Three-dimensional simulation of the pulverized coal combustion inside blast furnace tuyere

A three-dimensional multi-phase model using Eulerian approach has been developed to simulate the coal heat transfer, devolatilization and combustion process inside a blast furnace tuyere. The information including velocity field, temperature distribution and combustion characteristics has been obtained in details and the effect of coal particle diameter, coal type and coal injection angle on the pulverized coal combustion process has been presented. The predicted results show that the coal combustion process inside tuyere are affected by coal particle size, coal type and coal injection angle. For the smaller coal particle diameter, the volatile matter released from the coal more rapidly, this results in a higher coal burnout at the exit of the tuyere. The coal burnout is depended on the coal volatile matter content; a higher coal burnout will be obtained for the coal with a higher volatile matter content. The coal injection angle affects the flow patter inside the tuyere, which results in a different mixing and burning process of the pulverized coal. When the coal diameter changes from 30 μm to 90 μm, the coal burnout decreases from 51.03% to 44.21%; when the coal volatile matter is reduced from 34.32% to 19.95%, the coal burnout decreases from 46.04% to 35.02% and for the coal injection with an angle, the coal burnout is 46.04%, a little bit higher than that of 44.51% without injection angle.     

Large eddy simulation of non-premixed pulverized coal combustion in corner-fired furnace for various excess air ratios

Large-eddy simulations (LES) were carried out to study the effects of burning atmosphere on the coal combustion process in a corner-fired furnace. The LES for the turbulent gas was coupled with the discrete phase model (DPM) for coal particles trajectories and the non-premixed mixture fraction probability density function (MF-PDF) combustion model for pulverized coal combustion. The coal combustion processes, including the flame characteristics, burning coal behaviors and NO_x pollutant emissions, for different burning atmospheres are analyzed qualitatively and quantitatively. The heat and momentum transfer between burning coal and turbulent gas are greatly enhanced by the corner-fired flow. With a given particle size, the char particles present a similar distribution in the whole chamber. For a fuel-rich atmosphere, the concentration is obviously much higher and exhibits much higher spatial variability than the other two conditions. The coal combustion efficiency decreases in oxygen-rich and fuel-rich burning atmospheres, but the flame stability is more affected at the fuel-rich atmosphere by the lack of oxygen. NO pollutant is obviously reduced at the fuel-rich atmospheres, and the NO pollutant emissions are more affected by the reducing atmosphere than the low temperature. These findings may provide insight into strategies to design and monitor tangentially-fired pulverized coal boilers.     

Numerical simulation study on gas–solid two-phase flow in pre-calciner

A three-dimensional numerical simulation of DD (dual combustion and denitratior process) pre-calciner for cement production was conducted in this paper. In Euler coordinate system, the fluid phase is expressed with RNG k–ε two-equation model and the solid phase is expressed with particle stochastic trajectory model in Lagrange coordinate system. Four mixture fractions are deduced in this article to simulate the gas compositions. The results of numerical simulation predicted the burn-out ratio of coal and the decomposition ratio of limestone particles along with particle trajectories. It also supplied theoretical foundation for industrial analysis of the coupling relation between coal combustion and calcium carbonate decomposition.     

Modeling and control of surface gravity waves in a model of a copper converter

Undesirable splashing appears in copper converters when air is injected into the molten matte to trigger the conversion process. We consider here a cylindrical container horizontally placed and containing water, where gravity waves on the liquid surface are generated due to water injection through a lateral submerged nozzle. The fluid dynamics in a transversal section of the converter is modeled by a 2-D inviscid potential flow involving a gravity wave equation with local damping on the liquid surface. Once the model is established, using a finite element method, the corresponding natural frequencies and normal modes are numerically computed in the absence of injection, and the solution of the system with injection is obtained using the spectrum. If a finite number of modes is considered, this approximation leads to a system of ordinary differential equations where the input is represented by the fluid injection. The dynamics is simulated as perturbations around a constant fluid injection solution, which is the desired operating state of the system, considering that the conversion process does not have to be stopped or seriously affected by the control. The solution is naturally unstable without control and the resulting increase of amplitude of the surface waves are assimilable to the splashing inside the converter. We show numerically that a variable flow around the operating injection is able to sensibly reduce these waves. This control is obtained by a LQG feedback law by measuring the elevation of the free surface at the point corresponding to the opposite extreme to where the nozzle injection is placed.     

A comparison of one-dimensional and three-dimensional models for the simulation of gas–solids transport systems

This paper compares the use of one-dimensional (1-D) and a three-dimensional (3-D) models to simulate the flow of a gas–solids mixture through a pipeline. Both models solve steady flow conservation equations for mass, momentum and energy. The implementation of each model is presented in terms of the changes made to the generic model in order to describe this type of flow. Performance data was obtained for a pneumatic conveying system used to convey pulverised fuel ash (PFA) in a power station. Each model was used to simulate the behaviour of this ash transfer line.     

Numerical simulation of scour around a submarine pipeline using computational fluid dynamics and discrete element method

Scour under a submarine pipeline can lead to structural failure; hence, a good understanding of the scour mechanism is paramount. Various numerical methods have been proposed to simulate scour, such as potential flow theory and single-phase and two-phase turbulent models. However, these numerical methods have limitations such as their reliance on calibrated empirical parameters and inability to provide detailed information. This paper investigates the use of a coupled computational fluid dynamics-discrete element method (CFD-DEM) model to simulate scour around a pipeline. The novelty of this work is to use CFD-DEM to extract detailed information, leading to new findings that enhance the current understanding of the underlying mechanisms of the scour process. The simulated scour evolution and bed profile are found to be in good agreement with published experimental results. Detailed results include the contours of the fluid velocity and fluid pressure, particle motion and velocity, fluid forces on the particles, and inter-particle forces. The sediment transport rate is calculated using the velocity of each single particle. The quantitative analysis of the bed load layer is also presented. The numerical results reveal three scour stages: onset of scour, tunnel erosion, and lee-wake erosion. Particle velocity and force distributions show that during the tunnel erosion stage, the particle motion and particle–particle interactive forces are particularly intense, suggesting that single-phase models, which are unable to account for inter-particle interactions, may be inadequate. The fluid pressure contours show a distinct pressure gradient. The pressure gradient force is calculated and found to be comparable with the drag force for the onset of scour and the tunnel erosion. However, for the lee-wake erosion, the drag force is shown to be the dominant mechanism for particle movements.     

伴有磁场和纳米固体颗粒时的Jeffery-Hamel流动解析研究——Adomian分解法

用一种强有力的解析方法,称为Adomian分解法(ADM),来研究磁场和纳米颗粒对Jeffery-Hamel流动的影响.将该问题模型的控制方程,即将传统的流体力学Navier-Stokes方程和Maxwell电磁方程,简化为非线性的常微分方程.该方法得到的结果与Runge-Kutta方法得到的数值结果相一致,结果用表格列出.不同α,Ha和Re数下的图形表明,本方法可以得到高精度的结果.首先对不同的Hartmann数和管壁倾角,研究喇叭形管道中的流场;最后在没有磁场作用时,研究纳米固体颗粒体积率的影响.     

Gas-powder flow in blast furnace with different shapes of cohesive zone

With high PCI rate operations, a large quantity of unburned coal/char fines will flow together with the gas into the blast furnace. Under some operating conditions, the holdup of fines results in deterioration of furnace permeability and lower production efficiency. Therefore, it is important to understand the behaviour of powder (unburnt coal/char) inside the blast furnace when operating with different cohesive zone (CZ) shapes. This work is mainly concerned with the effect of cohesive zone shape on the powder flow and accumulation in a blast furnace. A model is presented which is capable of simulating a clear and stable accumulation region in the lower central region of the furnace. The results indicate that powder is likely to accumulate at the lower part of W-shaped CZs and the upper part of V- and inverse V-shaped CZs. For the same CZ shape, a thick cohesive layer can result in a large pressure drop while the resistance of narrow cohesive layers to gas-powder flow is found to be relatively small. Implications of the findings to blast furnace operation are also discussed.     

Numerical simulation of internal flow fields of swirl coaxial injector in a hot environment

Based on the fractional volume of fluid (VOF), a pure Eulerian model for defining and capturing the gas/liquid interface is developed in this paper. This model can describe gas/liquid interface in high refinement, which is better than the original VOF methodology. To validate the proposed model and the algorithm, the computational code is employed to predict the flow performance in a cylindrical swirl injector under cold-flow condition, and the predicted results agree well with experimental measurements. Furthermore, the proposed model is used to simulate gas-liquid reacting flows inside a gas/liquid coaxial swirl injector operating in a hot environment. The turbulent combustion process is simulated with the k−ε−f−g model. The numerical simulation is carried out under actual operating condition of the coaxial injector. The injector performances, such as liquid film thickness, liquid film injection velocity, spray angle, pressure drop, are obtained based on the detailed information of the internal flow field. The predicted results also show that droplets are shed from the liquid film in the recess cup of the coaxial injector because of the large velocity gradient between the gas and liquid streams, and a burning area, which is characterized by high temperature, is present inside the injector.     

Mathematical modelling of bottom evolution by particle deposition and resuspension

A two-dimensional numerical model for the evolution of a bottom due to particle deposition and resuspension by a fluid flow is here presented. A computational fluid dynamic approach is used to calculate the flow field and a Lagrangian particle tracking technique is applied to solve the dispersed phase. The evolution of the lower boundary is simulated taking into account the mass conservation of the solid phase and the geotechnical properties of the granular material. The model is characterized by two important features. First, fluid dynamics are coupled with the bottom evolution due to particle deposition and resuspension. This permits to use the model to simulate complex flow fields as well as complex time-evolving geometries. Second, the dispersed phase is calculated by a Lagrangian approach, which retains the discrete information of the individual particles of the granular bottom which may be of interest for some industrial processes (coating) and environmental flows (sediment stratification). First consistency checks have been performed for some deposition and resuspension test cases with fluid at rest. The model has also been tested by comparison with a physical experiment of deposition inside a cavity. Finally, as an example of possible applications of industrial and environmental interest, the model has been applied to investigate particle deposition in rectangular cavities and the evolution of a sand heap by a fluid flow.     

热幅射对抽吸或喷射三维Couette流温度分布的影响

在固定的底板上有横向正弦射流,而匀速运动的多孔介质顶板以常速率完全抽出的情况下,理论分析了热幅射对三维Couette流动温度分布的影响.在这种射流速度下,流动呈现三维流动.利用图形分析了Prandtl数、幅射参数和射流参数对传热速率的影响.Prandtl数对温度分布的影响比射流参数或幅射参数大得多.     

Prediction of risers’ tubes temperature in water tube boilers

A dynamic model is developed which enables the prediction of risers’ tubes temperature of water tube boilers under various operating conditions. The model is composed of fluid dynamics model representing the fluid flow in the drum-downcomer-riser loop and a dynamic thermal model of the riser’s temperature. The model gives a detailed account of the two-phase heat transfer process which takes place between the risers’ inner walls and the water–steam mixture flow inside the tubes. The model is used to simulate various operational scenarios of water tube boilers. Results of the simulation provide insight into the dynamic interactions of the boiler’s main variables including the drum pressure, water volume, steam quality and risers’ temperature. Such a model is useful in checking operational scenarios before their actual plant implementation, can be a basis for developing boiler start up procedures and online temperature predictions to prevent eminent tube overheating.     

Three-dimensional Couette flow of a dusty fluid with heat transfer

This work is focused on the mathematical modeling of three-dimensional Couette flow and heat transfer of a dusty fluid between two infinite horizontal parallel porous flat plates. The problem is formulated using a continuum two-phase model and the resulting equations are solved analytically. The lower plate is stationary while the upper plate is undergoing uniform motion in its plane. These plates are, respectively, subjected to transverse exponential injection and its corresponding removal by constant suction. Due to this type of injection velocity, the flow becomes three dimensional. The closed-form expressions for velocity and temperature fields of both the fluid and dust phases are obtained by solving the governing partial differential equations using the perturbation method. A selective set of graphical results is presented and discussed to show interesting features of the problem.     

Modeling and control of a novel pressure regulation mechanism for common rail fuel injection systems

This paper presents the modeling and control of a novel pressure regulation mechanism for the common rail (CR) fuel injection system of internal combustion engines (ICE). The pressure pulsations inside the common rail caused by the incoming and outgoing flows negatively affect the accuracy of both injected fuel quantities and flow rates. The objective of this work is to design a new regulating mechanism to suppress the pressure pulsation in the rail. We first present the one-dimensional distributed model for the common rail developed by using fluid flow equations, which can capture the distributed dynamics of the pressure pulsations in the rail and validating it with a physics based model developed in AMESim®. We then propose the concept of an active fluid storage device like a piezoelectric actuator (PZT) to minimize the pressure fluctuations. The location of the actuator on the common rail has also been evaluated to maximize its effect. The periodic nature of the injection event due to the stroke by stroke engine operation generates pressure pulsations in the rail which are periodic when represented in the rotational angle domain. To leverage this unique dynamic phenomenon we design a time-varying internal model-based controller to compensate the pressure pulsations.     

Analysis of performance of an iron-bath reactor using computational fluid dynamics

The performance of an iron-bath reactor has been studied using a comprehensive numerical model that combines a computational fluid dynamics approach for the gas phase and a heat and mass balance model for the bath. The model calculates:

• •coal, ore, flux and oxygen consumption;
• •post-combustion ratio (PCR);
• •heat-transfer efficiency (HTE);
• •off-gas temperature and composition;
• •heat transfer and chemical reactions between gas and iron and slag droplets; and
• •heat transfer between gas and bath, refractories and lance.

The model was validated with data reported by the Nippon Steel Corporation for a 100 t pilot plant, and the calculated and measured data are in good agreement. Modelling results showed that the dominant mechanisms of heat transfer from the gas to the bath are radiation to the slag surface and convection heat transfer to droplets.     

宾汉流体稠密两相湍流流动中的二阶矩模型

建立的Bingham流体稠密两相流动的二阶矩-颗粒动力论湍流模型（USM-theta模型）既体现了两相的作用,又体现了屈服应力所引起的附加项,并提出了USM-theta模型下考虑浓度修正值影响的两相湍流流动的算法．利用该模型对圆管内Bingham流体的单相湍流流动、稠密液固两相的湍流流动进行了计算,并和五方程湍流模型进行了比较,结果表明该模型的预测效果更好．利用USM-theta模型对含颗粒的Bingham流体的两相湍流流动进行了模拟,随着屈服应力的增加,Bingham流体相与颗粒相在管道中心附近的主流速度减小．液固两相湍流和Bingham流体两相湍流的计算结果表明屈服应力引起的附加项对流动有很重要的影响．     

Mathematical modeling of coupled turbulent flow and solidification in a single belt caster with electromagnetic brake

A mathematical model has been developed to simulate turbulent fluid flow and solidification in the presence of a DC magnetic field in an extended nozzle for metal delivery to a single belt caster. This paper reports on predicted effects of DC magnetic field conditions in modifying flows and solidification behavior in the metal delivery system. It is shown that the application of a DC magnetic brake to the proposed system can result in a reasonably uniform feeding of melt onto the cooled moving belt. This, in turn, optimises the rate of even shell growth along the chilled substrate. In order to account for the effects of turbulence, a revised low-Reynolds k–ε turbulent model was employed. A Darcy-porosity approach was used to simulate fluid flow within the mushy solidification region. Simulations were carried out for plain carbon steel strip casting. The fully coupled transport equations were numerically solved using the finite volume method. The computed flow patterns were compared with those reported in the literature. The performance of the magnetic flow control device proposed in this work is evaluated and compared with flow modifications obtained by inserting a ceramic filter within the reservoir.     

Simulation of uncompressible fluid flow through a porous media

Recently, a great interest has been focused for investigations about transport phenomena in disordered systems. One of the most treated topics is fluid flow through anisotropic materials due to the importance in many industrial processes like fluid flow in filters, membranes, walls, oil reservoirs, etc. In this work is described the formulation of a 2D mathematical model to simulate the fluid flow behavior through a porous media (PM) based on the solution of the continuity equation as a function of the Darcy’s law for a percolation system; which was reproduced using computational techniques reproduced using a random distribution of the porous media properties (porosity, permeability and saturation). The model displays the filling of a partially saturated porous media with a new injected fluid showing the non-defined advance front and dispersion of fluids phenomena.     

超音速探测器-刚性盘-缝-带型降落伞系统的大涡模拟研究

研究了Mach数为2时,流场不同块结构自适应网格加密精度对探测器-刚性盘-缝-带型降落伞系统的气动减速性能以及流场结构特性的影响.对于非定常可压缩流体流动,采用了兼顾激波与湍流的WENO(weighted essentially non-oscillatory)和TCD(tuned center difference)混合计算格式以及拉伸涡亚格子模型的大涡模拟方法.结果表明:在较低的流场块结构自适应网格分辨率下,是难以准确模拟计算降落伞系统重要的气动阻力系数和捕捉流场流动特征细节的.随后验证了流场自适应网格的收敛性.     

A numerical study on the effect of cavitation erosion in a diesel injector

The consequences of geometry alterations in a diesel injector caused by cavitation erosion are investigated with numerical simulations. The differences in the results between the nominal design geometry and the eroded one are analyzed for the internal injector flow and spray formation. The flow in the injector is modeled with a three-phase Eulerian approach using a compressible pressure-based multiphase flow solver. Cavitation is simulated with a nonequilibrium mass transfer rate model based on the simplified form of the Rayleigh–Plesset equation. Slip velocity between the liquid-vapor mixture and air is included in the model by solving two separate momentum conservation equations. The eroded injector is found to result in a loss in the rate of injection but also lower cavitation volume fraction inside the nozzle. The injected sprays are then simulated with a Lagrangian method considering as initial conditions the predicted flow characteristics at the exit of the nozzle. The results obtained show wider spray dispersion for the eroded injector and shorter spray tip penetration.