip conditions. The predicted pressure drop values are compared with two‐dimensional (2D) finite element calculations to identify contraction angles for which the analytical equations can be used. It is found that the disagreement increases with increase of the contraction angle and with increase of wall slip. At a given flow rate, the pressure drop from the analytical equations is found to decrease continuously with contraction angle, which agrees with the 2D calculations only at small contraction angles. At larger contraction angles, the 2D calculations show that pressure drop increases with contraction angle as opposed to the no‐slip case where pressure drop saturates. The existence of a minimum pressure at a specific taper angle depends on the rheological parameters of the fluid and the degree of slip (slip‐law exponent), and has scientific importance for the die designer. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Review of 3D CFD modeling of flow and mass transfer in narrow spacer-filled channels in membrane modules

The robustness, reliability and efficiency of modern numerical methods for obtaining solutions to flow problems have given rise to the adoption of Computational Fluid Dynamics (CFD) as a widely used analysis tool for membrane separation systems. In the past decade, many two-dimensional (2D) flow studies employing CFD have been published. Three-dimensional (3D) solutions are also slowly emerging. This paper reviews recent research utilizing 3D CFD models to simulate the flow conditions in narrow spacer-filled channels, such as those encountered in Spiral Wound Membrane (SWM) modules. Many of these studies have focused on optimizing spacer geometric parameters, while others have attempted to gain a better understanding of the mechanisms giving rise to mass transfer enhancement. Applications of 3D CFD to complex spacer geometries and multiple ionic component diffusion are also discussed.     

3D multiphase flow simulation of Marangoni convection on reactive absorption of CO2 by monoethanolamine in microchannel

A multiphase flow 3D numerical simulation method employing the coupled volume of fluid (VOF) and level set model is established to study the reactive absorption of CO₂ by the monoethanolamine (MEA) aqueous solution in a falling film microchannel. Based on the flow-reaction-mass transfer model of the MEA-CO₂ system in the falling film microchannel, the enhancement effect of the Marangoni convection in this reactive absorption process is analyzed. The enhancement factor of the Marangoni convection obtained in this work is in good agreement with experimental results in the literature. With consideration of the absorption ratio as well as the enhancement effect of the Marangoni convection, the influence of different MEA concentrations on absorption of CO₂ is investigated. Furthermore, the appropriate MEA concentration for absorption enhanced by the Marangoni convection is acquired.