Confined and Agitated Swirling Flows with Applications in Chemical Engineering

Turbulent, swirling flows are encountered frequently in chemical engineering practice. In this article, experiments and simulations on two classes of swirling flows, viz. agitated flows (stirred tanks), and confined swirling flows are discussed. Results of large-eddy simulations of stirred tank flow are compared with experimental data, mainly phase-resolved LDA data of the flow in the vicinity of the impeller. Next to the average velocity field, also the turbulent kinetic energy, and the anisotropy of the Reynolds stress tensor have been assessed. An important application of confined swirling flow is the cyclone separator (hydrocyclones for the separation of liquids, gas cyclones for gas-solid separation). The flow in a swirl tube geometry exhibiting many of the typical features of swirl flows (e.g. vortex breakdown) is discussed. Furthermore, a large-eddy simulation of the gas flow in a high-efficiency Stairmand cyclone separator is presented. Two examples of process modeling based on flow simulations are briefly treated: orthokinetic agglomeration of crystals in a stirred tank, and particle separation in a cyclone. This revised version was published online in July 2006 with corrections to the Cover Date.     

统一二阶矩模型用于模拟旋流湍流两相流动

用统一二阶矩模型（ＵＳＭ）模拟了旋流数为０４７和１５的气粒两相流动，并和实验结果以及ｋ ε ｋｐ模型的模拟结果进行了对比．研究结果表明，提高旋流数减小了轴向速度反流区，增大了切向速度似固核区．ＵＳＭ和ｋ ε ｋｐ模型预报旋流数为０４７时的两相速度场差别不大，并都和实验结果接近，但前者预报的旋流数为１５的两相速度场比后者有改进，在两种情况下，前者都能揭示出后者无法预报的两相湍流各向异性规律．     

Inviscid evolution of incompressible swirling flows in pipes: The dependence of the flow structure upon the inlet velocity field

This paper analyses the influence of the inlet swirl on the structure of incompressible inviscid flows in pipes. To that end, the inviscid evolution along a pipe of varying radius with a central body situated inside the pipe is studied for three different inlet swirling flows by solving the Bragg–Hawthorne equation both asymptotically and numerically. The downstream structure of the flow changes abruptly above certain threshold values of the swirl parameter (L). In particular, there exist a value L_r above which a near-wall region of flow reversal is formed downstream, and a critical value L_f above which the axial vortex flow breaks down. It is shown that the dependence upon the pipe geometry of these critical values of the swirl parameter varies strongly with the inlet azimuthal velocity profile considered. An excellent agreement between asymptotic and numerical results is found.     

Reynolds stress modelling of jet and swirl interaction inside a gas turbine combustor

Influences of the inlet swirl levels on the interaction between the dilution air jets and the swirling cross‐flow to the interior flow field inside a gas turbine combustor were investigated numerically by Reynolds stress transport model (RSTM). Due to the intense swirl and jet interaction, a high level of swirl momentum is transported to the centreline and hence, an intense vortex core is formed. The strength of the centreline vortex core was found to depend on the inlet swirl levels. For the higher swirling inlet, the decay of the swirling motion causes strong streamline variation of pressure; and consequently leads to an elevated level of deceleration of its axial velocity. Predictions contrasted with measurements indicate that the stress model reproduces the flow correctly and is able to reflect the influences of inlet swirl levels on the interior flow structure. Copyright © 1999 John Wiley & Sons, Ltd.     

Correlation of swirl number for a radial-type swirl generator

An experimental investigation was undertaken to derive a new correlation for the swirl number of a radial-type swirl generator under various Reynolds numbers and various vane angle conditions. A radial-type swirl generator with 16 rotary guide vanes was used to generate an annular swirling jet flow. The Reynolds numbers ranged from 60 to 6000, and the vane angles from 0° to 56°. Quantitative measurements for the velocities were made by using an optical method of laser-Doppler anemometry (LDA). Three-component velocity profiles of axial, radial, and azimuthal components at the swirling jet exit were measured for various flow conditions. A flow visualization method using smoke-wire and still photography was also applied to observe the flow patterns of the recirculation region behind the circular bluff body. Under low Reynolds number conditions, the swirl strength was found to be strongly dependent on the Reynolds number as well as on the guide vane angle. Based on the experimental results, a modified swirl number S is derived to characterize the swirling flow, which is useful for the design of a swirl generator.     

Stability of a viscous subsonic swirl flow

The results of calculating the stability of a three-dimensional swirl flow of a viscous heat-conducting gas are presented. The stability characteristics are determined using the linear time-dependent theory of plane-parallel flow stability. The main undisturbed axisymmetric vortex flow was determined numerically using a quasi-cylindrical approximation for the complete set of Navier-Stokes equations. The circulation of the peripheral velocity in the cocurrent flow surrounding the viscous vortex core was assumed to be constant. In analyzing the stability, nonaxisymmetric perturbations in the shape of waves traveling along the vortex axis with both positive and negative wavenumbers were considered; in these two cases the perturbation rotation is either the same or opposite in sense to the rotation in the vortex core. Neutral stability curves are determined for various values of the swirling parameter and the cocurrent flow Mach number. Moscow. Translated from Izvestiya Rossiiskoi Akademii Nauk, Mekhanika Zhidkosti i Gaza, No. 3, pp. 50–59, May–June, 1998.     

An experimental study of fluid flow and heat transfer in decaying swirl through a heated annulus

The mean and turbulent structures of turbulent swirling flow in a heated annulus have been measured. Both forced and free vortex swirling flows were generated, and the outer wall of the test section was heated uniformly. The maximum swirl number was 1.39, Reynolds numbers were up to 200000, and heat input was 10.5 kW. Mean and turbulent velocity components, air and wall temperatures, and wall static pressures were all measured. Hot-film techniques were developed to measure turbulence. From these parameters, the flow and temperature fields, pressure distribution, and heat transfer coefficients were determined. The mechanisms of heat transfer were identified.     

Large Eddy Simulations of Unconfined Non-reacting and Reacting Turbulent Low Swirl Jets

The low swirl flow is a novel method for stabilizing lean premixed combustion to achieve low emissions of nitrogen oxides. Understanding the characteristics of low swirl flows is of both practical and fundamental interest. In this paper, in order to gain better insight into low swirl stabilized combustion, large eddy simulation and dynamically thickened flame combustion modeling are used to characterize various features of non-reacting and reacting low swirl flows including vortex breakdown, shear layers’ instability, and coherent structures. Furthermore, four test cases with different equivalence ratios are studied to evaluate the effects of equivalence ratio on the flame and flow characteristics. A finite volume scheme on a Cartesian grid with a dynamic one equation eddy viscosity subgrid model is used for large eddy simulations. The obtained results show that the combustion heat release and increase in equivalence ratio toward the stoichiometric value decrease the local swirl number of the flow field, while increasing the flow spreading at the burner outlet. Results show that the flame becomes W shaped as the equivalence ratio increases. Moreover, the combination of the swirling motion and combustion heat release temporally imposes a vortex breakdown in the post-flame region, which leads to occurrence of a transient recirculation zone. The temporal recirculation zone disappears downstream of the burner outlet due to merging of the inner shear layer from all sides at the centerline. Also, various analyses of shear layers’ wavy and vortical structures show that combustion heat release has the effect of decreasing the instability amplitude and vortex shedding frequency.     

Computation of a drastic flow pattern change in an annular swirling jet caused by a small decrease in inlet swirl

This paper investigates the flow pattern change in an annular jet caused by a sudden change in the level of inlet swirl. The jet geometry consists of an annular channel followed by a specially designed stepped‐conical nozzle, which allows the existence of four different flow patterns as a function of the inlet swirl number. This paper reports on the transition between two of them, called the ‘open jet flow high swirl’ and the ‘Coanda jet flow.’ It is shown that a small sudden decrease of 4% in inlet swirl results in a drastic and irreversible change in flow pattern. The objective of this paper is to reveal the underlying physical mechanisms in this transition by means of numerical simulations. The flow is simulated using the unsteady Reynolds‐averaged Navier–Stokes (URANS) approach for incompressible flow with a Reynolds stress turbulence model. The analysis of the numerical results is based on a study of different forces on a control volume, which consists of the jet boundaries. The analysis of these forces shows that the flow pattern change consists of three different regimes: an immediate response regime, a quasi‐static regime and a Coanda regime. The simulation reveals that the pressure–tangential velocity coupling during the quasi‐static regime and the Coanda effect at the nozzle outlet during the Coanda regime are the driving forces behind the flow pattern change. These physical mechanisms are validated with time‐resolved stereo‐PIV measurements, which confirm the numerical simulations. Copyright © 2008 John Wiley & Sons, Ltd.     

Regimes of spray formation in gas-centered swirl coaxial atomizers

Spray formation in ambient atmosphere from gas-centered swirl coaxial atomizers is described by carrying out experiments in a spray test facility. The atomizer discharges a circular air jet and an axisymmetric swirling water sheet from its coaxially arranged inner and outer orifices. A high-speed digital imaging system along with a backlight illumination arrangement is employed to record the details of liquid sheet breakup and spray development. Spray regimes exhibiting different sheet breakup mechanisms are identified and their characteristic features presented. The identified spray regimes are wave-assisted sheet breakup, perforated sheet breakup, segmented sheet breakup, and pulsation spray regime. In the regime of wave-assisted sheet breakup, the sheet breakup shows features similar to the breakup of two-dimensional planar air-blasted liquid sheets. At high air-to-liquid momentum ratios, the interaction process between the axisymmetric swirling liquid sheet and the circular air jet develops spray processes which are more specific to the atomizer studied here. The spray exhibits a periodic ejection of liquid masses whose features are dominantly controlled by the central air jet.     

Vortex simulation of the intake flow in a planar piston-chamber device

A numerical scheme based on the application of the vortex method to update the vorticity field and the implementation of the finite element method to satisfy the normal velocity boundary condition inside a complex time-dependent geometry is applied to simulate the flow produced by a piston sliding out of a chamber equipped with single or multiple intakes. This unsteady confined vortex flow is of interest in many applications. We use the idealization that the flow is incompressible, two-dimensional and planar and we analyse the results to study the flow during the intake process inside a model of an engine cylinder. The chamber top is fitted with an inlet channel, an inlet port or an inlet valve. In all cases when the intake channel axis coincides with that of the chamber, the flow in each side of the chamber consists essentially of two large counter-rotating eddies of almost the same size. The computed structures of these flows resemble qualitatively those which have been observed experimentally. The fluid motion is also computed for the case of a chamber equipped with an intake whose axis is not aligned with the chamber axis. In this case the flow at the end of the stroke is dominated by a single large eddy produced by the merging of the two eddies forming on the sides of the port.     

An experimental investigation of pneumatic swirl flow induced by a three lobed helical pipe

This paper presents a discussion of the results and conclusions drawn from a series of experiments conducted to investigate the swirl flow that are generated by a three lobed helical pipe mounted within a laboratory scale pneumatic conveying rig. The experiments employed Laser Doppler Anemometry (LDA) to quantify the strength of the induced vortex formations and the decay rates of the observed downstream swirl flows over a range of Reynolds number in the turbulent regime. Instantaneous point velocity measurements were resolved in three directions across regular measurement grids transcribed across parallel planes located at four distances downstream of the swirl inducing pipe section. The equivalent axial, radial and tangential velocities were subsequently computed at these grids points. The degree of swirl measured across each measurement plane was expressed in terms of a defined swirl number.It was concluded that the three lobed helical pipe gave rise to a wall jet type of swirl whose rate of observed downstream decay is related to the Reynolds number of the upstream flow and the distance downstream of the swirl pipe. The decay rates for the swirl flows were found to be inversely proportional to the Reynolds number of the upstream flow. The swirl pipe was observed to create a redistribution of the downstream velocity field from axial to tangential, accompanied by a transfer of axial to angular momentum. The findings of this paper are believed to improve understanding to assist the selective use of swirl flow within lean phase particles pneumatic transport systems.     

Fluid Dynamical Analysis of Atmospheric Reacting and Isothermal Swirling Flows

A series of unconfined swirling premixed natural gas/air flames was investigated. Reynolds-numbers spanned from 10,000 to 42,300. Respective isothermal flows were studied additionally to gain insight into changes of fluid dynamical features caused by combustion. Statistical moments, Reynolds-stresses, temporal time scales, spatial length scales, and power spectral densities were deduced from one- and two-point laser Doppler velocimetry (LDV) data. Properties of the turbulent flows and dependencies on Reynolds-number, swirl number, and chemical reactions are discussed. Most distinct differences between combusting and isothermal flows were precessing vortex cores (PVC) occurring only for the latter cases. The study is aimed to serve as a database of a generic flame geometry featuring important characteristics of industrial applications for validation of numerical simulations. Therefore, nozzle exit profiles as important inlet conditions to numerical simulations are thoroughly documented.     

Swirl number and nozzle confinement effects in a flat-vane axial swirler

This paper presents the results of a parametric experimental study of free swirling flow at the exit of a flat-vane axial swirler. A total of 16 data sets were acquired by combining four swirler vane angles (22°, 29°, 50.5°, and 58.3°) and four exit nozzles of different diameters (30, 40, 52, and 76 mm). Sophisticated pressure probes consisting of precise microphones and a two-component LDV system were used to investigate the effect of these geometrical parameters on swirling flow regimes characterized by the swirl number. Particular attention was paid to the precessing vortex core (PVC) phenomenon observed at the exit of the swirler nozzle. It has been shown that by varying the vane angle and the diameter of the exit nozzle, it is possible to independently control the swirl number value and the occurrence of a PVC. A distinct correlation has been found between the PVC-induced pressure pulsations detected by acoustic probes and the tangential velocity fluctuations measured by LDV. The use of microphones provides a quick way to measure the frequency response of swirl flow in a wide range of geometries and flow configurations. The PVC effect does not occur at low subcritical values of the integral swirl number (S < 0.5) and in the case of strong swirl flow (S_g = 0.9 and 1.2) in the absence of constriction by the nozzle (D_e/D₀ = 1). The disappearance of the PVC effect for strong swirl flow without constriction is due to the extreme displacement of the flow to the nozzle walls. The absence of a PVC in the flow was inferred not only from measurements of the frequency response of the flow over a wide range of Re numbers, but also from the absence of specific markers in velocity RMS distributions. Measurement results are used to derive an empirical correlation of the integral swirl number and the Strouhal number with a modified geometric swirl number. This allows a generalization of the frequency characteristics of swirling flows with a PVC for flat-vane axial swirlers, which are widely used in engineering.     

Resonance in flow past oscillating cylinder under subcritical conditions

Flow around an oscillating cylinder in a subcritical region are numerically studied with a lattice Boltzmann method(LBM). The effects of the Reynolds number,oscillation amplitude and frequency on the vortex wake modes and hydrodynamics forces on the cylinder surface are systematically investigated. Special attention is paid to the phenomenon of resonance induced by the cylinder oscillation. The results demonstrate that vortex shedding can be excited extensively under subcritical conditions, and the response region of vibration frequency broadens with increasing Reynolds number and oscillation amplitude. Two distinct types of vortex shedding regimes are observed. The first type of vortex shedding regime(VSR I) is excited at low frequencies close to the intrinsic frequency of flow, and the second type of vortex shedding regime(VSR II)occurs at high frequencies with the Reynolds number close to the critical value. In the VSR I, a pair of alternately rotating vortices are shed in the wake per oscillation cycle,and lock-in/synchronization occurs, while in the VSR II, two alternately rotating vortices are shed for several oscillation cycles, and the vortex shedding frequency is close to that of a stationary cylinder under the critical condition. The excitation mechanisms of the two types of vortex shedding modes are analyzed separately.     

Cubic eddy‐viscosity turbulence models for strongly swirling confined flows with variable density

An investigation on the predictive performance of cubic eddy‐viscosity turbulence models for strongly swirling confined flows with variable density is presented. Comparisons of the prediction with the experiments show some improvements of cubic models over the linear k–ε model. The linear k–ε model does not contain any mechanism to represent the interaction of swirl and density variation and as a consequence it performs poorly. With appropriate modelling, two‐equation cubic turbulence models can capture the subcritical nature of the flow, represent the azimuthal velocity profiles of combined forced‐free vortex motion, and predict the combined effects of swirl and density variation fairly well. However, the calibration of model coefficients is still a topic of investigation. Further amendments are also needed for the equations of k and ε to take into account the effects of swirl and density gradients correctly. Copyright © 2004 John Wiley & Sons, Ltd.     

Atmospheric low swirl burner flow characterization with stereo PIV

The lean premixed prevaporized (LPP) burner concept is now used in most of the new generation gas turbines to reduce flame temperature and pollutants by operating near the lean blow-off limit. The common strategy to assure stable combustion is to resort to swirl stabilized flames in the burner. Nevertheless, the vortex breakdown phenomenon in reactive swirling flows is a very complex 3D mechanism, and its dynamics are not yet completely understood. Among the available measurement techniques to analyze such flows, stereo PIV (S-PIV) is now a reliable tool to quantify the instantaneous three velocity components in a plane (2D–3C). It is used in this paper to explore the reactive flow of a small scale, open to atmosphere, LPP burner (50 kW). The burner is designed to produce two distinct topologies (1) that of a conventional high swirl burner and (2) that of a low swirl burner. In addition, the burner produces a lifted flame that allows a good optical access to the whole recirculation zone in both topologies. The flow is studied over a wide range of swirl and Reynolds numbers at different equivalence ratios. Flow statistics are presented for 1,000 S-PIV snapshots at each configuration. In both reactive and cold nonreactive flow, stability diagrams define the domains of the low and high swirl topologies. Due to the relatively simple conception of the physical burner, this information can be easily used for the validation of CFD computations of the burner flow global structure. Near field pressure measurements reveal the presence of peaks in the power spectra, which suggests the presence of periodical coherent features for almost all configurations. Algorithms have been developed to identify and track large periodic traveling coherent structures from the statistically independent S-PIV realizations. Flow temporal evolution is reconstructed with a POD-based method, providing an additional tool for the understanding of flow topologies and numerical codes validation.     

Flow field characteristics of an axisymmetric sudden-expansion pipe flow with different initial swirl distribution

The results of an experimental investigation depicting the effects of swirl profile on confined flows in a sudden-expansion coaxial dump combustor are presented. Three swirlers (free vortex, forced vortex, and constant angle) with the same nominal swirl number were designed and fabricated to study the effects of swirl type on the isothermal dump combustor flow field. Imparting swirl to the inlet flow resulted in a considerable reduction of the corner recirculation length, a marked increase in turbulent mixing activity, and in one case creation of a central recirculation zone. This article highlights the importance of the combustor inlet swirl profile and shows that swirl type as well as swirl strength can affect the flow field significantly. The present database is well suited for numerical codes development and validation.     

Prediction of Pressure Oscillations in a Premixed Swirl Combustor Flow and Comparison to Measurements

The most common and reliable technique used for flame stabilization of industrial combustors with high thermal loads is the application of strongly swirling flows. In addition to stabilization, swirl flames offer the possibility to influence emission characteristics by simply changing the swirl intensity or the type of swirl generation. Despite of these major advantages, swirling flows tend to evolve flow instabilities, that considerably constitute a significant source of noise. In general, noise generation is substantially enhanced, when such a swirling flow is employed for flames. Thus, the minimization of the resulting noise emissions under conservation of the benefit of high ignition stability is one major design challenge for the development of modern swirl stabilized combustion devices. The present investigation makes an attempt to determine mechanisms and processes to influence the noise generation of flames with underlying swirling flows. Therefore, a new burner has been designed, that offers the possibility to vary geometrical parameters as well as the type of swirl generation, typically applied in industrial devices. Experimental data has been acquired for the isothermal flow as well as swirl flames by means of 3-D-LDV-diagnostics comprising the components of long-time averaged mean and rms-velocities as well as spectrally resolved velocity fluctuations for all components. The noise emission data was acquired with microphone probes resulting in sound pressure levels outside the zone of the perceptible fluid flow. Along to the experiments, numerical simulations using RANS and LES have been carried out for isothermal cases with different burner outlet geometries. The results of the measurements show a distinct rise of the sound pressure level, obtained by changing both the test setup from the isothermal into the flame configuration as well as the geometrical parameters. This is also resembled by the LES simulation results. Furthermore, a physical model has been developed from experiments and verified by the LES simulation, that explains the formation of coherent flow structures and allows to separate their contribution to the overall noise emission from ordinary turbulent noise sources.