Dynamic coupling of fluid and structural mechanics for simulating particle motion and interaction in high speed compressible gas particle laden flow

In this work, structural finite element analyses of particles moving and interacting within high speed compressible flow are directly coupled to computational fluid dynamics and heat transfer analyses to provide more detailed and improved simulations of particle laden flow under these operating conditions. For a given solid material model, stresses and displacements throughout the solid body are determined with the particle–particle contact following an element to element local spring force model and local fluid induced forces directly calculated from the finite volume flow solution. Plasticity and particle deformation common in such a flow regime can be incorporated in a more rigorous manner than typical discrete element models where structural conditions are not directly modeled. Using the developed techniques, simulations of normal collisions between two 1 mm radius particles with initial particle velocities of 50–150 m/s are conducted with different levels of pressure driven gas flow moving normal to the initial particle motion for elastic and elastic–plastic with strain hardening based solid material models. In this manner, the relationships between the collision velocity, the material behavior models, and the fluid flow and the particle motion and deformation can be investigated. The elastic–plastic material behavior results in post collision velocities 16–50% of their pre-collision values while the elastic-based particle collisions nearly regained their initial velocity upon rebound. The elastic–plastic material models produce contact forces less than half of those for elastic collisions, longer contact times, and greater particle deformation. Fluid flow forces affect the particle motion even at high collision speeds regardless of the solid material behavior model. With the elastic models, the collision force varied little with the strength of the gas flow driver. For the elastic–plastic models, the larger particle deformation and the resulting increasingly asymmetric loading lead to growing differences in the collision force magnitudes and directions as the gas flow strength increased. The coupled finite volume flow and finite element structural analyses provide a capability to capture the interdependencies between the interaction of the particles, the particle deformation, the fluid flow and the particle motion.     

Discrete element-embedded finite element model for simulation of soft particle motion and deformation

The motion and deformation of soft particles are commonly encountered and important in many applications. A discrete element-embedded finite element model (DEFEM) is proposed to solve soft particle motion and deformation, which combines discrete element and finite element methods. The collisional surface of soft particles is covered by several dynamical embedded discrete elements (EDEs) to model the collisional external forces of the particles. The particle deformation, motion, and rotation are independent of each other in the DEFEM. The deformation and internal forces are simulated using the finite element model, whereas the particle rotation and motion calculations are based on the discrete element model. By inheriting the advantages of existing coupling methods, the contact force and contact search between soft particles are improved with the aid of the EDE. Soft particle packing is simulated using the DEFEM for two cases: particle accumulation along a rectangular straight wall and a wall with an inclined angle. The large particle deformation in the lower layers can be simulated using current methods, where the deformed particle shape is either irregular in the marginal region or nearly hexagonal in the tightly packed central region. This method can also be used to simulate the deformation, motion, and heat transfer of non-spherical soft particles.     

Onset velocity of circulating fluidization and particle residence time distribution: A CFD–DEM study

Until now, the onset velocity of circulating fluidization in liquid–solid fluidized beds has been defined by the turning point of the time required to empty a bed of particles as a function of the superficial liquid velocity, and is reported to be only dependent on the liquid and particle properties. This study presents a new approach to calculate the onset velocity using CFD–DEM simulation of the particle residence time distribution (RTD). The onset velocity is identified from the intersection of the fitted lines of the particle mean residence time as a function of superficial liquid velocity. Our results are in reasonable agreement with experimental data. The simulation indicates that the onset velocity is influenced by the density and size of particles and weakly affected by riser height and diameter. A power-law function is proposed to correlate the mean particle residence time with the superficial liquid velocity. The collisional parameters have a minor effect on the mean residence time of particles and the onset velocity, but influence the particle RTD, showing some humps and trailing. The particle RTD is found to be related to the particle trajectories, which may indicate the complex flow structure and underlying mechanisms of the particle RTD.     

Estimation of particle dynamics in 2-D fluidized beds using particle tracking velocimetry

The experimental characterization of particle dynamics in fluidized beds is of great importance in fostering an understanding of solid phase motion and its effect on particle properties in granulation processes. Commonly used techniques such as particle image velocimetry rely on the cross-correlation of illumination intensity and averaging procedures. It is not possible to obtain single particle velocities with such techniques. Moreover, the estimated velocities may not accurately represent the local particle velocities in regions with high velocity gradients. Consequently, there is a need for devices and methods that are capable of acquiring individual particle velocities. This paper describes how particle tracking velocimetry can be adapted to dense particulate flows. The approach presented in this paper couples high-speed imaging with an innovative segmentation algorithm for particle detection, and employs the Voronoi method to solve the assignment problem usually encountered in densely seeded flows. Lagrangian particle tracks are obtained as primary information, and these serve as the basis for calculating sophisticated quantities such as the solid-phase flow field, granular temperature, and solid volume fraction. We show that the consistency of individual trajectories is sufficient to recognize collision events.     

Analysis of gas–solid flow and shaft-injected gas distribution in an oxygen blast furnace using a discrete element method and computational fluid dynamics coupled model

Ironmaking using an oxygen blast furnace is an attractive approach for reducing energy consumption in the iron and steel industry. This paper presents a numerical study of gas–solid flow in an oxygen blast furnace by coupling the discrete element method with computational fluid dynamics. The model reliability was verified by previous experimental results. The influences of particle diameter, shaft tuyere size, and specific ratio (X) of shaft-injected gas (SIG) flowrate to total gas flowrate on the SIG penetration behavior and pressure field in the furnace were investigated. The results showed that gas penetration capacity in the furnace gradually decreased as the particle diameter decreased from 100 to 40 mm. Decreasing particle diameter and increasing shaft tuyere size both slightly increased the SIG concentration near the furnace wall but decreased it at the furnace center. The value of X has a significant impact on the SIG distribution. According to the pressure fields obtained under different conditions, the key factor affecting SIG penetration depth is the pressure difference between the upper and lower levels of the shaft tuyere. If the pressure difference is small, the SIG can easily penetrate to the furnace center.     

Investigation into improving the efficiency and accuracy of CFD/DEM simulations

The Euler-Lagrange approach combined with a discrete element method has frequently been applied to elucidate the hydrodynamic behavior of dense fluid-solid flows in fluidized beds. In this work, the efficiency and accuracy of this model are investigated. Parameter studies are performed; in these studies, the stiffness coefficient, the fluid time step and the processor number are varied under conditions with different numbers of particles and different particle diameters. The obtained results are compared with measurements to derive the optimum parameters for CFD/DEM simulations. The results suggest that the application of higher stiffness coefficients slightly improves the simulation accuracy. However, the average computing time increases exponentially. At larger fluid time steps, the results show that the average computation time is independent of the applied fluid time step whereas the simulation accuracy decreases greatly with increasing the fluid time step. The use of smaller time steps leads to negligible improvements in the simulation accuracy but results in an exponential rise in the average computing time. The parallelization accelerates the DEM simulations if the critical number for the domain decomposition is not reached. Above this number, the performance is no longer proportional to the number of processors. The critical number for the domain decomposition depends on the number of particles. An increase in solid contents results in a shift of the critical decomposition number to higher numbers of CPUs.     

Numerical simulation of tetrahedral particle mixing and motion in rotating drums

A regular tetrahedron is the simplest three-dimensional structure and has the largest non-sphericity. Mixing of tetrahedral particles in a thin drum mixer was studied by the soft-sphere-imbedded pseudo-hard particle model and compared with that of spherical particles. The two particle types were simulated with different rotation speeds and drum filling levels. The Lacey mixing index and Shannon information entropy were used to explore the effects of sphericity on the mixing and motion of particles. Moreover, the probability density functions and mean values and variances of motion velocities, including translational and rotational, were computed to quantify the differences between the motion features of tetrahedra and spheres. We found that the flow regime depended on the particle shape in addition to the rotation speed and filling level of the drum. The mixing of tetrahedral particles was better than that of spherical particles in the rolling and cascading regimes at a high filling level, whereas it may be poorer when the filling level was low. The Shannon information entropy is better than the Lacey mixing index to evaluate mixing because it can reflect the real change of flow regime from the cataracting to the centrifugal regime, whereas the mixing index cannot.     

Effects of particle size and concentration on bubble coalescence and froth formation in a slurry bubble column

A new approach for simulating the formation of a froth layer in a slurry bubble column is proposed. Froth is considered a separate phase, comprised of a mixture of gas, liquid, and solid. The simulation was carried out using commercial flow simulation software (FIRE v2014) for particle sizes of 60–150 μm at solid concentrations of 0–40 vol%, and superficial gas velocities of 0.02–0.034 m/s in a slurry bubble column with a hydraulic diameter of 0.2 m and height of 1.2 m. Modelling calculations were conducted using a Eulerian–Eulerian multiphase approach with k–ε turbulence. The population balance equations for bubble breakup, bubble coalescence rate, and the interfacial exchange of mass and momentum were included in the computational fluid dynamics code by writing subroutines in Fortran to track the number density of different bubble sizes. Flow structure, radial gas holdup, and Sauter mean bubble diameter distributions at different column heights were predicted in the pulp zone, while froth volume fraction and density were predicted in the froth zone. The model was validated using available experimental data, and the predicted and experimental results showed reasonable agreement. To demonstrate the effect of increasing solid concentration on the coalescence rate, a solid-effect multiplier in the coalescence efficiency equation was used. The solid-effect multiplier decreased with increasing slurry concentration, causing an increase in bubble coalescence efficiency. A slight decrease in the coalescence efficiency was also observed owing to increasing particle size, which led to a decrease in Sauter mean bubble diameter. The froth volume fraction increased with solid concentration. These results provide an improved understanding of the dynamics of slurry bubble reactors in the presence of hydrophilic particles.     

Landmarks in the application of electrical tomography in particle science and technology

Selected milestones in the development and use of electrical tomography in powder conveying, slurry processing and multi-phase flow are highlighted. The ability to map concentration in opaque mixtures under process-realistic conditions was a major innovation for the method and has had far reaching implications. Subsequent developments have enabled velocity information to be abstracted resulting in the ability to measure component flux and motion.     

Experimental investigation of bubbling in particle beds with high solid holdup

A series of experiments on bubbling behavior in particle beds was performed to clarify three-phase flow dynamics in debris beds formed after core-disruptive accident (CDA) in sodium-cooled fast breeder reactors (FBRs). Although in the past, several experiments have been performed in packed beds to investigate flow patterns, most of these were under comparatively higher gas flow rate, which may be not expected during an early sodium boiling period in debris beds. The current experiments were conducted under two dimensional (2D) and three dimensional (3D) conditions separately, in which water was used as liquid phase, and bubbles were generated by injecting nitrogen gas from the bottom of the viewing tank. Various particle-bed parameters were varied, including particle-bed height (from 30 mm to 200 mm), particle diameter (from 0.4 mm to 6 mm) and particle type (beads made of acrylic, glass, alumina and zirconia). Under these experimental conditions, three kinds of bubbling behavior were observed for the first time using digital image analysis methods that were further verified by quantitative detailed analysis of bubbling properties including surface bubbling frequency and surface bubble size under both 2D and 3D conditions. This investigation, which hopefully provides fundamental data for a better understanding and an improved estimation of CDAs in FBRs, is expected to benefit future analysis and verification of computer models developed in advanced fast reactor safety analysis codes.     

CFD modeling of pressure drop and drag coefficient in fixed beds: Wall effects

Simulations of fixed beds having column to particle diameter ratio (D/dp ) of 3, 5 and 10 were performed in the creeping, transition and turbulent flow regimes, where Reynolds number (dp VLL/L ) was varied from 0.1 to 10,000. The deviations from Ergun’s equation due to the wall effects, which are important in D/d p<15 beds were well explained by the CFD simulations. Thus, an increase in the pressure drop was observed due to the wall friction in the creeping flow, whereas, in turbulent regime a decrease in t...     

Numerical study of coarse coal particle breakage in pneumatic conveying

Pneumatic conveying of coarse coal particles with various pipeline configurations and swirling intensities was investigated using a coupled computational fluid dynamics and discrete element method. A particle cluster agglomerated by the parallel-bond method was modeled to analyze the breakage of coarse coal particles. The numerical parameters, simulation conditions, and simulation results were experimentally validated. On analyzing total energy variation in the agglomerate during the breakage process, the results showed that downward fluctuation of the total particle energy was correlated with particle and wall collisions, and particle breakage showed a positive correlation with the energy difference. The correlation between the total energy variation of a particle cluster and particle breakage was also analyzed. Particle integrity presented a fluctuating upward trend with pipe bend radius and increased with swirling number for most bend radii. The degree of particle breakage differed with pipeline bending direction and swirling intensity: in a horizontal bend, the bend radius and swirling intensity dominated the total energy variations; these effects were not observed in a vertical bend. The total energy of the particle cluster exiting a bend was generally positively correlated with the bend radius for all conditions and was independent of bending direction.     

Effects of grid size on predictions of bed expansion in bubbling fluidized beds of Geldart B particles: A generalized rule for a grid-independent solution of TFM simulations

Numerical simulations of gas–solid fluidized beds based on the kinetic theory of granular flow exhibit a significant dependence on domain discretization. Bubble formation, bubble size and shape all vary greatly with the discretization, and the use of an inappropriate scale resolution leads to inaccurate predictions of fluidization hydrodynamics. In this study, grid-independent solutions of the two fluid model were examined by comparing the bed expansions obtained from numerical simulations with experimental results and empirical predictions, based on bubbling fluidized beds of Geldart B particles. Grid independence was achieved with a grid resolution equal to 18 times the particle diameter. The simulation results were compared with previously published data for verification purposes. The results of this work should provide a guideline for choosing the appropriate grid size and thereby minimize the time and expense associated with large simulations.     

Experimental and numerical study of pseudo-2D circulating fluidized beds

We present experimental investigations and numerical simulations of a pseudo-2D riser. Experiments were performed for various airflow rates, particle types/diameters, and particle size distributions. Pressure distributions along the wall of the riser were measured. Additional measurements from a smaller pseudo-2D riser (Kallio et al., 2009; Shah et al., 2012) were used to analyze horizontal solids volume fraction profiles. The experimental data were compared with simulation results carried out using an Euler–Euler approach. A mesh sensitivity study was conducted for numerical simulations and effects associated with simplifying real 3D geometry to a 2D model were examined. In addition, the effect of using an algebraic equation to represent the granular temperature versus a full partial differential equation also was examined for numerical simulations. Results showed small but significant near-wall sensitivity of the flow variables to mesh size. Substantial differences in mean pressure, solids distribution, and solid velocities were obtained, when 2D and 3D simulation results were compared. Finally, applying the simplified granular temperature equation for turbulent fluidization and for dilute-phase transport can lead to incorrect predictions in models.     

Evaluation of coarse-grained CFD-DEM models with the validation of PEPT measurements

Computational Fluid Dynamics coupled with Discrete Element Method (CFD-DEM) is a commonly used numerical method to model gas-solid flow in fluidised beds and other multiphase systems. A significant limitation of CFD-DEM is the feasibility of the realistic simulation of large numbers of particles. Coarse-graining (CG) approaches, through which groups of multiple individual particles are represented by single, larger particles, can substantially reduce the total number of particles while maintaining similar system dynamics. As these three CG models have not previously been compared, there remains some debate, however, about the best practice in the application of CG in CFD-DEM simulations. In this paper, we evaluate the performance of three typical CG methods based on simulations of a bubbling fluidised bed. This is achieved through the use of a numerical validation framework, which makes full use of the high-resolution 3D positron emission particle tracking (PEPT) measurements to rigorously validate the outputs of CFD-DEM simulations conducted using various different coarse-graining models, and various different degrees of coarse-graining. The particle flow behaviours in terms of the particle occupancy field, velocity field, circulation time, and bubble size and velocity, are comprehensively analysed. It is shown that the CG simulation starts to fail when the size ratio between the bed chamber and the particles decreases to approximately 20. It is also observed, somewhat surprisingly, that the specific CG approach applied to interparticle contact parameters does not have a substantial effect on the simulation results for the bubbling bed simulations across a wide range of CG factors.     

Particle convective heat transfer near the wall in a supercritical water fluidized bed by single particle model coupled with CFD-DEM

Supercritical water fluidized bed (SCWFB) is a promising reactor to gasify biomass or coal. Its optimization design is closely related to wall-to-bed heat transfer, where particle convective heat transfer plays an important role. This paper evaluates the particle convective heat transfer coefficient (h_pc) at the wall in SCWFB using the single particle model. The critical parameters in the single particle model which is difficult to get experimentally are obtained by the computational fluid dynamics-discrete element method (CFD-DEM). The contact statistics related to particle-to-wall heat transfer, such as contact number and contact distance, are also presented. The results show that particle residence time (τ), as the key parameter to evaluate h_pc, is found to decrease with rising velocity, while increase with larger thermal boundary layer thickness. τ follows a gamma function initially adopted in the gas–solid fluidized bed, making it possible to evaluate h_pc in SCWFB by a simplified single particle model. The theoretical predicted h_pc tends to increase with rising thermal gradient thickness at a lower velocity (1.5 U_mf), while first decreases and then increases at higher velocity (1.75 and 2 U_mf). h_pc occupies 30%–57% of the overall wall-to-bed heat transfer coefficient for a particle diameter of 0.25 mm. The results are helpful to predict the overall wall-to-bed heat transfer coefficient in SCWFB combined with a reasonable fluid convective heat transfer model from a theoretical perspective.     

DEM simulation of particle percolation in a packed bed

The phenomenon of spontaneous particle percolation under gravity is investigated by means of the discrete element method. Percolation behaviors such as percolation velocity,residence time distribution and radial dispersion are examined under various conditions. It is shown that the vertical velocity of a percolating particle moving down through a packing of larger particles decreases with increasing the restitution coefficient between particles and diameter ratio of the percolating to packing particles. With the increase of the restitution coefficient,the residence time and radial dispersion of the percolating particles increase. The packing height affects the residence time and radial dispersion. But,the effect can be eliminated in the analysis of the residence time and radial dispersion when they are normalized by the average residence time and the product of the packing height and packing particle diameter,respectively.In addition,the percolation velocity is shown to be related to the vertical acceleration of the percolating particle when an extra constant vertical force is applied. Increasing the feeding rate of percolating particles decreases the dispersion coefficient.     

DEM simulation of particle percolation in a packed bed

The phenomenon of spontaneous particle percolation under gravity is investigated by means of the discrete element method. Percolation behaviors such as percolation velocity, residence time distribution and radial dispersion are examined under various conditions. It is shown that the vertical velocity of a percolating particle moving down through a packing of larger particles decreases with increasing the restitution coefficient between particles and diameter ratio of the percolating to packing particles. With the increase of the restitution coefficient, the residence time and radial dispersion of the percolating particles increase. The packing height affects the residence time and radial dispersion. But, the effect can be eliminated in the analysis of the residence time and radial dispersion when they are normalized by the average residence time and the product of the packing height and packing particle diameter, respectively. In addition, the percolation velocity is shown to be related to the vertical acceleration of the percolating particle when an extra constant vertical force is applied. Increasing the feeding rate of percolating particles decreases the dispersion coefficient.     

Effect of heat-source geometry on distribution and deposition of particulates in a ventilated chamber

To investigate the effect of near-wall heat-source shape on particulate motion, the particulate distribution and deposition in a ventilated chamber with different heat-source configurations were numerically modeled. Using the discrete random walk model of the Lagrangian method, the trajectories of 3200 mono-disperse particulates ranging from 1 to 10 μm with a density of 1400 kg/m³ were tracked. Airflow pattern, temperature fields, the distribution of particulate concentrations, and deposition patterns are calculated and presented. The results show that the shape of a near-wall heat source has an influence on the airflow as well as the temperature field in the chamber and hence affects the particulate distribution and deposition.     

Numerical simulation of polygonal particles moving in incompressible viscous fluids

A two-dimensional coupled lattice Boltzmann immersed boundary discrete element method is introduced for the simulation of polygonal particles moving in incompressible viscous fluids. A collision model of polygonal particles is used in the discrete element method. Instead of a collision model of circular particles, the collision model used in our method can deal with particles of more complex shape and efficiently simulate the effects of shape on particle–particle and particle–wall interactions. For two particles falling under gravity, because of the edges and corners, different collision patterns for circular and polygonal particles are found in our simulations. The complex vortexes generated near the corners of polygonal particles affect the flow field and lead to a difference in particle motions between circular and polygonal particles. For multiple particles falling under gravity, the polygonal particles easily become stuck owing to their corners and edges, while circular particles slip along contact areas. The present method provides an efficient approach for understanding the effects of particle shape on the dynamics of non-circular particles in fluids.