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

lronmaking 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 fur- nace 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 （51G） flowrate to total gas flowrate on the SIC 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.

A combined multiscale modeling and experimental study on surface modification of high-volume micro-nanoparticles with atomic accuracy

Surface modification for micro-nanoparticles at the atomic and close-to-atomic scales is of great importance to enhance their performance in various applications,including high-volume battery,persistent luminescence,etc.Fluidized bed atomic layer deposition(FB-ALD)is a promising atomic-scale manufacturing technology that offers ultrathin films on large amounts of particulate materials.Nevertheless,nanoparticles tend to agglomerate due to the strong cohesive forces,which is much unfavorable to the film conformality and also hinders their real applications.In this paper,the particle fluidization process in an ultrasonic vibration-assisted FB-ALD reactor is numerically investigated from micro-scale to macro-scale through the multiscale computational fluid dynamics and discrete element method(CFD-DEM)modeling with experimental verification.Various vibration amplitudes and frequencies are investigated in terms of their effects on the fluid dynamics,distribution of particle velocity and solid volume fraction,as well as the size of agglomerates.Results show that the fluid turbulent kinetic energy,which is the key power source for the particles to obtain the kinetic energy for overcoming the interparticle agglomeration forces,can be strengthened obviously by the ultrasonic vibration.Besides,the application of ultrasonic vibration is found to reduce the mean agglomerate size in the FB.This is bound to facilitate the heat transfer and precursor diffusion in the entire FB-ALD reactor and the agglomerates,which can largely shorten the coating time and improve the film conformality as well as precursor utilization.The simulation results also agree well with our battery experimental results,verifying the validity of the multiscale CFD-DEM model.This work has provided momentous guidance to the mass manufacturing of atomic-scale particle coating from lab-scale to industrial applications.

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.

Investigation of particle-wall interaction in a pseudo-2D fluidized bed using CFD-DEM simulations

We report on discrete element method simulations of a pseudo-two-dimensional （pseudo-2D） fluidized bed to investigate particle-wall interactions. Detailed information on macroscopic flow field variables, including solids pressure, granular temperature, and normal and tangential wall stresses are analyzed. The normal wall stress differs from the solids pressure because of the strong anisotropic flow behavior in the pseudo-2D system. A simple linear relationship exists between normal wall stress and solids pressure. In addition, an effective friction coefficient can be derived to characterize particle-wall flow interaction after evaluating the normal and tangential wall stresses. The effects of inter-particle and particle-wall friction coefficients are evaluated. Strong anisotropic flow behavior in the pseudo-2D system needs to be considered to validate the two-fluid model where the boundary condition is usually developed based on an isotropic assumption. The conclusion has been confirmed by simulation with different particle stiffnesses. Assumptions in the newly developed model for 2D simulation are further examined against the discrete element method simulation.

Eulerian-Lagrangian simulation of distinct clustering phenomena and RTDs in riser and downer

Numerical simulation of fully developed hydrodynamics of a riser and a downer was carried out using an Eulerian-Lagrangian model, where the particles are modeled by the discrete element method （DEM） and the gas by the Navier-Stokes equations. Periodic flow domain with two side walls was adopted to simulate the fully developed dynamics in a 2D channel of 10 cm in width. All the simulations were carried out under the same superficial gas velocity and solids holdup in the domain, starting with a homogenous state for both gas and solids, and followed by the evolution of the dynamics to the heterogeneous state with distinct clustering in the riser and the downer. In the riser, particle clusters move slowly, tending to suspend along the wall or to flow downwards, which causes wide residence time distribution of the particles. In the downer, clusters still exist, but they have faster velocities than the discrete particles. Loosely collected particles in the clusters move in the same direction as the bulk flow, resulting in plug flow in the downer. The residence time distribution （RTD） of solids was computed by tracking the displacements of all particles in the flow direction. The results show a rather wide RTD for the solids in the riser hut a sharp peak RTD in the downer, much in agreement with the experimental findings in the literature. The ensemble average of transient dynamics also shows reasonable profiles of solids volume fraction and solids velocity, and their dependence on particle density.

A hybrid DEM/CFD approach for solid-liquid flows

A hybrid scheme coupling the discrete element method （DEM） with the computational fluid dynamics （CFD） is developed to model solid-liquid flows. Instead of solving the pressure Poisson equation, we use the compressible volume-averaged continuity and momentum equations with an isothermal stiff equation of state for the liquid phase in our CFD scheme. The motion of the solid phase is obtained by using the DEM, in which the particle-particle and particle-wall interactions are modelled by using the theoretical contact mechanics. The two phases are coupled through the Newton＇s third law of motion. To verify the proposed method, the sedi-mentation of a single spherical particle is simulated in water, and the results are compared with experimental results reported in the literature. In addition, the drafting, kissing, and tumbling （DKT） phenomenon between two particles in a liquid is modelled and rea-sonable results are obtained. Finally, the numerical simulation of the density-driven segregation of a binary particulate suspension in-volving 10 000 particles in a closed container is conducted to show that the presented method is potentially powerful to simulate real particulate flows with large number of moving particles.

Modeling and simulation of chemically reacting flows in gas-solid catalytic and non-catalytic processes

This paper gives an overview of the recent development of modeling and simulation of chemically react- ing flows in gas-solid catalytic and non-catalytic processes. General methodology has been focused on the Eulerian-Lagrangian description of particulate flows, where the particles behave as the catalysts or the reactant materials. For the strong interaction between the transport phenomena （i.e., momentum, heat and mass transfer） and the chemical reactions at the particle scale, a cross-scale modeling approach, i.e., CFD-DEM or CFD-DPM, is established for describing a wide variety of complex reacting flows in multiphase reactors, Representative processes, including fluid catalytic cracking （FCC）, catalytic conversion of syngas to methane, and coal pyrolysis to acetylene in thermal plasma, are chosen as case studies to demonstrate the unique advantages of the theoretical scheme based on the integrated particle-scale information with clear physical meanings, This type of modeling approach provides a solid basis for understanding the multiphase reacting flow problems in general.

Unsteady analysis of six-DOF motion of a 6:1 prolate spheroid in viscous fluid

Free-moving simulations of airplanes, submarines and other automobiles under extreme and emergency conditions are becoming increasingly important from operational and tactical perspectives. Such simulations are fairly challenging due to the extreme unsteady motions and high Re(Reynolds) numbers. The aim of this study is to perform a six-DOF motion simulation of a 6:1prolate spheroid that is falling in a fluid field. Prior to conducting the six-DOF simulation, some verification simulations were performed. First, a laminar flow past an inclined prolate spheroid at a Re number of 1000 and incidence angle of 45. with a tetrahedral mesh was simulated to verify the relevant targeted discrete method for an unstructured mesh. Second, to verify the LES(large eddy simulation) models and dependent parameters for the DDES(delayed detached eddy simulation), a turbulent flow past a sphere was performed at a subcritical Re number of 10000. Third, a steady maneuvering problem about a prolate spheroid pitching up from 0. to 30. incidence at a uniform angular velocity was established based on a dynamic tetrahedral mesh with changing topology and the ALE(arbitrary Lagrangian-Eulerian) method of fluid-structure coupling at a Re number of 4.2 × 10~6.Finally, two six-DOF motions of an inclined 6:1 prolate spheroid at an initial incidence of 45. were simulated at different Re numbers of 10000 and 4.2 × 10~6.