Numerical investigation of coarse powder and air flow in an electrostatic powder coating process

The work presented here reports on the numerical simulation of an electrostatic powder coating process that uses a commercial computational fluid dynamic code, FLUENT v6.1. The purpose of this study was to understand the gas and particle flow fields inside a coating booth under given operating conditions and the effect of particle sizes on its trajectories and the final coating quality. The air and powder particle flows in a coating booth were modeled as a three-dimensional turbulent continuous gas flow with solid particles as a discrete phase. The continuous gas flow was calculated by solving Navier-Stokes equations including the standard k − ε turbulence model with non-equilibrium wall function and the discrete phase was modeled based on the Langrangian approach. Since the solid phase volumetric fraction was less than 0.1%, the effect of particle-particle interaction on particle trajectories was not taken into account. In addition to drag force and gravity, the electrostatic force including the effect of space charge due to the free ions was considered in the equation of motion and implemented using user defined scalars and functions. The governing equations were solved using the second order upwind scheme. Information was provided on the particle trajectories with respect to the particle diameters that could be used to develop suitable operating conditions for the use of fine powders in a powder coating process.     

Experimental study of particle trajectory in electrostatics powder coating process

Experimental studies of particle trajectory were conducted in an isolated Plexiglass coating booth. Polyester particles were injected with a Norsdon® electrostatics spray gun with a fixed distance from the gun to a grounded plate. Using a Dantec® Particle Dynamic Analyzer, the particle velocity and size distribution were measured simultaneously. The experimental results showed that the effect of electrostatics charging on the particle trajectory is strong in the close vicinity of the target, but can be neglected at locations away from the target. The influence on particle size and velocity profile due to the electric field between the charged particles and grounded target was weakened as more particles deposited on the target. When no charge is introduced on the coating powder, particle segregation is observed for particles larger than 100 μm. Particle gravitational settlement is noticed even near the gun tip. However, particle charging largely eliminates the segregation at a gun-to-target distance of 25 cm and helps break agglomerates formed in the spray system. The gun-to-target velocities of larger particles exhibited noticeable deviation from those of the flow field as the grounded target was approached. The study revealed that the onset of electrostatic coating is an important period that can affect the transfer efficiency and film thickness.     

Numerical investigation on the hydrodynamics of an LSCFB riser

Analysis of fluid flow in a liquid-solid circulation fluidized bed (LSCFB) is necessary to understand its behavior under different operating parameters. In this work, ample parametric studies have been carried out numerically, which provides a view how an LSCFB operates under different operating parameters, and the numerical model has been validated using the experimental data. This study aims to get an insight of the behavior of LSCFB under different operating parameters, which include solids circulation rate, primary and auxiliary liquid velocity. In addition to this task, numerical modeling has also been carried out to predict the behavior of different particles with different densities upon fluidization in an LSCFB, which resolves the problem of experimentation with a wide spectrum of new particles that might have a wide variety of applications in an LSCFB. LSCFBs always involve high Reynolds number flow and dense solids concentration, which demands for proper modeling of the turbulent flow, liquid-solid interactions and particle-particle interactions. Kinetic theory based on Eulerian-Eulerian two-phase model is used to account for particle interactions and is applied to model the solids viscosity and solids pressure, which takes into account the particle-particle collisions.     

Three-dimensional numerical simulation method for gas–solid injector

A three-dimensional turbulent gas–solid two-phase flow model for a gas–solid injector is developed in the present study. Time-averaged conservation equation for mass and momentum and a two-equation k– closure are used to model the carried fluid phase. The solid phase is simulated by using a Lagrangian approach. In this model, the drag and lift forces on particles, the multi-body collisions among particles and the mutual interaction between gas and particles were taken into account. Interparticle interactions and particle–wall collisions are emulated by using the three-dimensional distinct element method (DEM). A new correlation, which represents the transfer of kinetic energy of the particle motion to kinetic energy of the carrier fluid, is introduced in the additional source term S_d of the transport equation of turbulence kinetic energy, K. The calculated pressure distributions along the axis in the different parts of gas–solid injectors using pressured pneumatic conveying system under different driving jet velocities, pressures and values of angle of convergent section () are found to be in agreement with the experimental results. The axial mean velocity of particles and the behavior of gas and particles in the gas–solid injector are calculated, their results reasonably explaining actual phenomenon observed in experiment.     

Numerical simulation of particle motion in vibrated fluidized bed

The particle motion in vibrated fluidized bed was examined by using numerical simulation. A two-dimensional fluidized bed was used, and discrete element method (DEM) was used as for calculating the particle motion in vibrated fluidized bed. Geldart group B particle, which is regarded to have no effect of agglomerate, was used as the fluidizing particle. The vibration directions (vertical and horizontal) and vibration parameters (frequency and amplitude of vibration) were changed.In the case with vertical vibration, large bubbles caused by vibration gap (defined as the gap between particle bed and wall caused by vibration) appear in bed. When the vibration strength is high and the vibration frequency is low, it is difficult to fludize the particle bed in the case with horizontal vibration because the vibration gap acts like the channel. When the vibration frequency increases at the same vibration strength, the effect of vibration on the particle motion becomes small. The effect of vibration on the pressure loss in particle bed is large in the case with horizontal vibration.     

Numerical study on particle size distribution in the process of preparing ultrafine particles by reactive precipitation

Based on the population balance and mass balance in a reactive precipitation process, a numerical simulation model was developed to predict the particle size distribution (PSD) in the reactive precipitation process. The precipitation system of BaCl₂ with Na₂SO₄ to prepare BaSO₄ in aqueous solution was adopted to obtain ultrafine particles in a stirred precipitation reactor and the particle size distribution and the morphology of the particle were observed under transmission electron microscope. It was illustrated by the experimental observation of the micrographs of BaSO₄ particles obtained that apparent agglomeration occurred between the particles, which phenomenon must be taken into consideration in PSD modeling. The population balance equation was calculated by discretization method to obtain particle number and particle size distribution. By implementing the model, the reactive precipitation process in a batch reactor including reaction, nucleation, growth and agglomeration was simulated. The simulation results were validated by the experimental data of BaSO₄ precipitation. Further analysis was endeavored to explore the effects of some important factors such as the supersaturation degree and agglomeration on the evolution of the volume-based characteristic particle size and the variance of volume-based characteristic size of the particles. It was depicted that particle size and particle size distribution are controlled by the supersaturation degree and agglomeration between the particles. Stemming from the analysis in the context, the disciplinarian of the influences of these factors and the method for controlling particle size distribution were presented for the reactive precipitation process.     

Numerical simulations of gas-solid flow in tapered risers

Hydrodynamic behavior of gas-solid flow in tapered risers was simulated using the two-fluid model based on the kinetic theory of granular flow representing the constitutive relations of the solid phase. Present numerical model was verified by comparing with experimentally measured solid mass fluxes, particle concentrations and velocities in column risers. Computed results showed that the core-annular flow structure existing in the column riser may disappear in the tapered risers. The distributions of particle concentration tend to be more uniform in the tapered riser than that in the column riser under the same operating conditions. The uniform particle distribution can be achieved by changing the inclined angle of the tapered riser under specific operating conditions.     

Numerical simulations of flow behavior of gas and particles in spouted beds using frictional-kinetic stresses model

Flow behavior of gas and particles is simulated in the spouted beds using a Eulerian-Eulerian two-fluid model on the basis of kinetic theory of granular flow. The kinetic-frictional constitutive model for dense assemblies of solids is incorporated. The kinetic stress is modeled using the kinetic theory of granular flow, while the friction stress is from the combination of the normal frictional stress model proposed by Johnson and Jackson (1987) and the frictional shear viscosity model proposed by Schaeffer (1987) to account for strain rate fluctuations and slow relaxation of the assembly to the yield surface. An inverse tangent function is used to provide a smooth transitioning from the plastic and viscous regimes. The distributions of concentration, velocity and granular temperature of particles are obtained in the spouted bed. Calculated particle velocities and concentrations in spouted beds are in agreement with the experimental data obtained by He et al. (1994a, b). Simulated results indicate that flow behavior of particles is affected by the concentration of the transition point in spouted beds.     

弯管内部油水两项流的数值模拟

在油井出油管道以及石化生产中,油水两项流是非常常见的现象。为了减少能耗、便于制订防腐措施,利用GAMBIT软件建模以及FLUENT软件的可实现模型对弯管中油水两项流的压力场和速度场进行模拟。结果表明,管内入口直管压力呈逐阶减小趋势;弯管内壁出形成低压区且又内向外逐渐增大;而速度分布正好与压力分布规律相反,恰好与自由涡流理论的模型相符。且通过对油水两项所占体积分数分别为30%、50%、80%三种情况的模拟得出,由于水密度大于油的原因,随着油相体积分数的下降,管内整体压强减小,整体速度增大。     

Numerical simulation of cohesive particle motion in vibrated fluidized bed

The effect of vibration on the cohesive particle motion in the bed was examined by using discrete element method(DEM). The bed of dried fine particles was treated as the objective of calculation. The van der Waals force was used as the cohesive force because the van der Waals force was considered to be the main cohesive force in this case. Since the actual calculation time was too long, the fine cohesive particle was difficult to be treated. So a relatively large particle (1.0 mm in diameter) was used in calculation and the van der Waals force was assumed that the ratio of gravity force to van der Waals force of particle used in this calculation was equal to that of a fine particle (6.0 μm in diameter), to express the effect of van der Waals force significantly. The calculation results were compared with that case of cohesionless particle.In the case with vibration, the cohesive particle motion in the bed is observed, though no fluidization state appears in the case without vibration, and there is no bubble in the bed even the fluidization state. In the case of cohesive particle, the collision energy between particle and wall caused by vibration gap propagates from the bottom to top of bed, and the particle moves vigorously at the top of bed in the case with vibration. As the vibration gap increases, the effect of vibration on the cohesive particle motion becomes larger, i.e., the low vibration frequency at the same vibration strength or the large vibration strength at the same vibration frequency promotes the fluidization of the bed.     

空气钻井环空气固两相流动规律数值模拟

基于FLUENT软件中Euler模型,采用有限容积法建立了空气钻井环空气固两相流三维计算模型,分析了压力分布规律、流体分布规律、浓度分布规律。研究表明,从井底到井口压力逐渐降低;速度在钻铤内逐渐增大,在交界面处迅速降低,而后在钻杆内呈现增大趋势,岩屑速度在整体环空内逐渐降低;在交界面处形成漩涡,对岩屑进行了不同程度的清洗;同时空气浓度达到最大值、岩屑浓度为最小值;随着入口空气的逐渐增加,空气速度、岩屑速度变化率逐渐增大,而交界面处高空气浓度、低岩屑浓度区域逐渐增大,能较大程度的清洗岩屑。     

水平一上倾圆管水滴运移数值模拟研究

运用VOF模型对爬坡圆管油水两相三维流场进行了数值模拟,对油水分层波浪流产生的水滴的运移规律进行了研究.模拟研究表明,油水界面波是水滴产生的直接原因.对界面波动的相关参数与产生水滴的频率和体积的关系进行了研究,同时对所产生的水滴的几何参数(几何形状、长度、截面积等)、产生时间、间隔时间和出口流速也进行了讨论.     

Numerical analysis of interphase heat and mass transfer of cluster in a circulating fluidized bed

Interphase heat and mass transfer characteristics of a naphthalene particle cluster in a circulating fluidized riser are numerically analyzed using a three-dimensional CFD model. Heat and mass transfer characteristics of gas over an in-line array of three naphthalene particles and an isolated naphthalene particle are analyzed. Distributions of gas concentration, temperature and velocity are obtained. The heat and mass transfer rates of gas-to-cluster increase with the increase of the cluster porosity and Reynolds number. Present simulations indicate that the small cluster gives higher heat and mass transfer coefficients than those of the large cluster. The heat and mass transfer rates of individual particles in the cluster are lower than that of an isolated particle and particles in an in-line array under a given cluster porosity.     

Multi-fluid simulation of turbulent bubbly pipe flows

Radial distributions of void fraction α_G, bubble aspect ratio E, phasic velocities V_G and V_L and turbulent kinetic energy k in bubbly pipe flows are measured using an image processing method and a laser Doppler velocimetry. Multi-fluid simulations are conducted to examine applicability of state-of-the-art closure relations to the turbulent bubbly pipe flows. The experimental results indicate that aspect ratio of bubbles in the near wall region takes a higher value than that of free rising bubbles due to the presence of wall, and that the change in the aspect ratio induces decrease in relative velocity between bubbles and liquid in the near wall region. Drag coefficient C_D of a bubble in a bubbly pipe flow tends to increase with magnitude of shear flow, and the effect of shear flow on C_D is estimated by the correlation proposed by Legendre and Magnaudet (1998). Comparison between the simulated and the measured results indicate that the effects of bubble shape and shear flow on drag force acting on bubbles should be taken into account for accurate predictions of bubbly pipe flows. The turbulence models proposed by Lopez de Bertodano et al. (1994) and by Hosokawa and Tomiyama (2004a) give good predictions for turbulence modification caused by bubbles.     

含煤粉的煤层气T型管道颗粒分布特性

煤层气开采过程中,煤粉不可避免地进入集输管网,进而形成气固两相流动。基于湍流模型,采用FLUENT模拟软件计算广泛应用于煤层气集输管网的水平T型弯管的流场,得到气体和煤粉的速度场分布及各出口煤粉浓度,并分析管道分支处煤粉在气流扰动下的浓度分布,结果表明:气流经过支管后,部分煤粉滞留于管壁,支管两侧管壁煤粉浓度相差较大,各出口煤粉排出量也存在差异。     

水平管气力输送的数值模拟研究

对气体相湍动能采用修正的k-ε二方程模型,颗粒相湍动动能采用颗粒动力学方法,考虑两相间的相互作用,发展建立了水平管气力输送的数学物理模型和计算方法.该模型能计算颗粒相压力、粘性系数、扩散系数、导热系数、颗粒温度等流体力学特性参数.用文献实验得到的压降和转捩速度验证了所建模型和计算方法的正确性.就水平管中圆柱坐标系下典型的三维悬浮气力输送过程进行了初步数值研究,得到了管道沿程压降、平均气体速度、平均颗粒速度和平均颗粒浓度的变化、以及输送方向上不同截面处的颗粒浓度分布.结果表明:在给定的输送条件下,颗粒在管中并不总是维持同样的悬浮状态,在入口和快速加速度段,悬浮颗粒易集中于管中心区域,从加速段到恒速段,悬浮颗粒逐渐向管底沉降;颗粒浓度在管截面上有两种分布状态.为进一步利用该法研究气力输送打下了基础.     

伞罩型除尘脱硫塔内气固二相流数值模拟分析

利用FLUENT软件对新型的伞罩型湿法除尘脱硫塔内的三维二相流场进行数值模拟,气相采用κ-ε湍流模型,颗粒相采用离散相模型(DPM)和欧拉模型,选择SIMPLEC算法进行计算。分析塔内x=0截面的气固二相的浓度,体积分数、速度矢量和压力等参数的分布。结果表明,伞形罩使烟气在塔体内分布得更均匀,延长了气体在塔内停留时间,从而实现高效净化气体的目的;在入口粉尘浓度很低的情况下,DPM更适合气固二相流。模拟结果对设备的优化设计和实际运行有一定的指导作用。     

Numerical Simulation of Liquid-Solid Countercurrent Fluidization inside an Extraction Column Based on Particle Trajectory Model

The liquid–solid countercurrent fluidization process in an extraction column was numerical y simulated based on the particle trajectory model of Eulerian–Lagrangian method. The simulation approach was ...     

Thermochemical and isoconversional kinetic analysis of a polyester–epoxy hybrid powder coating resin for wood based panel finishing

Powder coating is an established technology especially for the surface finishing of metallic substrates for example in the automotive industry. Moreover, powder technology holds also great promises for the coating of non-conventional substrates like plastics or wood due to the lack of solvents and good recoverability. Here, low-temperature curing resins are required and especially mild processing conditions are demanded by the substrates. Advanced characterization methods need to be established that allow the precise balancing of the processing conditions required for adequate melting, flowing and curing of the powder with the process conditions that can be tolerated by the temperature-sensitive substrates. In the present contribution it is shown that differential scanning calorimetry (DSC) in combination with isoconversional kinetic analysis (ICKA) provides great potential for this purpose. DSC is a standard thermo-chemical method that can be successfully used to study both the melting and curing processes of powder coatings and to determine, for example the glass transition temperature of the cured coating directly from the measured thermograms. However, still more information can be extracted from the enthalpy signals when more sophisticated methods of data post-treatment and analysis are employed. Isoconversional kinetic analysis techniques such as the Kissinger–Akahira–Sunose (KAS) or the advanced Vyazovkin (VA) approaches allow calculating the time-dependencies of physical and chemical processes at various temperatures based on the estimates of activation energies which are obtained from DSC raw data. These analyses allow for example to calculate the time required for a certain degree of cross-linking in the coating after processing the coating under specified curing conditions. In the present contribution the application of ICKA of DSC measurements for the analysis of the flowing and curing behaviour of a powder coating based on a polyester–epoxy hybrid resin is illustrated and the potential of this approach to predict optimal curing times for arbitrary curing temperatures is demonstrated. This is especially useful when temperature-sensitive substrates like wood-based panels are coated. Additionally, the potential to relate the thermo-chemical properties of the powder coating to the surface properties of the coated substrates is discussed.