Mathematical Modelling and Design of Helical Coil Heat Exchanger for Production of Hot Air for Fluidized Bed Dryer

In global industrialization, efforts have been made to increase the rate of heat transfer in heat exchanger, minimizing the size of heat exchanger to reduce cost as well as increasing the effectiveness. Helical coil heat exchanger (HCHE) has been proven to be effective in improving heat transfer due to its large surface area. In this study, HCHE was designed to provide hot air needed for fluidized bed drying processes. The HCHE design model was fabricated and evaluated to study the efficiency of the hot air output for a laboratory fluidized bed dryer. The mathematical model for estimation of the final (output) temperature of air, Taf, passing through the HCHE was developed and validated experimentally. The drying of bitter kola particulates was carried out with a drying temperature of 50C 3C and a bed height-to-bed diameter ratio (H/D) of 1.5. The time taken to dry bitter kola particulates to 0.4% moisture content was 1 hour 45 minutes. Hence, HCHE is recommended for use in the production of hot for laboratory-scale fluidized bed dryers.

Heat and Mass Transfer for a Nanofluid Flow in Fluidized Bed Dryer in Presence of Induced Magnetic Field

This research entails the study of heat and mass transfer of nanofluid flow in a fluidized bed dryer used in tea drying processes in presence of induced magnetic field. A mathematical model describing the fluid flow in a Fluidized bed dryer was developed using the nonlinear partial differential equations. Due to their non-linearity, the equations were solved numerically by use of the finite difference method. The effects of physical flow parameters on velocity, temperature, concentration and magnetic induction profiles were studied and results were presented graphically. From the mathematical analysis, it was deduced that addition of silver nanoparticles into the fluid flow enhanced velocity and temperature profiles. This led to improved heat transfer in the fluidized bed dryer, hence amplifying the tea drying process. Furthermore, it was noted that induced magnetic field tends to decrease the fluid velocity, which results in uniform distribution of heat leading to efficient heat transfer between the tea particles and the fluid, thus improving the drying process. The research findings provide information to industries on ways to optimize thermal performance of fluidized bed dryers.

Analysis of Gas-Solid Flow Characteristics in a Spouted Fluidized Bed Dryer by Means of Computational Particle Fluid Dynamics

In order to grasp the particle flow characteristics and energy consumption of industrial fluidized spouted beds,we conduct numerical simulations on the basis of a Computational Particle Fluid Dynamics(CPFD)approach.In particular,the traction model of Wen-Yu-Ergun is used and different inlet conditions are considered.Using a low-speed fluidizing gas,the flow state of the particles is better and the amount of particles accumulated at the bottom of the bed wall becomes smaller.For the same air intake,the energy loss of a circular nozzle is larger than that of a square nozzle.

Fluidized-Bed Drying of Biological Materials:Two Case Studies

Drying is the last operation for processing most biomaterials. Due to the heat and moisture sensitivity of biomaterials, selections of drying methods and operating parameters are very important to keep the viability of these materials. In the present study, experiments were carried out in fluidized bed drying of photosynthetic microorganism liquid and mixed culture animal food. Results show that most activities can be kept in dried products. Appropriate operation parameters were determined.

Investigation and analysis of a fluidized bed dryer by process tomography sensor

In the pharmaceutical industry,fluidized beds are typically used for pellets drying,coating and granulation.The gas-solids flow characteristic in the process plays an important role to control the heat and mass transfer as well as the end-point product quality.Therefore,it is necessary to investigate the flow characteristics based on advanced measurement technologies.In this research,electrical capacitance tomography(ECT)sensor with eight electrodes was used to investigate the pharmaceutical fluidized bed drying process with different operation conditions.Key process parameters including solids concentration,particle moisture and capacitance signals in the process are given and analysed based on the ECT sensor.In addition,the fluidized bed process with Wurster tube is also investigated based on this ECT sensor.The effect of Wurster tube on the hydrodynamic behaviour and the dominant frequency spectrum distribution in the chamber were analysed based on fast Fourier transform.Test results reveal that process moisture change can be addressed from the raw capacitance of adjacent electrode pair combined with calibration model.Experimental result also indicates that ECT technology can provide useful information for process monitor in a fluidized bed dryer.

VALIDATION OF A MODEL OF FLUID BED DRYING AND COOLING OF WHITE SUGAR BY INDUSTRIAL SCALE EXPERIMENTS

Fluid bed drying of white sugar is lately becoming an industry standard in Europe. This paper presents the results of measurements of the performance of an industrial scale fluid bed dryer/cooler for sugar having 500 t/d capacity. The results are compared with the cor responding results of a computer simulation model. The influence of several model parameters is discussed. Satisfactory agreement of the simulated and measured results has been found.

Experimental Study of Drying Process of COLZA Seeds in Fluidized Bed Dryer by Statistical Methods

In this study the effect of initial parameters such as inlet gas temperature, initial particles temperature and gas velocity on temperature changes of solid particles and outlet gas temperature in a fluidized bed dryer was studied. For testing, an experimental setup was established. With combination of air and Colza seeds belonging to D groups of the Geldart classification (Geldart, 1986) fluidization regime was carried out. With five test series with maintaining the inlet gas temperature, solid particle temperature and outlet gas temperature during time were carefully measured. To analyze these data by using regression analysis to predict solid particle and outlet gas temperature, 2 correlations on initial pa-rameters were presented. The result has shown that temperature gradients in the beginning of fluidization, is very high and therefore the exponential functions in the regression model is used to predict the temperature changes.

Mechanical behaviours of bedded sandstone under hydromechanical coupling

The combination of the dipping effect and hydromechanical(H-M)coupling effect can easily lead to water inrush disasters in water-rich roadways with different dip angles in coal mines.Therefore,H-M coupling tests of bedded sandstones under identical osmotic pressure and various confining pressures were conducted.Then,the evolution curves of stress-strain,permeability and damage,macro-and mesoscopic failure characteristics were obtained.Subsequently,the mechanical behaviour was characterized,and finally the failure mechanism was revealed.The results showed that:(1)The failure of the sandstone with the bedding angle of 45°or 60°was the structure-dominant type,while that with the bedding angle of 0°,30°or 90°was the force-dominant type.(2)When the bedding angle was in the range of(0°,30°)or(45°,90°),the confining pressure played a dominant role in influencing the peak strength.However,withinβ∈(30°,45°),the bedding effect played a dominant role in the peak strength.(3)With the increase in bedding angle,the cohesion increased first,then decreased and finally increased,while the internal friction angle was the opposite.(4)When the bedding angle was 0°or 30°,the“water wedging”effect and the“bedding buckling”effect would lead to the forking or converging shear failure.When the bedding angle was 45°or 60°,the sliding friction effect would lead to the shear slipping failure.When the bedding angle was 90°,the combination of the“bedding buckling”effect and shear effect would lead to the mixed tension-shear failure.The above conclusions obtained are helpful for the prevention of water inrush disasters in water-rich roadways with different dips in coal mines.

Hydrodynamic analysis of carbon nanotube clusters in distributor-less conical fluidized beds with step-by-step scaling

As a high-performance material with great application potential,the application of carbon nanotubes has been limited by their production volume.A distributor-less conical fluidized bed is the main equipment used in the industrial production of carbon nanotubes.To improve the production volume and product quality of carbon nanotubes,the study of fluidized-bed-diameter scaling is important.Three different diameters of distributor-less conical fluidized beds were established,and then the particle behavior and bubble characteristics of carbon nanotube clusters at these bed diameters were investigated.Time-series and wavelet analysis methods were used to analyze the pressure-fluctuation signals inside the fluidized beds.Results showed that the distributor-less design caused the airflow to break through the middle of the bed,which did not change with the change in bed diameter.The powder-bridging phenomenon of carbon nanotube clusters in a 100-mm-diameter fluidized bed was related to the special microstructure of carbon nanotube clusters.The frequency of pressure fluctuations in the bed decreased nonlinearly with increasing bed diameter.This study can guide the design and scale-up of distributor-less conical fluidized beds,especially for the scale-up of carbon nanotube production equipment,which can contribute to the improvement of carbon nanotubes’capacity and quality in industrial production.

Hole cleaning evaluation and installation spacing optimization of cuttings bed remover in extended-reach drilling

In extended-reach or long-horizontal drilling,cuttings usually deposit at the bottom of the annulus.Once cuttings accumulate to a certain thickness,complex problems such as excessive torque and drag,tubing buckling,and pipe stuck probably occur,which results in a lot of non-productive time and remedial operations.Cuttings bed remover can efficiently destroy deposited cuttings in time through hydraulic and mechanical stirring effects.This paper aims to build a method for hole cleaning evaluation and installation spacing optimization of cuttings bed remover to improve the wellbore cleaning effect.Firstly,a Computational Fluid Dynamics approach with Eulerian—Eulerian multiphase model was utilized to investigate the mechanism of cuttings transportation,and a new type of cuttings bed remover was designed.Next,an evaluation method of hole cleaning effect of remover was established.After that,the effects of several drilling parameters on hole cleaning including flow rate of drilling fluid,rotational speed of drillpipe,rate of penetration,wellbore size,rheological property of drilling fluid,and remover eccentricity on the performance of cuttings bed remover were investigated.The results demonstrate that the new type of remover with streamline blade performs better than conventional removers.The efficiency of hole cleaning is greatly improved by increasing the rotational speed of drillpipe,flow rate of drilling fluid,remover eccentricity,and 6 rpm Fann dial reading for drilling fluid.While higher rate of penetration and large wellbore size result in worse hole cleaning.These findings can serve as an important guide for the structure optimization design of cuttings bed remover and installation spacing of removers.

Influence of High-Density Bedding Plane Characteristics on Hydraulic Fracture Propagation in Shale Oil Reservoir

The existence of high-density bedding planes is a typical characteristic of shale oil reservoirs.Understanding the behavior of hydraulic fracturing in high-density laminated rocks is significant for promoting shale oil production.In this study,a hydraulic fracturing model considering tensile failure and frictional slip of the bedding planes is established within the framework of the unified pipe-interface element method(UP-IEM).The model developed for simulating the interaction between the hydraulic fracture and the bedding plane is validated by comparison with experimental results.The hydraulic fracturing patterns in sealed and unsealed bedding planes are compared.Additionally,the effects of differential stress,bedding plane permeability,spacing,and the friction coefficient of the bedding plane are investigated.The results showed that a single main fracture crossing the bedding planes is more likely to form in sealed bedding planes under high differential stress.The decrease in bedding plane permeability and the increase in the friction coefficient also promote the fracture propagating perpendicular to the bedding planes.Shale with high-density bedding planes has a poorer fracturing effect than that with low-density bedding planes,as the hydraulic fracture is prone to initiate and propagate along the bedding planes.Moreover,higher injection pressure is needed to maintain fracture propagation along the bedding.An increase in bedding density will lead to a smaller fracturing area.Fracturing fluid seepage into the bedding planes slows shale fracturing.It is recommended that increasing the injection flow rate,selecting alternative fracturing fluids,and employing multi-well/multi-cluster fracturing may be efficient methods to improve energy production in shale oil reservoirs.

Stability of bedded rock slopes subjected to hydro-fluctuation and associated strength deterioration

Reservoir-induced earthquakes(RIEs)occur frequently in the Three Gorges Reservoir Area(TGRA)and the rock mass strength of the hydro-fluctuation belt(HFB)deteriorates severely due to the reservoirinduced seismic loads.Three models of typical bedded rock slopes(BRSs),i.e.gently(GIS),moderately(MIS),and steeply(SIS)inclined slopes,were proposed according to field investigations.The dynamic response mechanism and stability of the BRSs,affected by the rock mass deterioration of the HFB,were investigated by the shaking table test and the universal distinct element code(UDEC)simulation.Specifically,the amplification coefficient of the peak ground acceleration(PGA)of the slope was gradually attenuated under multiple seismic loads,and the acceleration response showed obvious“surface effect”and“elevation effect”in the horizontal and vertical directions,respectively.The“S-type”cubic function and“steep-rise type”exponential function were used to characterize the cumulative damage evolution of the slope caused by microseismic waves(low seismic waves)and high seismic waves,respectively.According to the dynamic responses of the acceleration,cumulative displacement,rock pressure,pore water pressure,damping ratio,natural frequency,stability coefficient,and sliding velocity of the slope,the typical evolution processes of the dynamic cumulative damage and instability failure of the slope were generalized,and the numerical and experimental results were compared.Considering the dynamic effects of the slope height(SH),slope angle(SA),bedding plane thickness(BPT),dip angle of the bedding plane(DABP),dynamic load amplitude(DLA),dynamic load frequency(DLF),height of water level of the hydro-fluctuation belt(HWLHFB),degradation range of the hydro-fluctuation belt(DRHFB),and degradation shape of the hydro-fluctuation belt(DSHFB),the sensitivity of factors influencing the slope dynamic stability using the orthogonal analysis method(OAM)was DLA>DRHFB>SA>SH>DLF>HWLHFB>DSHFB>DABP>BPT.

Mutual impact of true triaxial stress, borehole orientation and bedding inclination on laboratory hydraulic fracturing of Lushan shale

Unconventional resources like shale gas has been the focus of intense research and development for two decades. Apart from intrinsic geologic factors that control the gas shale productivity (e.g. organic matter content, bedding planes, natural fractures, porosity and stress regime among others), external factors like wellbore orientation and stimulation design play a role. In this study, we present a series of true triaxial hydraulic fracturing experiments conducted on Lushan shale to investigate the interplay of internal factors (bedding, natural fractures and in situ stress) and external factors (wellbore orientation) on the growth process of fracture networks in cubic specimens of 200 mm in length. We observe relatively low breakdown pressure and fracture propagation pressure as the wellbore orientation and/or the maximum in situ stress is subparallel to the shale bedding plane. The wellbore orientation has a more prominent effect on the breakdown pressure, but its effect is tapered with increasing angle of bedding inclination. The shale breakdown is followed by an abrupt response in sample displacement, which reflects the stimulated fracture volume. Based on fluid tracer analysis, the morphology of hydraulic fractures (HF) is divided into four categories. Among the categories, activation of bedding planes (bedding failure, BF) and natural fractures (NF) significantly increase bifurcation and fractured areas. Under the same stress regime, a horizontal wellbore is more favorable to enhance the complexity of hydraulic fracture networks. This is attributed to the relatively large surface area in contact with the bedding plane for the horizontal borehole compared to the case with a vertical wellbore. These findings provide important references for hydraulic fracturing design in shale reservoirs.

Influence of heat treatment on microstructure,mechanical and corrosion behavior of WE43 alloy fabricated by laser-beam powder bed fusion

Magnesium(Mg)alloys are considered to be a new generation of revolutionary medical metals.Laser-beam powder bed fusion(PBF-LB)is suitable for fabricating metal implants withpersonalized and complicated structures.However,the as-built part usually exhibits undesirable microstructure and unsatisfactory performance.In this work,WE43 parts were firstly fabricated by PBF-LB and then subjected to heat treatment.Although a high densification rate of 99.91%was achieved using suitable processes,the as-built parts exhibited anisotropic and layeredmicrostructure with heterogeneously precipitated Nd-rich intermetallic.After heat treatment,fine and nano-scaled Mg24Y5particles were precipitated.Meanwhile,theα-Mg grainsunderwent recrystallization and turned coarsened slightly,which effectively weakened thetexture intensity and reduced the anisotropy.As a consequence,the yield strength and ultimate tensile strength were significantly improved to(250.2±3.5)MPa and(312±3.7)MPa,respectively,while the elongation was still maintained at a high level of 15.2%.Furthermore,the homogenized microstructure reduced the tendency of localized corrosion and favoredthe development of uniform passivation film.Thus,the degradation rate of WE43 parts was decreased by an order of magnitude.Besides,in-vitro cell experiments proved their favorable biocompatibility.

Influence of layer thickness on formation quality,microstructure,mechanical properties,and corrosion resistance of WE43 magnesium alloy fabricated by laser powder bed fusion

Laser powder bed fusion(L-PBF)of Mg alloys has provided tremendous opportunities for customized production of aeronautical and medical parts.Layer thickness(LT)is of great significance to the L-PBF process but has not been studied for Mg alloys.In this study,WE43 Mg alloy bulk cubes,porous scaffolds,and thin walls with layer thicknesses of 10,20,30,and 40μm were fabricated.The required laser energy input increased with increasing layer thickness and was different for the bulk cubes and porous scaffolds.Porosity tended to occur at the connection joints in porous scaffolds for LT40 and could be eliminated by reducing the laser energy input.For thin wall parts,a large overhang angle or a small wall thickness resulted in porosity when a large layer thicknesses was used,and the porosity disappeared by reducing the layer thickness or laser energy input.A deeper keyhole penetration was found in all occasions with porosity,explaining the influence of layer thickness,geometrical structure,and laser energy input on the porosity.All the samples achieved a high fusion quality with a relative density of over 99.5%using the optimized laser energy input.The increased layer thickness resulted to more precipitation phases,finer grain sizes and decreased grain texture.With the similar high fusion quality,the tensile strength and elongation of bulk samples were significantly improved from 257 MPa and 1.41%with the 10μm layer to 287 MPa and 15.12%with the 40μm layer,in accordance with the microstructural change.The effect of layer thickness on the compressive properties of porous scaffolds was limited.However,the corrosion rate of bulk samples accelerated with increasing the layer thickness,mainly attributed to the increased number of precipitation phases.

Role of heterogenous microstructure and deformation behavior in achieving superior strength-ductility synergy in zinc fabricated via laser powder bed fusion

Zinc(Zn)is considered a promising biodegradable metal for implant applications due to its appropriate degradability and favorable osteogenesis properties.In this work,laser powder bed fusion(LPBF)additive manufacturing was employed to fabricate pure Zn with a heterogeneous microstructure and exceptional strength-ductility synergy.An optimized processing window of LPBF was established for printing Zn samples with relative densities greater than 99%using a laser power range of 80∼90 W and a scanning speed of 900 mm s−1.The Zn sample printed with a power of 80 W at a speed of 900 mm s−1 exhibited a hierarchical heterogeneous microstructure consisting of millimeter-scale molten pool boundaries,micrometer-scale bimodal grains,and nanometer-scale pre-existing dislocations,due to rapid cooling rates and significant thermal gradients formed in the molten pools.The printed sample exhibited the highest ductility of∼12.1%among all reported LPBF-printed pure Zn to date with appreciable ultimate tensile strength(∼128.7 MPa).Such superior strength-ductility synergy can be attributed to the presence of multiple deformation mechanisms that are primarily governed by heterogeneous deformation-induced hardening resulting from the alternative arrangement of bimodal Zn grains with pre-existing dislocations.Additionally,continuous strain hardening was facilitated through the interactions between deformation twins,grains and dislocations as strain accumulated,further contributing to the superior strength-ductility synergy.These findings provide valuable insights into the deformation behavior and mechanisms underlying exceptional mechanical properties of LPBF-printed Zn and its alloys for implant applications.

Alloy design for laser powder bed fusion additive manufacturing:a critical review

Metal additive manufacturing(AM)has been extensively studied in recent decades.Despite the significant progress achieved in manufacturing complex shapes and structures,challenges such as severe cracking when using existing alloys for laser powder bed fusion(L-PBF)AM have persisted.These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes,overlooking the fast cooling rates,steep temperature gradients and multiple thermal cycles of L-PBF.To address this,there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies.This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF.It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys.The review begins by discussing the features of the L-PBF processes,focusing on rapid solidification and intrinsic heat treatment.Next,the printability of the four main existing alloys(Fe-,Ni-,Al-and Ti-based alloys)is critically assessed,with a comparison of their conventional weldability.It was found that the weldability criteria are not always applicable in estimating printability.Furthermore,the review presents recent advances in alloy development and associated strategies,categorizing them into crack mitigation-oriented,microstructure manipulation-oriented and machine learning-assisted approaches.Lastly,an outlook and suggestions are given to highlight the issues that need to be addressed in future work.

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Laser powder bed fusion(L-PBF) has attracted significant attention in both the industry and academic fields since its inception, providing unprecedented advantages to fabricate complex-shaped metallic components. The printing quality and performance of L-PBF alloys are infuenced by numerous variables consisting of feedstock powders, manufacturing process,and post-treatment. As the starting materials, metallic powders play a critical role in infuencing the fabrication cost, printing consistency, and properties. Given their deterministic roles, the present review aims to retrospect the recent progress on metallic powders for L-PBF including characterization, preparation, and reuse. The powder characterization mainly serves for printing consistency while powder preparation and reuse are introduced to reduce the fabrication costs.Various powder characterization and preparation methods are presented in the beginning by analyzing the measurement principles, advantages, and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed, focusing on steels, nickel-based superalloys, titanium and titanium alloys, and aluminum alloys. The evolution trends of powders and L-PBF parts vary depending on specific alloy systems, which makes the proposal of a unified reuse protocol infeasible. Finally,perspectives are presented to cater to the increased applications of L-PBF technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total costs from the perspective of powders.

Microstructure and thermal properties of dissimilar M300–CuCr1Zr alloys by multi-material laser-based powder bed fusion

Multi-material laser-based powder bed fusion (PBF-LB) allows manufacturing of parts with 3-dimensional gradient and additional functionality in a single step. This research focuses on the combination of thermally-conductive CuCr1Zr with hard M300 tool steel.Two interface configurations of M300 on CuCr1Zr and CuCr1Zr on M300 were investigated. Ultra-fine grains form at the interface due to the low mutual solubility of Cu and steel. The material mixing zone size is dependent on the configurations and tunable in the range of0.1–0.3 mm by introducing a separate set of parameters for the interface layers. Microcracks and pores mainly occur in the transition zone.Regardless of these defects, the thermal diffusivity of bimetallic parts with 50vol% of CuCr1Zr significantly increases by 70%–150%compared to pure M300. The thermal diffusivity of CuCr1Zr and the hardness of M300 steel can be enhanced simultaneously by applying the aging heat treatment.

Comparative analysis on gas–solid drag models in MFIX-DEM simulations of bubbling fluidized bed

In this study,the open-source software MFIX-DEM simulations of a bubbling fluidized bed(BFB)are applied to assess nine drag models according to experimental and direct numerical simulation(DNS)results.The influence of superficial gas velocity on gas–solid flow is also examined.The results show that according to the distribution of time-averaged particle axial velocity in y direction,except for Wen–Yu and Tenneti–Garg–Subramaniam(TGS),other drag models are consistent with the experimental and DNS results.For the TGS drag model,the layer-by-layer movement of particles is observed,which indicates the particle velocity is not correctly predicted.The time domain and frequency domain analysis results of pressure drop of each drag model are similar.It is recommended to use the drag model derived from DNS or fine grid computational fluid dynamics–discrete element method(CFD-DEM)data first for CFD-DEM simulations.For the investigated BFB,the superficial gas velocity less than 0.9 m·s^(-1) should be adopted to obtain normal hydrodynamics.