Large Eddy Simulation of the spray formation in confinements

The particle and powder properties produced within spray drying processes are influenced by various unsteady transport phenomena in the dispersed multiphase spray flow in a confined spray chamber. In this context differently scaled spray structures in a confined spray environment have been analyzed in experiments and numerical simulations. The experimental investigations have been carried out with Particle-Image-Velocimetry to determine the velocity of the gas and the discrete phase. Large-Eddy-Simulations have been set up to predict the transient behaviour of the spray process and have given more insight into the sensitivity of the spray flow structures in dependency from the spray chamber design.     

Modelling and simulation of sprays in laminar flames

In the present paper we model and numerically simulate steady, laminar, premixed spray flames. The gasphase is described in Eulerian form by the equations governing the conservation of overall mass, momentum, energy and species mass. The liquid phase is described in Lagrangian form by the overall continuity equation, which reduces to an equation for the droplet size, the equations of motion, the energy equation and a droplet density function transport equation. The latter is the so-called spray equation, which, at any position in the chemically reacting flowfield, describes the joint distribution of droplet size, droplet velocity and droplet temperature. Herein the spray equation is solved using a Monte Carlo method. Detailed models of the exchange of mass, momentum and energy between the gaseous and the liquid phase are taken into account. The results presented in this paper are for an octane-air flame, where small amounts of liquid octane in form of a liquid spray are added to a fresh, unburnt gaseous octane-air mixture.Presented at Euromech Colloquium 324: The Combustion of Drops, Sprays and Aerosols, 25th–27th July 1994, Marseilles, France.     

Experimental analysis of the flow characteristics of a pressure-atomised spray

An experimental setup has been created to allow measurements of the properties of the gas phase, the liquid phase and the mixture in a pressure-atomised spray of water, in terms of both mean quantities and Reynolds stresses. This setup involves laser Doppler velocimetry for determining the velocity of either the gas or liquid phase, according to the parameters used, such as seeding or no-seeding of the ambient air, laser source power, or photo-multiplier gains, droplet tracking velocimetry for determining the velocity and characteristic size of the droplets, and a single optical probe for determining the mean volume fraction of the liquid, from which the liquid mean mass fraction and the mean density of the mixture are inferred. The experimental conditions, in particular in terms of liquid and gas Weber numbers, were chosen in a range for which the liquid phase turbulent kinetic energy should be mainly responsible for the liquid-jet primary break-up, these flow conditions lying within the second wind-induced atomization regime. Results reported herein are more specifically focused on the region ranging from 400 nozzle diameters to 800 nozzle diameters, where the liquid core is disrupted. They provide new information about the formation and properties of such pressure-atomised sprays, in particular in terms of the role played by the Reynolds stresses resulting from the slip velocity between the liquid and the gas. The mean slip velocity is directly related to the turbulent flux of liquid. Such information will be used in the future to develop new turbulence models since very limited experimental information is so far available for these terms.     

Microgravity experiments and numerical studies on ethanol/air spray flames

Spray flames are known to exhibit amazing features in comparison with single-phase flames. The weightless situation offers the conditions in which the spray characteristics can be well controlled before and during combustion. The article reports on a joint experimental/numerical work that concerns ethanol/air spray flames observed in a spherical chamber using the condensation technique of expansion cooling (based on the Wilson cloud chamber principle), under microgravity.We describe the experimental set-up and give details on the creation of a homogeneous and nearly monosized aerosol. Different optical diagnostics are employed successfully to measure the relevant parameters of two-phase combustion. A classical shadowgraphy system is used to track the flame speed propagation and allow us to observe the flame front instability. The complete characterization of the aerosol is performed with a laser diffraction particle size analyser by measuring the droplet diameter and the droplet density number, just before ignition. A laser tomography device allows us to measure the temporal evolution of the droplet displacement during flame propagation, as well as to identify the presence of droplets in the burnt gases. The numerical modelling is briefly recalled. In particular, spray-flame propagation is schematized by the combustion spread in a 2-D lattice of fuel droplets surrounded by an initial gaseous mixture of fuel vapour and air.In its spherical expansion, the spray flame presents a corrugated front pattern, while the equivalent single-phase flame does not. From a numerical point of view, the same phenomena of wrinkles are also observed in the simulations. The front pattern pointed out by the numerical approach is identified as of Darrieus–Landau (DL) type. The droplets are found to trigger the instability. Then, we quantitatively compare experimental data with numerical predictions on spray-flame speed. The experimental results show that the spray-flame speed is of the same order of magnitude as that of the single-phase premixed flame. On the other hand, the numerical results exhibit the role played by the droplet radius in spray-flame propagation, and retrieve the experiments only when the droplets are small enough and when the Darrieus–Landau instability is triggered. A final discussion is developed to interpret the various patterns experimentally observed for the spray-flame front.     

Flow and atomization characteristics of a twin-fluid nozzle with internal swirling and self-priming effects

A twin-fluid nozzle was proposed for low-pressure atomization. The nozzle is featured by swirling air flows in the mixing chamber. Liquid medium is thereby inhaled due to the pressure difference. An experimental work was performed to investigate the atomization performance of the nozzle and the hydrogen peroxide solution served as the liquid medium. Droplet size and droplet velocity were measured. Effects of the diameter of the air-injection orifice and the air-injection pressure were investigated. The results show that small droplet size is achieved with the proposed nozzle. As the spray develops, Sauter mean diameter (SMD) of the droplets decreases first and then increases, irrespective of the variation of the air-injection orifice diameter and the air-injection pressure. Overall SMD varies inversely with the air-injection orifice diameter and air-injection pressure. Near the nozzle, cross-sectional velocity distribution exhibits a peak-valley pattern, which is replaced with uniformized velocity distributions away from the nozzle. Similarity of cross-sectional radial velocity distribution at different air pressures is evidenced. Furthermore, the correlation between droplet size and droplet velocity is established.     

Consistency issues of Lagrangian particle tracking applied to a spray jet in crossflow

Numerical simulations are performed for multiphase jets in crossflow. The flow solver uses an Eulerian/Lagrangian approach. Turbulence in the gas phase is modeled in the framework of large eddy simulation. The dispersed phase is handled using Lagrangian particle tracking. The model assumptions of solvers for Lagrangian particle tracking are critically assessed for typical flow conditions of spray jets in crossflow. The droplets are assumed to be spherical and isolated. It is shown that several model assumptions are apparently inconsistent in larger portions of the flow field. Firstly, average Weber numbers can be so large that the model assumption to regard droplets as spherical is questionable, not only near the nozzle, but also in the far-field. Secondly, the average droplet spacing can be so low that droplets directly interact with each other, again also in the far-field. Thirdly, the average Stokes numbers in the jet region can be so large that the phase coupling between the dispersed and continuous phase is weak. Some remedies to these deficiencies are proposed.     

An experimental investigation into modeling solids friction for fluidized dense-phase pneumatic transport of powders

Results are presented of an ongoing investigation into modeling friction in fluidized dense-phase pneumatic transport of bulk solids. Many popular modeling methods of the solids friction use the dimensionless solids loading ratio and Froude number. When evaluated under proper scale-up conditions of pipe diameter and length, many of these models have resulted in significant inaccuracy. A technique for modeling solids friction has been developed using a new combination of dimensionless numbers, volumetric loading ratio and the ratio of particle free settling velocity to superficial conveying air velocity, to replace the solids loading ratio and Froude number. The models developed using the new formalism were evaluated for accuracy and stability under significant scale-up conditions for four different products conveyed through four different test rigs (subject to diameter and length scale-up conditions). The new model considerably improves predictions compared with those obtained using the existing model, especially in the dense-phase region. Whereas the latter yields absolute average relative errors varying between 10% and 86%, the former yielded results with errors from 4% to 20% for a wide range of scale-up conditions. This represents a more reliable and narrower range of prediction that is suitable for industrial scale-up requirements.     

Effect of particle degradation on electrostatic sensor measurements and flow characteristics in dilute pneumatic conveying

Vigorous particle collisions and mechanical processes occurring during high-velocity pneumatic conveying often lead to particle degradation. The resulting particle size reduction and particle number increase will impact on the flow characteristics, and subsequently affect the electrostatic type of flow measurements. This study investigates this phenomenon using both experimental and numerical methods. Particle degradation was induced experimentally by recursively conveying the fillite material within a pneumatic pipeline. The associated particle size reduction was monitored. Three electrostatic sensors were embedded along the pipeline to monitor the flow. The results indicated a decreasing trend in the electrostatic sensor outputs with decreasing particle size, which suggested the attenuation of the flow velocity fluctuation. This trend was more apparent at higher conveying velocities, which suggested that more severe particle degradation occurred under these conditions. Coupled computational fluid dynamics and discrete element methods (CFD–DEM) analysis was used to qualitatively validate these experimental results. The numerical results suggested that smaller particles exhibited lower flow velocity fluctuations, which was consistent with the observed experimental results. These findings provide important information for the accurate application of electrostatic measurement devices in pneumatic conveyors.     

Effect of ambient pressure on penetration of a diesel spray

In the present experimental and theoretical work the propagation of a high-speed fuel spray at distances much longer than the breakup length is studied. The motion of the spray is modeled in two regions: the main region of the steady flow and the front region of the spray. The analysis yields the equation of propagation of the tip of the spray. These theoretical results have been validated against experimental data obtained from a common-rail diesel injection nozzle and from other data available in the literature. The importance of the shock wave propagation at the initial stage of the spray injection is demonstrated.     

Numerical investigation of droplet pre-dispersion in a monodisperse droplet spray dryer

Monodisperse droplet spray dryers have great advantages in particle formation through spray drying because of their ability to produce uniform sized particles. Experimental analyses of this system have shown that droplets atomized through the piezoceramic nozzle need to be sufficiently well dispersed before entering the drying chamber to achieve sufficiently dried particles. However, the dispersion dynamics cannot be readily observed because of experimental limitations, and key factors influencing the dispersion state currently remain unclear. This study carried out numerical simulations for droplet dispersions in the dispersion chamber, which allow this important process to be visualized. The systematic and quantitative analyses on the dispersion states provide valuable data for improving the design of the dispersion chamber, and optimizing the spray drying operation.     

Quadrature method of moments for modeling multi-component spray vaporization

This article puts forward the quadrature method of moments (QMoM) for modeling droplet composition during the spray vaporization process. This method is implemented for solving the Continuous Thermodynamic Model (CTM) of multi-component droplet vaporization, an advantageous alternative to the classical Discrete Component Model (DCM) when the droplet is formed of a great number of components. The CTM approach consists in modeling the droplet’s composition using a probability density function (PDF). This method was first tried out for vaporizing droplets by Hallett, who assumed a Gamma-function for the PDF. However, Harstadt et al. underlined some problems in the case of vapor condensation on the droplet surface, since the Gamma-PDF model presumes the PDF’s mathematical form. The QMoM which does not require this hypothesis is studied in this article, according to Lage’s research dealing with QMoM application to phase equilibria. The numerical features of QMoM are investigated in detail, and then the method is implemented for the difficult test case of vapor condensation. The results are analyzed to illustrate the application of QMoM to multi-component droplet vaporization modeling and to provide a better understanding of the QMoM main advantages and limitations.     

Predicting the mode of flow in pneumatic conveying systems-A review

An initial prediction of the particulate mode of flow in pneumatic conveying systems is beneficial as this knowledge can provide clearer direction to the pneumatic conveying design process.There are three general categories of modes of flow,two dense flows:fluidised dense phase and plug flow,and dilute phase only.Detailed in this paper is a review of the commonly used and available techniques for predicting mode of flow.Two types of predictive charts were defined:basic particle parameter based (e.g.particle size and density) and air-particle parameter based (e.g.permeability and de-aeration).The basic particle techniques were found to have strong and weak areas of predictive ability,on the basis of a comparison with data from materials with known mode of flow capability.It was found that there was only slight improvement in predictive ability when the particle density was replaced by loose-poured bulk density in the basic parameter techniques.The air-particle-parameter-based techniques also showed well-defined regions for mode of flow prediction though the data set used was smaller than that for the basic techniques.Also,it was found to be difficult to utilise de-aeration values from different researchers and subsequently,an air-particle-based technique was developed which does not require any de-aeration parameter in its assessment.     

Dynamic pressure based prediction of spray cooling heat transfer coefficients

An important goal of spray cooling research is the ability to predict local heat transfer from the spray hydrodynamics. It is postulated that the local normal pressure exerted by the spray onto the heated surface can be used to obtain the local heat transfer coefficient. This hypothesis was tested using data obtained from hollow cone, full cone, and linear sprays at four nozzle pressures and three stand-off distances. A correlation between the pressure and heat transfer coefficient was determined from the data, then used to “predict” the heat transfer coefficient to verify the accuracy of the correlation. The area averaged heat transfer coefficient could be predicted within 25%, indicating that pressure can be used to predict the local heat transfer coefficient in the single-phase regime.     

Predicting the mode of flow in pneumatic conveying systems-- A review

An initial prediction of the particulate mode of flow in pneumatic conveying systems is beneficial as this knowledge can provide clearer direction to the pneumatic conveying design process. There are three general categories of modes of flow, two dense flows： fluidised dense phase and plug flow, and dilute phase oniy. Detailed in this paper is a review of the commonly used and available techniques for predicting mode of flow. Two types of predictive charts were defined： basic particle parameter based （e.g. particle size and density） and air-particle parameter based （e.g. permeability and de-aeration）. The basic particle techniques were found to have strong and weak areas of predictive ability, on the basis of a comparison with data from materials with known mode of flow capability. It was found that there was only slight improvement in predictive ability when the particle density was replaced by loose-poured bulk density in the basic parameter techniques. The air-particle-parameter-based techniques also showed well-defined regions for mode of flow prediction though the data set used was smaller than that for the basic techniques. Also, it was found to be difficult to utilise de-aeration values from different researchers and subsequently, an air-particle-based technique was developed which does not require any de-aeration parameter in its assessment.     

Modeling the evolution of droplet size distribution in two-phase flows

A theoretical model is developed in the present study to simulate droplet motion and the evolution of droplet size distribution (DSD) in two-phase air/dispersed water spray flows. The model takes into account several processes which influence DSD and droplet trajectory: droplet collision and coalescence, evaporation and cooling, gravitational settling, and turbulent dispersion of dispersed phase. The DSDs determined by the model at different locations in a two-phase flow are evaluated by comparing them to experimental observations obtained in an icing wind tunnel. The satisfactory coincidence between simulation and experimental results proves that the model is reliable when modeling two-phase flows under icing conditions. The model is applied for two particular examples in which the modification of DSD is calculated in two-phase flows under conditions describing in-cloud icing and freezing drizzle.     

Energy loss at bends in the pneumatic conveying of fly ash

An accurate estimation of the total pressure drop of a pipeline is important to the reliable design of a pneumatic conveying system. The present paper presents results from an investigation into the modelling of the pressure drop at a bend in the pneumatic conveying of fly ash. Seven existing bend models were used (in conjunction with solids friction models for horizontal and vertical straight pipes, and initial acceleration losses) to predict the total pipeline pressure drop in conveying fly ash (median particle diameter: 30 μm; particle density: 2300 kg/m³; loose-poured bulk density: 700 kg/m³) in three test rigs (pipelines with dimensions of 69 mm inner diameter (I.D.) × 168 m length; 105 mm I.D. × 168 m length; 69 mm I.D. × 554 m length). A comparison of the pneumatic conveying characteristics (PCC) predicted using the seven bend models and experimental results shows that the predicted total pipeline PCC and trends depend on the choice of bend model. While some models predict trends that agree with the experimental results, other models predicted greater bend pressure drops for the dense phase of fly ash than for the dilute phase. Models of Pan, R. (1992). Improving scale-up procedures for the design of pneumatic conveying systems. Doctoral dissertation, University of Wollongong, Australia, Pan, R., & Wypych, P.W. (1998). Dilute and dense phase pneumatic conveying of fly ash. In Proceedings of the sixth International Conference on Bulk Materials Storage and Transportation (pp. 183–189), Wollongong, NSW, Australia and Chambers, A.J., & Marcus, R.D. (1986). Pneumatic conveying calculations. In Proceedings of the second International Conference on Bulk Materials Storage and Transportation (pp. 49–52), Wollongong, Australia reliably predicted the bend losses for systems conveying fly ash over a large range of air flows.     

CFD–DEM simulation of turbulence modulation in horizontal pneumatic conveying

A study is presented to evaluate the capabilities of the standard k–ε turbulence model and the k–ε turbulence model with added source terms in predicting the experimentally measured turbulence modulation due to the presence of particles in horizontal pneumatic conveying, in the context of a CFD–DEM Eulerian–Lagrangian simulation. Experiments were performed using a 6.5-m long, 0.075-m diameter horizontal pipe in conjunction with a laser Doppler anemometry (LDA) system. Spherical glass beads with two sizes, 1.5 and 2 mm, were used. Simulations were performed using the commercial discrete element method software EDEM, coupled with the computational fluid dynamics package FLUENT. Hybrid source terms were added to the conventional k–ε turbulence model to take into account the influence of the dispersed phase on the carrier phase turbulence intensity. The simulation results showed that the turbulence modulation depends strongly on the model parameter C_ε3. Both the standard k–ε turbulence model and the k–ε turbulence model with the hybrid source terms could predict the gas phase turbulence intensity trend only generally. A noticeable discrepancy in all cases between simulation and experimental results was observed, particularly for the regions close to the pipe wall. It was also observed that in some cases the addition of the source terms to the k–ε turbulence model did not improve the simulation results when compared with those of the standard k–ε turbulence model. Nonetheless, in the lower part of the pipe where particle loading was greater due to gravitational effects, the model with added source terms performed somewhat better.     

Experimental study of the blockage boundary for dense-phase pneumatic conveying of powders through a horizontal slit

The estimation of the blockage boundary for pneumatic conveying through a slit is of significant importance. In this paper, we investigate the characteristics for blockage of powder (48 μm average diameter) through a horizontal slit (1.6 m × 0.05 m × 0.002 m). The results show that the required critical solid mass flow rate increases as the superficial air velocity increases superficial air velocity. The solid loading ratio and superficial air velocity displayed a decreasing power law relationship. This finding agrees with existing theory and experimental results. However, a minimum inlet solid loading ratio exists. When the air velocity is greater than the corresponding air velocity of the minimum solid loading ratio, the solid loading ratio exhibits an increasing trend in power law. We also found that when the inlet conveying pressure increased, the critical solid mass flow rate required for blockage, the inlet solid loading ratio, and the minimum inlet solid loading ratio increased.