Simulation of particle flow in a bell-less type charging system of a blast furnace using the discrete element method

A three-dimensional model was established by the discrete element method （DEM） to analyze the flow and segregation of particles in a charging process in detail. The simulation results of the burden falling trajectory obtained by the model were compared with the industrial charging measurements to validate the applicability of the model. The flow behavior of particles from the weighing hopper to the top layer of a blast furnace and the heaping behavior were analyzed using this model. A radial segregation index （RSI） was used to evaluate the extent of the size segregation in the charging process. In addition, the influence of the chute inclination angle on the size segregation and burden profile during the charging process was investigated.     

Experimental study on filtration performance of the moving bed granular filter with axial flow

The filtration performance of the moving bed granular filter with axial flow (MBGF-AF) is investigated through a large cold experiment. The effect of different operation parameters on the filtration performance (collection efficiency, pressure drop) of the axial-flow moving bed filter is investigated in combination with the dust deposition effect and the mechanism of trapping dust by the capturing particles. The results show that the collection efficiency of MBGF-AF is enhanced by decreasing the superficial gas velocity, increasing the inlet dust concentration properly, or decreasing the moving velocity of the capturing particles. A model covering the above operation parameters is established to calculate the collection efficiency of the moving bed granular filter. It is used in a wide range of operating parameters for the MBGFs.     

Interaction of a shock wave with a loose dusty bulk layer

The interaction of a planar shock wave with a loose dusty bulk layer has been investigated both experimentally and numerically. Experiments were conducted in a shock tube. The incident shock wave velocity and particle diameters were measured with the use of pressure transducers and a Malvern particle sizer, respectively. The flow fields, induced by shock waves, of both gas and granular phase were visualized by means of shadowgraphs and pulsed X-ray radiography with trace particles added. In addition, a two-phase model for granular flow presented by Gidaspow is introduced and is extended to describe such a complex phenomenon. Based on the kinetic theory, such a two-phase model has the advantage of being able to clarify many physical concepts, like particulate viscosity, granular conductivity and solid pressure, and deduce the correlative constitutive equations of the solid phase. The AUSM scheme was employed for the numerical calculation. The flow field behind the shock wave was displayed numerically and agrees well with our corresponding experimental results.      

Filtration characteristics of a binary multi-layer granular bed filter based on CFD-DEM coupling simulation

The coupled CFD-DEM method with the JKR (Johnson-Kendall-Roberts) model for describing the contact adhesion of dust to filter particles (FPs) is used to simulate the distribution pattern of dust particle deposition in the granular bed filter (GBF) with multi-layer media. The minimum inlet flow velocity must meet the requirement that the contact probability between dust and FPs is in the high contact probability region. The air flow forms vortices on the leeward side of the FPs and changes abruptly at the intersection of different particle size FPs layers. Dust particles form large deposits at the intersection of the first and second layers and the different particle size filter layers. Dual element multilayer GBF can further optimize the bed structure by interlacing filter layers with different particle sizes. Compared with single particle size multi-layer GBF, the bed pressure drop is reduced by 40.24%–50.65% and the dust removal efficiency is increased by 21.93%–55.09%.     

Penetration into a granular bed in the presence of upward gas flows

We present a numerical study on the penetration of spherical projectiles into a granular bed in the presence of upward gas flows. Due to the presence of interstitial fluid, the force chains between particles in the granular bed are weakened significantly, and this distinguishes the penetration behavior from that in the absence of fluid. An interesting phenomenon, namely granular jet, is observed during the penetration, and the mechanism for its formation and growth is attributed to the merging of granular vortices generated by the interaction between the intruder and primary particles. Moreover, both the final penetration depth and the maximum diameter of the crater are found to follow a power-law dependence with the impact velocity, and the maximum height reached by the granular jet tends to increase linearly as the impact velocity increases, agreeing well with the experimental results reported in the literature.     

Experimental and computational studies on flow behavior of gas-solid fluidized bed with disparately sized binary particles

This paper presents experimental and computational studies on the flow behavior of a gas-solid fluidized bed with disparately sized binary particle mixtures. The mixing/segregation behavior and segregation efficiency of the small and large particles are investigated experimentally.Particle composition and operating conditions that influence the fluidization behavior of mixing/segregation are examined. Based on the granular kinetics theory, a multi-fluid CFD model has been developed and verified against the experimental results. The simulation results are in reasonable agreement with experimental data. The results showed that the smaller particles are found near the bed surface while the larger particles tend to settle down to the bed bottom in turbulent fluidized bed. However, complete segregation of the binary particles does not occur in the gas velocity range of 0.695--0.904 m/s. Segregation efficiency increases with increasing gas velocity and mean residence time of the binary particles, but decreases with increasing the small particle concentration. The calculated results also show that the small particles move downward in the wall region and upward in the core. Due to the effect of large particles on the movement of small particles, the small particles present a more turbulent velocity profile in the dense phase than that in the dilute phase.     

Experimental and computational studies on flow behavior of gas–solid fluidized bed with disparately sized binary particles

This paper presents experimental and computational studies on the flow behavior of a gas-solid fluidized bed with disparately sized binary particle mixtures. The mixing/segregation behavior and segregation efficiency of the small and large particles are investigated experimentally. Particle composition and operating conditions that influence the fluidization behavior of mixing/segregation are examined. Based on the granular kinetics theory, a multi-fluid CFD model has been developed and verified against the experimental results. The simulation results are in reasonable agreement with experimental data. The results showed that the smaller particles are found near the bed surface while the larger particles tend to settle down to the bed bottom in turbulent fluidized bed. However, complete segregation of the binary particles does not occur in the gas velocity range of 0.695-0.904 m/s. Segregation efficiency increases with increasing gas velocity and mean residence time of the binary particles, but decreases with increasing the small particle concentration. The calculated results also show that the small particles move downward in the wall region and upward in the core. Due to the effect of large particles on the movement of small particles, the small particles present a more turbulent velocity profile in the dense phase than that in the dilute phase.     

The influence of the drag force due to the interstitial gas on granular flows down a chute

Fully-developed steady flow of granular material down an inclined chute has been a subject of much research interest, but the effect of the interstitial gas has usually been ignored. In this paper, new expressions for the drag force and energy dissipation caused by the interstitial gas (ignoring the turbulent fluctuations of the gas phase) are derived and used to modify the governing equations derived from the kinetic theory approach for granular–gas mixture flows, where particles are relatively massive so that velocity fluctuations are caused by collisions rather than the gas flow. This new model is applied to fully-developed, steady mixture flows down an inclined chute and the results are compared with other simulations. Our results show that the effect of the interstitial gas plays a significant role in modifying the characteristics of fully developed flow. Although the effect of the interstitial gas is less pronounced for large particles than small ones, the flowfields with large particles are still very different from granular flows which do not incorporate any interactions with the interstitial gas.     

Particle–wall interaction in entrained-flow slagging coal gasifiers: Granular flow simulation and experiments in a cold flow model reactor

Entrained-flow slagging coal gasifiers display large conversion efficiencies and small levels of unconverted carbon at the exhaust. Both features are apparently at odds with the fairly small “space-time” of the particle-laden gas feeding, as compared with the time scale of heterogeneous gasification of carbon. This apparent inconsistency can be explained by considering that fuel residence times are longer than the “space-time” due to segregation of fuel particles in the near-wall region of the gasifier. Segregation is promoted by swirl flow, by particle–wall interaction as the wall is covered by a molten layer of slag and by the establishment of a dense-dispersed flow of granular solids in the proximity of the wall.This study presents results of granular flow simulations of the interaction of a dense-dispersed particle flow with the confining wall. Simulations consider that both the particles and the wall may be either “sticky” or “non sticky”, based on the prevailing elastic vs plastic behaviour upon collision. The effect of drag forces exerted on particles by swirled gas flow is simulated in a simplified manner. Particle–particle collisions are modelled with a Hertzian approach that includes torque and cohesion. The extent and time scale of segregation of a lump of particles loaded into a cylindrical vessel are assessed. Results clearly indicate the different structure of the layer of particles establishing at the wall surface in the different interaction regimes.Results of simulations are qualitatively compared with results of an experimental campaign performed in a reactor representing a cold flow model of the entrained-flow gasifier, where solid, molten or semi-molten particles have been simulated by atomized wax as surrogate material. Altogether, the results confirm the importance of the particle–particle and particle–wall micromechanical interactions for a correct prevision of the segregation of fuel particles in entrained-flow slagging gasifiers.     

Mixing and segregation of solid particles in a conical spouted bed: Effect of particle size and density

In this work, the mixing and segregation of binary mixtures of particles with different sizes and densities in a pseudo-2D spouted bed were studied experimentally. A binary mixture of solid particles including sand, gypsum, and polyurethane was used. To determine the particles mass fraction, and their mixing and segregation in the bed, an image-processing technique was developed and used. Important hydrodynamic parameters, such as the axial and radial segregation profiles of the solid particles, were measured. The effects of air velocity, particle size, and particle mass fraction were also evaluated. The flow regime in the spouted bed and the time required for reaching the equilibrium state of the solid particles were discussed. The results showed that the segregation of solid particles and the time to equilibrium both decreased when the air velocity increased to much larger than the minimum spouting velocity. The axial segregation increased with the diameter ratio of the particles. Upon completion of the test, coarse particles were concentrated mainly in the spout region, while fine particles were aggregated in the annulus region. Examination of the flow pattern in the spouted bed showed that the particles near the wall had longer flow paths, while those near the spout region had shorter flow paths.     

Discrete element method study of shear-driven granular segregation in a slowly rotating horizontal drum

Segregation and mixing of granular materials are complex processes and are not fully understood. Motivated by industrial need, we performed a simulation using the discrete element method to study size segregation of a binary mixture of granular particles in a horizontal rotating drum. Particles of two different sizes were poured into the drum until it was 50% full. Shear-driven segregation was induced by rotating the side-plates of the drum in the opposite direction to that of the cylindrical wall. We found that radial segregation diminished in these systems but did not completely vanish. In an ordinary rotating drum, a radial core of smaller particles is formed in the center of the drum, surrounded by larger revolving particles. In our system, however, the smaller particles were found to migrate toward the side-plates. The shear from anti-spinning side-plates reduces the voidage and increases the bulk density. As such, smaller particles in the mixer tend to move to denser regions. We varied the shear by changing the coefficient of friction on the side-plates to study the influence of shear rate on this migration. We also compared the extent of radial segregation with stationary side-plates and with side-plates moving in different angular directions.     

DEM simulation of particle mixing in a sheared granular flow

Mixing behaviors of particles are simulated in a sheared granular flow using differently colored but otherwise identical glass spheres, with five different bottom wall velocities. By DEM simulation, the solid fractions, velocities, velocity fluctuations and granular temperatures are measured.The mixing layer thicknesses are compared with the calculations from a simple diffusion equation using the data of apparent self-diffusion coefficients obtained from the current simulation measurements. The calculations and simulation results showed good agreements, demonstrating that the mixing process of granular materials occurred through the diffusion mechanism.     

DEM simulation of particle mixing in a sheared granular flow

Mixing behaviors of particles are simulated in a sheared granular flow using differently colored but otherwise identical glass spheres, with five different bottom wall velocities. By DEM simulation, the solid fractions, velocities, velocity fluctuations and granular temperatures are measured. The mixing layer thicknesses are compared with the calculations from a simple diffusion equation using the data of apparent self-diffusion coefficients obtained from the current simulation measurements. The calculations and simulation results showed good agreements, demonstrating that the mixing process of granular materials occurred through the diffusion mechanism.     

An analysis of the chaotic motion of particles of different sizes in a gas fluidized bed

The dynamic behavior of individual particles during the mixing/segregation process of particle mixtures in a gas fluidized bed is analyzed. The analysis is based on the results generated from discrete particle simulation, with the focus on the trajectory of and forces acting on individual particles.Typical particles are selected representing three kinds of particle motion:a flotsam particle which is initially at the bottom part of the bed and finally fluidized at the top part of the bed; a jetsam particle which is initially at the top part of the bed and finally stays in the bottom de-fluidized layer of the bed; and a jetsam particle which is intermittently joining the top fluidized and bottom de-fluidized layers. The results show that the motion of a particle is chaotic at macroscopic or global scale, but can be well explained at a microscopic scale in terms of its interaction forces and contact conditions with other particles, particle-fluid interaction force, and local flow structure. They also highlight the need for establishing a suitable method to link the information generated and modeled at different time and length scales.     

Force and flow characteristics of an intruder immersed in 3D dense granular matter

The motion of a projectile impact onto a granular target results in both the resistance force exerted on the projectile and rheology of granular media. A horizontal arrangement of cylinder quasistatically and dynamically intruding into granular media under different velocities and angles is simulated using discrete element method. Three distinguished drag force regimes are exhibited, including hydrostatic-like force independent of velocity, viscous force related to velocity, and inertial drag force proportional to the square of velocity. Meanwhile, the influence of penetration angles on drag force is examined for these three regimes, and a force model, which is related to penetration depth and angle, is proposed for quasi-static penetration. Then, flow characteristics of the granular media, such as velocity field, pressure field, packing fraction etc., are traced, and a rheology model of packing fraction and inertial number is established.     

Non-invasive measurements of granular flows by magnetic resonance imaging

Magnetic Resonance Imaging (MRI) was used to non-invasively measure velocity and concentration of granular flows in a partially filled, steadily rotating, long, horizontal cylinder. First, rigid body motion of a cylinder filled with granular material was studied to confirm the validity of this method. Then, the density variation and the depth of the flowing layer, where particles collide and dilate, and the flow velocity profile were obtained as a function of the cylinder rotation rate.     

An analysis of the chaotic motion of particles of different sizes in a gas fluidized bed

The dynamic behavior of individual particles during the mixing/segregation process of particle mixtures in a gas fluidized bed is analyzed. The analysis is based on the results generated from discrete particle simulation, with the focus on the trajectory of and forces acting on individual particles. Typical particles are selected representing three kinds of particle motion： a flotsam particle which is initially at the bottom part of the bed and finally fluidized at the top part of the bed; a jetsam particle which is initially at the top part of the bed and finally stays in the bottom de-fluidized layer of the bed; and a jetsam particle which is intermittently joining the top fluidized and bottom de-fluidized layers. The results show that the motion of a particle is chaotic at macroscopic or global scale, but can be well explained at a microscopic scale in terms of its interaction forces and contact conditions with other particles, particle-fluid interaction force, and local flow structure. They also highlight the need for establishing a suitable method to link the information generated and modeled at different time and length scales.     

Numerical simulation of fast granular flow facing obstacles on steep terrains

The interaction between fast shallow granular flow and obstacles on steep terrain is an important aspect of granular mechanics and defending against geological hazards. In this study, we used a depth-averaged model for granular flow facing obstacles on steep terrains in a bed-fitted coordinate system where the obstacle system is treated as a local bed deviation term. A second-order Riemann-free scheme is extended to compute the depth-averaged model with a wetting–drying technique, which is verified by several granular flow cases, such as aluminum bar collapse and granular flow runout on a steep slope. Numerical simulations were performed for the case of granular flow facing a (i) single hemispherical obstacle and (ii) system of three hemispherical obstacles to produce a dynamical process and deposit profile, and show good agreement with experimental results. Granular flow facing a single obstacle on a concave plane produces a detached shock wave that moves upstream and a tailing rapid transition zone that moves down, which will merge to form a new shock for deposition. Granular flows facing a three-hemisphere obstacle system produce a tailing rapid transition zone that moves downstream and a downstream wavy shock that results from the interaction of three bow shocks in front of each obstacle. The downstream wavy shock moves upstream and merges with the upstream transition zone to form a new curved shock, which later relaxes to a deposit owing to bed friction. These findings provide some supplemental understandings of flow structures of fast granular flow facing obstacles.     

稠密气固两相流各向异性颗粒相矩方法

基于气体分子动力学和颗粒动理学方法,考虑颗粒速度脉动各向异性,建立颗粒相二阶矩模型.应用初等输运理论,对三阶关联项进行模化和封闭.考虑颗粒与壁面之间的能量传递和交换,建立颗粒相边界条件模型.采用Koch等计算方法模拟气固脉动速度关联矩.考虑气体-颗粒间相互作用,建立稠密气体-颗粒流动模型.数值模拟提升管内气固两相流动特性,模拟结果表明提升管内颗粒相湍流脉动具有明显的各向异性.预测颗粒速度、浓度和颗粒脉动速度二阶矩与Tartan等实测结果相吻合.模拟结果表明轴向颗粒速度脉动强度约为平均颗粒相脉动强度的1.5倍,轴向颗粒脉动能大约是径向颗粒脉动能3.0倍.     

煤仓内煤散料流动状态与力学行为影响因素

针对煤仓内煤散料流动问题及其力学行为,采用三维颗粒流模拟程序PFC3D建立了某型号煤仓与某种煤散料的离散元模型,简述了其力学模型与求解步骤,模拟分析了煤仓内煤散料卸料流动状态。通过分析水平向侧压力、颗粒速度场和接触力场,重点讨论了煤仓下部锥体内壁面摩擦系数、锥仓倾角和卸料口径等对煤散料颗粒流动状态和力学行为的影响。结果显示,深仓卸料流动为整体流动与中心流动混合状态,煤仓内壁摩擦系数、锥体倾角和卸料孔开口半径均对煤散料流动和水平侧压力有较大影响。