GPU-enhanced DEM analysis of flow behaviour of irregularly shaped particles in a full-scale twin screw granulator

During twin screw granulation (TSG), small particles, which generally have irregular shapes, agglomerate together to form larger granules with improved properties. However, how particle shape impacts the conveying characteristics during TSG is not explored nor well understood. In this study, a graphic processor units (GPUs) enhanced discrete element method (DEM) is adopted to examine the effect of particle shape on the conveying characteristics in a full scale twin screw granulator for the first time. It is found that TSG with spherical particles has the smallest particle retention number, mean residence time, and power consumption; while for TSG with hexagonal prism (Hexp) shaped particles the largest particle retention number is obtained, and TSG with cubic particles requires the highest power consumption. Furthermore, spherical particles exhibit a flow pattern closer to an ideal plug flow, while cubic particles present a flow pattern approaching a perfect mixing. It is demonstrated that the GPU-enhanced DEM is capable of simulating the complex TSG process in a full-scale twin screw granulator with non-spherical particles.     

Application of a screw conveyor with axial tilt blades on a shearer drum and investigation of conveying performance based on DEM

Screw conveyors are widely employed in industrial fields for conveying bulk materials. The shearer drum which uses the screw conveying principle is responsible for excavation and conveying coal particles onto the chain conveyor. Screw conveyor performance is affected by potential factors, such as the blade axial tilt angle and style, core shaft form and diameter. The effect of blade axial tilt angle on the conveying performance was investigated with the help of DEM. In the case of the screw conveyor, the mass flow rate, and particle axial velocity increased with increasing positive axial tilt angle, and declined with increasing negative axial tilt angle. In the case of the drum, the mass flow rate, particle axial velocity, and loading rate first increased and then decreased with increasing positive axial tilt angle, and decreased with increasing negative axial tilt angle. These results can be considered as a benchmark for screw conveyor and drum structural designs with axial tilt screw blades.     

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.     

Superquadric DEM-SPH coupling method for interaction between non-spherical granular materials and fluids

The research on the coupling method of non-spherical granular materials and fluids aims to predict the particle–fluid interaction in this study. A coupling method based on superquadric elements is developed to describe the interaction between non-spherical solid particles and fluids. The discrete element method (DEM) and the smoothed particle hydrodynamics (SPH) are adopted to simulate granular materials and fluids. The repulsive force model is adopted to calculate the coupling force and then a contact detection method is established for the interaction between the superquadric element and the fluid particle. The contact detection method captures the shape of superquadric element and calculates the distance from the fluid particle to the surface of superquadric element. Simulation cases focusing on the coupling force model, energy transfer, and large-scale calculations have been implemented to verify the validity of the proposed coupling method. The coupling force model accurately represents the water entry process of a spherical solid particle, and reasonably reflects the difference of solid particles with different shapes. In the water entry process of multiple solid particles, the total energy of the water entry process of multiple solid particles tends to be stable. The collapse process of the partially submerged granular column is simulated and analyzed under different parameters. Therefore, this coupling method is suitable to simulate fluid–particle systems containing solid particles with multiple shapes.     

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.     

非球形固体颗粒对弯管内壁的磨损机制

为研究弯管内固体颗粒在液相夹带条件下的运动特性及颗粒对弯管内壁的磨损,采用计算流体动力学与离散元耦合的方法,建立数值模型,考虑固液两相之间的作用,对弯管内的固液两相流动进行数值模拟;通过软件的应用程序编程接口嵌入自编译磨损模型;借助试验结果,验证数值模型的有效性.结果表明,所建立的数值模拟方案可以准确地模拟颗粒在管内的运动特征并能够预测弯管内壁的磨损位置以及磨损程度.弯管内的二次流对颗粒运动有重要影响,弯管外侧壁面中心线附近的磨损较严重,磨损的形式以小角度划擦切削为主.弯管磨损主要与颗粒对壁面的碰撞速度、碰撞角度及碰撞频率有关.运动中的颗粒与壁面发生多次碰撞,碰撞角度逐渐减小.随着颗粒球形度的增大,在相同碰撞条件下引起的磨损量变小,但是会降低颗粒的随流性.颗粒形状影响颗粒在流场中的运动速度以及颗粒与壁面的碰撞.随着颗粒球形度增大,严重磨损区域向弯管进口方向移动,壁面平均磨损量先减小后增大;当输送颗粒的球形度为0.91时,壁面磨损量最小.     

Reliability study of super-ellipsoid DEM in representing the packing structure of blast furnace

In industrial blast furnaces (BFs), the investigations involving the flow behaviors of particles and the resultant burden structure are essential to optimize its operation stability and energy consumption. With the advance of computing capability and mathematical model, the discrete element method (DEM) specialized in characterizing particle behavior has manifested its power in the investigation of BFs. In the framework of DEM, many particle models have been developed, but which model is more suitable for simulating the particle behaviors of BFs remains a question because real particles in BFs have large shape and size dispersity. Among these particle models, the super-ellipsoid model possesses the ability to change shape flexibly. Therefore, the focus of this study is to investigate whether the super-ellipsoid model can meet the requirement of authenticity and accuracy in simulating the behaviors of particles with large shape and size dispersity. To answer this question, a simplified BF charging system composed of a hopper and a storage bin is established. The charging process and the final packing structure are analyzed and compared between experiments and simulations with different shape indexes. The results show that super-ellipsoid particles have prominent advantages over spherical particles in terms of representing the real BF particles, and it can more reasonably reproduce the flow behaviors and packing structure of experimental particles. The computation cost of super-ellipsoid particles is also acceptable for engineering applications. Finally, the micro-scale characteristics of packing structure is analyzed and the single-ring charging process in industry-scale BF using super-ellipsoid particles is conducted.     

CFD-DEM simulation of the hole cleaning process in a deviated well drilling: The effects of particle shape

We investigate the effect of particle shape on the transportation mechanism in well-drilling using a three-dimensional model that couples computational fluid dynamics (CFD) with the discrete element method (DEM). This numerical method allows us to incorporate the fluid–particle interactions (drag force, contact force, Saffman lift force, Magnus lift force, buoyancy force) using momentum exchange and the non-Newtonian behavior of the fluid. The interactions of particle−particle, particle−wall, and particle−drill pipe are taken into account with the Hertz–Mindlin model. We compare the transport of spheres with non-spherical particles (non-smooth sphere, disc, and cubic) constructed via the multi-sphere method for a range of fluid inlet velocities and drill pipe inclination angles. The simulations are carried out for laboratory-scale drilling configurations. Our results demonstrate good agreement with published experimental data. We evaluate the fluid–particle flow patterns, the particle velocities, and the particle concentration profiles. The results reveal that particle sphericity plays a major role in the fluid–solid interaction. The traditional assumption of an ideal spherical particle may cause inaccurate results.     

An extended unresolved CFD-DEM coupling method for simulation of fluid and non-spherical particles

This study develops an extended unresolved CFD-DEM coupling method for simulation of the fluid–solid flow with non-spherical particles. The limitation of fluid grid size is discussed, by simulating the settling of a cylinder in a Newtonian fluid based on the resolved and unresolved CFD-DEM coupling method. Then, the calculation of porosity and the fluid–particle relative velocity based on the particle shape enlargement method for simulation of non-spherical particles is proposed. The availability of the particle shape enlargement method for the simulation of non-spherical particles with different sphericity is discussed in this work, by comparing it with the results from the equivalent diameter enlargement method. The limitation of the equivalent diameter enlargement method for non-spherical particles is revealed from the simulation results. Several typical cases are employed to elaborate and verify the extended unresolved CFD-DEM method based on particle shape enlargement method, by presenting a good consistency with the experimental results. It proves that the extended unresolved CFD-DEM method is suitable for different CFD grid size ratios, and consolidates that it is a universal calculation method for CFD-DEM coupling simulation.     

Multi-level DEM study on silo discharge behaviors of non-spherical particles

The silo discharge of non-spherical particles has been widely practiced in engineering processes, yet the understanding of multi-level mechanisms during solid transportation is still lacking. In this study, a high-fidelity super-ellipsoid Discrete Element Method (DEM) model is established to investigate the discharge behaviors of non-spherical particles with different size distributions. After the comprehensive model validations, we investigated the effects of particle shape (aspect ratio and particle sharpness) on the particle level discharge behaviors. The discharge rates of the ellipsoid particles used in the current work are larger than the spherical particles due to the larger solid fraction. The discharge rates of the cuboid-like particles are determined by the combined effect of the solid fraction and the contact force. Parcel level data show that the translational movements of the ellipsoid particles are more ordered, which is supported by the global level data. Strong correlations exist between the particle level and parcel level data, especially the ellipsoid particles and the large particles in the polydispersed cases.     

Modelling of gas–solid turbulent channel flow with non-spherical particles with large Stokes numbers

This paper describes a complete framework to predict the behaviour of interacting non-spherical particles with large Stokes numbers in a turbulent flow. A summary of the rigid body dynamics of particles and particle collisions is presented in the framework of Quaternions. A particle-rough wall interaction model to describe the collisions between non-spherical particles and a rough wall is put forward as well. The framework is coupled with a DNS-LES approach to simulate the behaviour of horizontal turbulent channel flow with 5 differently shaped particles: a sphere, two types of ellipsoids, a disc, and a fibre. The drag and lift forces and the torque on the particles are computed from correlations which are derived using true DNS.The simulation results show that non-spherical particles tend to locally maximise the drag force, by aligning their longest axis perpendicular to the local flow direction. This phenomenon is further explained by performing resolved direct numerical simulations of an ellipsoid in a flow. These simulations show that the high pressure region on the acute sides of a non-spherical particle result in a torque if an axis of the non-spherical particle is not aligned with the flow. This torque is only zero if the axis of the particle is perpendicular to the local direction of the flow. Moreover, the particle is most stable when the longest axis is aligned perpendicular to the flow.The alignment of the longest axis of a non-spherical particle perpendicular to the local flow leads to non-spherical particles having a larger average velocity compared to spherical particles with the same equivalent diameter. It is also shown that disc-shaped particles flow in a more steady trajectory compared to elongated particles, such as elongated ellipsoids and fibres. This is related to the magnitude of the pressure gradient on the acute side of the non-spherical particles. Finally, it is shown that the effect of wall roughness affects non-spherical particles differently than spherical particles. Particularly, a collision of a non-spherical particle with a rough wall induces a significant amount of rotational energy, whereas a corresponding collision with a spherical particle results in mostly a change in translational 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.     

Effect of wall rougheners on cross-sectional flow characteristics for non-spherical particles in a horizontal rotating cylinder

Discrete-element-method （DEM） simulations have been performed to investigate the cross-sectional flow of non-spherical particles in horizontal rotating cylinders with and without wall rougheners. The non-spherical particles were modeled using the three-dimensional super-quadric equation. The influence of wall rougheners on flow behavior of grains was studied for increasing particle blockiness. Moreover, for approximately cubic particles （squareness parameters [555]）, the rotational speed, gravitational acceleration and particle size were altered to investigate the effect of wall rougheners under a range of operating conditions. For spherical and near-spherical particles （approximately up to the squareness parameters [344]）, wall rougheners are necessary to prevent slippage of the bed against the cylinder wall. For highly cubic particle geometries （squareness parameters larger than [3441）, wall rougheners resulted in a counter-intuitive decrease in the angle of repose of the bed. In addition, wall rougheners employed in this study were demonstrated to have a higher impact on bed dynamics at higher rotational speeds and lower gravitational accelerations. Nevertheless, using wall rougheners had a comparatively small influence on particle-flow characteristics for a bed composed of finer grains.     

Simulation of proppant transport at intersection of hydraulic fracture and natural fracture of wellbores using CFD-DEM

Proppants transport is an advanced technique to improve the hydraulic fracture phenomenon, in order to promote the versatility of gas/oil reservoirs. A numerical simulation of proppants transport at both hydraulic fracture (HF) and natural fracture (NF) intersection is performed to provide a better understanding of key factors which cause, or contribute to proppants transport in HF–NF intersection. Computational fluid dynamics (CFD) in association with discrete element method (DEM) is used to model the complex interactions between proppant particles, host fluid medium and fractured walls. The effect of non-spherical geometry of particles is considered in this model, using the multi-sphere method. All interaction forces between fluid flow and particles are considered in the computational model. Moreover, the interactions of particle–particle and particle–wall are taken into account via Hertz–Mindlin model. The results of the CFD-DEM simulations are compared to the experimental data. It is found that the CFD-DEM simulation is capable of predicting proppant transport and deposition quality at intersections which are in agreement with experimental data. The results indicate that the HF–NF intersection type, fluid velocity and NF aperture affect the quality of blockage occurrence, presenting a new index, called the blockage coefficient which indicates the severity of the blockage.     

粗粒土离散元非球趋真颗粒模型

颗粒形状对粗粒土的物理力学特性有着显著的影响。离散元法广泛应用于粗粒土宏观物理力学特性的细观机理研究。为了考虑颗粒形状的影响,亟待发展计算高效的离散元非球趋真颗粒模型。本文基于X射线CT扫描技术并结合数字图像处理技术,对光滑和棱角性两类典型粗粒土（鹅卵石与碎石）进行三维重构,并提出了两类趋真颗粒模型,分别采用扩展超椭球模型和球多面体模型进行趋真逼近;开展了两类颗粒试样的3D打印和单轴压缩试验,分析了配位数和局部孔隙率分布等细观特性;基于离散元开源程序SudoDEM开展了两类试样的离散元模拟,并将模拟细观分析结果与物理试验进行了对比。结果表明,提出的两类趋真颗粒模型能够较好地对粗粒土颗粒进行离散元建模。     

基于水平集-离散元方法的球谐函数颗粒材料缓冲性能分析

在自然环境与工业领域中,颗粒材料是一种常见的缓冲材料,其中大量形态各异的非球形颗粒表现出复杂的力学特性并应用于不同工程领域。本文采用球谐函数构造不同球面度和表面凹凸特性的非规则颗粒,通过水平集方法计算球谐函数颗粒间的接触点和碰撞力,并对冲击过程中球形和凹形颗粒的缓冲性能进行离散元分析。数值结果表明,颗粒床厚度、冲击速度和颗粒形状显著影响球谐函数颗粒材料的缓冲性能。颗粒床底部的冲击力峰值随着颗粒床厚度和表面凹凸性的增加而降低,同时冲击力峰值随着冲击速度和颗粒球面度的增加而增加。与球形颗粒相比,球谐函数颗粒具有凹凸表面和多接触点特性,这有利于冲击荷载向四周扩展并提高凹形颗粒的缓冲效果。     

Numerical simulation of the accumulation of heavy particles in a circular bounded vortex flow

In present work, an Eulerian–Lagrangian CFD model based on the discrete element method (DEM) and immersed boundary method (IBM) has been developed, validated and used to investigate the accumulation of heavy particles in a circular bounded viscous vortex flow. The inter-particle and particle-wall collisions are resolved by a hard-sphere model. Effects of one-way and two-way coupling, Reynolds number, and particle diameter are systematically explored. Results show that, in case of one-way coupling, the majority of particles will spiral into an accumulation point located near the stagnation point of the flow field. The accumulation point represents a stable equilibrium point as the drag created by the flow field balances the destabilizing centrifugal force on the particle. However, in case of two-way coupling, there does not exist a stable accumulation point due to the strong interaction between the particles and fluid dynamics. Instead most particles are expelled from the circular domain and accumulate on the confining wall. The percentage of accumulated particles on the wall increases with increasing Reynolds number and particle diameter. Moreover, influence of three well-known drag models is also studied and they give consistent results on the particle accumulation behavior, although small quantitative differences can still be discerned.     

DISCRETE AND CONTINUUM MODELLING OF GRANULAR FLOW

This paper analyses three popular methods simulating granular flow at different time and length scales： discrete element method （DEM）, averaging method and viscous, elastic-plastic continuum model. The theoretical models of these methods and their applications to hopper flows are discussed. It is shown that DEM is an effective method to study the fundamentals of granular flow at a particle or microscopic scale. By use of the continuum approach, granular flow can also be described at a continuum or macroscopic scale. Macroscopic quantities such as velocity and stress can be obtained by use of such computational method as FEM. However, this approach depends on the constitutive relationship of materials and ignores the effect of microscopic structure of granular flow. The combined approach of DEM and averaging method can overcome this problem. The approach takes into account the discrete nature of granular materials and does not require any global assumption and thus allows a better understanding of the fundamental mechanisms of granular flow. However, it is difficult to adapt this approach to process modelling because of the limited number of particles which can be handled with the present computational capacity, and the difficulty in handling non-spherical particles. Further work is needed to develoo an aoorooriate aooroach to overcome these problems.     

离散颗粒流动堆积行为离散元模拟及实验研究

工程应用中存在许多颗粒流动堆积问题.首先设计了一系列测量方法,通过大量的实验和统计分析,得到了颗粒的多种物理参数.并以工程中高炉炉顶称量料罐为背景,采用离散元方法模拟不同物理条件下离散颗粒的流动堆积行为,得出料罐内颗粒系统中颗粒之间力的分布不均匀,而且强力链分布主要与料罐的左下壁方向平行.同时,设计并制作了具有多参数调节的离散颗粒料罐实验模型,进行了相应的物理实验,实测结果与数值模拟吻合良好.