A numerical study of mixing intensification for highly viscous fluids in multistage rotor-stator mixers

How to achieve uniform mixing of highly viscous fluids with low energy consumption is a major industry demand and one of the hot spots of mixing research.A typical multistage rotor-stator mixer(MRSM)equipped with a distributor was investigated to disclose the effects on the mixing performance and power consumption for highly viscous fluids via numerical simulation,considering the influence factors associated with different geometric parameters of both MRSM and the distributor.The mixing index and power consumption are used to evaluate the performance of the mixers.The dimensionless correlations for the mixing index and the power consumption are established considering the factors including the flow rate,rotor speed,the number of mixing units.Adopting the optimized mixer with the distributor(X1-T1),the mixing index increases to 0.85(obviously higher than 0.46 for the mixer T1 without a distributor),meanwhile the corresponding power consumption is about 1/5 of that of T1 achieving the same mixing effect.It illustrates that the distributor can significantly improve the mixing of highly viscous fluids in the MRSM without the cost of large power consumption.These results would provide a guidance on the design and optimization of multistage rotor-stator mixers in industrial applications.

CFD Numerical Simulation of Hydrodynamics in a Rotor-Stator Reactor for Biodiesel Synthesis

In this paper a rotor-stator spinning disk reactor for intensified biodiesel synthesis is described and numerically simulated. The reactor consists of two flat disks, located coaxially and parallel to each other with a gap ranging from 0.1 mm to 0.2 mm between the disks. The upper disk is located on a rotating shaft while the lower disk is stationary. The feed liquids, triglycerides (TG) and methanol are introduced coaxially along the center line of rotating disk and stationary disk, respectively. Fluid hydrodynamics in the reactor for synthesis of biodiesel from TG and methanol in the presence of a sodium hydroxide catalyst are simulated, using convection-diffusion-reaction species transport model by the CFD software ANSYS? Fluent v. 13.0. The effects of upper disk’s spinning speed and gap size are evaluated.

Visual study on the characteristics of liquid and droplet in a novel rotor-stator reactor

Rotor–stator reactor(RSR), an efficient mass transfer enhancer, has been applied in many fields. However,the hydrodynamic characteristics of liquid flow in RSR are still a mystery despite they are fundamental for the mass transfer performance and processing capacity. In view of the above, this paper studies the liquid–liquid flow and liquid holdup in RSR under various conditions with a high-speed camera. The paper firstly demonstrates two flow patterns and liquid holdup patterns that we obtained from our experiment and then presents in succession a flow pattern and a liquid holdup criterion for the transition of film flow to filament flow and complete filling to incomplete filling. It is found that experimental parameters, including rotor–stator distance, rotational speed and volume flow rate exert great influence on the average droplet diameter and size distribution. Besides, by comparison and contrast, we also find that the experimental values match well with our previous predicted calculations of the average diameter, and the relation between the average diameter and the mean energy dissipation rate.

MATCH-MODE METHOD AND ITS NUMERICAL SIMULATION FOR ROTOR-STATOR INTERACTION SOURCE MODES AND PROPAGATION MODES IN AN ANNULAR DUCT WITH MULTI-TREATMENTS

The suppressing design of the engine nacelle in an aircraft can benefit from the development of the prediction system for the sound fields in engine ducts which includes the prediction of the source generation and that of sound propagation in ducts. First, the acoustic match mode principle between the source modes of rotor stator interaction noise and the propagation modes is presented in this paper. Second, by utilizing this principle, the theoretical prediction method for rotor stator interaction noise generation and its propagation and attenuation in an annular duct with multi treatments is developed. That means that the prediction of sound propagation and attenuation in the segmented ducts might no longer completely depend on the in duct mode measurements, and the investigation on the sound propagation and attenuation in ducts can be accomplished not only by acoustic mode measurement, but also by making use of the source prediction to determine the source modes excited by rotor stator interaction. The effects of fan speed, blade/vane numbers, axial spacing between rotor and stator on the in duct sound attenuation and generated sound power level before and after ducts (also including the sound power level of blade passing frequency and its harmonics at the inlet of ducts) have been numerically calculated by using this prediction method. The reliability of this prediction method is verified by reasonable agreement between the predicted results with measured results in references. By analyzing the results of calculating cases, some reference criteria are provided for the engineering design of the suppressing engine nacelle.

Investigation of flow characteristics in a rotor-stator cavity under crossflow using wall-modelled large-eddy simulation

Rotor-stator cavities are frequently encountered in engineering applications such as gas turbine engines.They are usually subject to an external hot mainstream crossflow which in general is highly swirled under the effect of the nozzle guide vanes.To avoid hot mainstream gas ingress,the cavity is usually purged by a stream of sealing flow.The interactions between the external crossflow,cavity flow,and sealing flow are complicated and involve all scales of turbulent unsteadiness and flow instability which are beyond the resolution of the Reynolds-average approach.To cope with such a complex issue,a wall-modeled large-eddy simulation(WMLES)approach is adopted in this study.In the simulation,a 20°sector model is used and subjected to a uniform pre-swirled external crossflow and a stream of radial sealing flow.It is triggered by a convergent Reynoldsaveraged Navier-Stokes(RANS)result in which the shear stress transport(SST)turbulent model is used.In the WMLES simulation,the Smagoringsky sub-grid scale(SGS)model is applied.A scalar transportation equation is solved to simulate the blending and transportation process in the cavity.The overall flow field characteristics and deviation between RANS and WMLES results are discussed first.Both RANS and WMLES results show a Batchelor flow mode,while distinct deviation is also observed.Deviations in the small-radius region are caused by the insufficiency of the RANS approach in capturing the small-scale vortex structures in the boundary layer while deviations in the large-radius region are caused by the insufficiency of the RANS approach in predicting the external crossflow ingestion.The boundary layer vortex and external ingestion are then discussed in detail,highlighting the related flow instabilities.Finally,the large-flow structures induced by external flow ingress are analyzed using unsteady pressure oscillation signals.

Laser Measurements in High Speed Compressors for Rotor-Stator Interaction Analysis

This paper deals with the experimental quantification of the unsteady effects of the interactions between rotor and stator rows in high speed compressors. Due to the fact that the levels of the periodic fluctuations arising from the unsteady interaction may be low compared with the random fluctuations arising from the measurement uncertainties, it is crucial to minimize the errors inherent to the used technique. The first part of the paper concentrates on technical details relative to the experimental process. The second part is devoted to the data post-processing. Two tools for analysing the rotor-stator interactions are presented. The first tool is based on a decomposition of the flow field which was initially introduced to solve numerical problems when attempting to calculate the flow field in a multi-row configuration. The second tool is based on a spectral analysis of the signal, that qualifies the interaction in a sense of circumferential spinning lobes. Experimental results obtained within both an axial and a centrifugal high speed compressors are used to illustrate the data processing. In both cases, the effects of the unsteady interaction are quantified.

Investigations of an enclosed annular rotor-stator system with LES method

In this study, the flows in an enclosed annular rotor-stator system with the Reynolds number ranging from 0.75×105 to 3.75×105 and an aspect ratio of 36.5 are investigated using the LES method. Few studies have explored such a rotor-stator system with this aspect ratio and the flow structure on the rotor side. The mean flow structure varies from a torsional Couette type to a Batchelor type as the Reynolds number increases. The onset of the instability in the B?dewadt layer adjacent to the stator is delayed,whereas it is promoted in the Ekman layer adjacent to the rotor. Both the layers demonstrate rich spiral structures. Turbulent spirals are observed to occur at the rotor disk side that also generates TS-wave-like(Tollmien-Schlichting) structures between adjacent spiral arms. Further, the turbulence at the stator is complex and interesting. Statistically, the turbulence is highly anisotropic near both the rotating and nonrotating disks, which is depicted by the Reynolds stresses.

Modal Decomposition for the Analysis of the Rotor-stator Interactions in Multi-stage Compressors

A modal analysis method of the rotor-stator interactions in multistage compressors has been developed by LMFA. This method, based on a double modal decomposition of the flow over space and time, has been applied to nu- merical and experimental results of the high-speed 3Y2-stage compressor CREATE based at LMFA, Lyon-France. It reveals the presence of a very strong rotor-stator interaction which completely drives the flow at casing behind all the rotors. This modal analysis method applied to an unsteady RANS simulation permits to calculate the en- ergy of the rotor-stator interactions and to plot energetic meridian maps to explain experimental results and to analyze the interaction in the whole machine.

Unsteady Flow Variability Driven by Rotor-stator Interaction at Rotor Exit

Numerical investigation of the unsteady flow variability driven by rotorstator interaction in a transonic axial compressor is performed. Two models with close and far axial gap between rotor and stator rows are studied in the simulation. Particular attention is attached to the analysis of mechanisms involved in driving rotor wake oscillation, rotor wake skewing and flow angle fluctuation at rotor exit. The results show that smaller axial gap is favorable to enhance the interaction in the region between two adjacent rows, and the fluctuation of the static pressure difference between two sides of rotor wake is improved by potential field from down stator, which is the driving force for rotor wake oscillation. The interaction between rotor and stator is weakened by increasing axial distance, rotor wake shifts to suction side of rotor blade with 5%-10% of rotor pitch, the absolute value of flow angle at rotor exit is less than that in the case of close interspace for every time step, and the fluctuation amplitude is also decreased.

An experimental study of rotational pressure loss in rotor-stator gap

The annular gap between rotor and stator is an inevitable flow path of a throughflow ventilated electrical machine,but the flow entering the rotor-stator gap is subjected to the effects of rotation.The pressure loss and volumetric flow rate across the rotor-stator gap were measured and compared between rotating and stationary conditions.The experimental measurements found that the flow entering the rotor-stator gap is affected by an additional pressure loss.In the present study,the rotational pressure loss at the entrance of rotor-stator gap is characterised.Based upon dimensional analysis,the coefficient of entrance loss can be correlated with a dimensionless parameter,i.e.rotation ratio.The investigation leads to an original correlation for the entrance loss coefficient of rotor-stator gap arisen from the Coriolis and centrifugal effects in rotating reference frame.

Safety Analysis of Flow Parameters in a Rotor-stator Cavity

In order to ensure the safety of engine life limited parts （ELLP） according to airworthiness regulations, a numerical approach integrating one-way fluid structure interaction （FSI） and probabilistic risk assessment （PRA） is developed, by which the variation of flow parameters in a rotor-stator cavity on the safety of gas turbine disks is investigated. The results indicate that the flow parameters affect the probability of fracture of a gas turbine disk since they can change the distribution of stress and temperature of the disk. The failure probability of the disk rises with increasing rotation Reynolds number and Chebyshev number, but descends with increasing inlet Reynolds number. In addition, a sampling based sensitivity analysis with finite difference method is conducted to determine the sensitivities of the safety with respect to the flow parameters. The sensitivity estimates show that the rotation Reynolds number is the dominant variable in safety analysis of a rotor-stator cavity among the flow parameters.

Flow characteristics in a rotor-stator cavity with cooling air inlet at low radius

Experiments were conducted on a typical rotor-stator system where air entered through an annular slot at low radius and flowed out of the cavity axially through a rim seal between the rotor and the stator.For the seal in this rotor-stator system,the stationary shroud overlapped the rotating one.Pressure distributions at the stator surface and flow resistance coefficients of the rotor-stator cavity with a maximum gap of 67mm were measured under different dimensionless mass flow rates from 1.32×104 to 4.87×104 with a large range of rotational Reynolds numbers from 0.418×106 to 2.484×106.The results show that pressure on the stator surface decreases with the increase of rotational Reynolds number when the dimensionless mass flow rate is below 1.3×104;when the dimensionless mass flow rate is above 3.034×104,the trend reverses.This is the so-called"pressure inversion effect".However,dimensionless pressure does not show the same changes when rotational dynamic pressure is chosen as the denominator.The resistance coefficient of the rotor-stator cavity is determined by the dimensionless mass flow rate and rotational Reynolds number;for practical application,the resistance coefficient can also be estimated by the turbulent flow parameter in the range of turbulent parameter from 0.1to 1.6.

Numerical investigation of windage heating within shrouded rotor-stator cavity system with central inflow

The rotating disk surface temperature rise due to windage heating effect by numerically modeling the turbulent flow within a rotor-stator cavity which is available with a peripheral shroud and imposed through airflow was dealt with.The windage heating may be defined as viscous friction heating caused by relative velocity differences across the boundary layers between the fluid and the rotating disk surface.The kinetic energy dissipation process could transform the rotating shaft power into thermal heating.Commercial finite volume based solver,ANSYS/CFX was employed to numerically simulate this physical process by using the shear stress transport(SST)turbulence model.CFD results include the rotating disk surface temperature axial distribution and tangential velocity distribution of the fluid domain.The velocity difference between the result obtained by particle image velocimetry(PIV)experiments and CFD simulation are within 5%.The adiabatic disk temperature rise can be calculated by the tangential velocity of disk and fluid in large gap ratio and turbulent parameter.CFD temperature distribution results and those estimated via velocity differences are within 10%.

Investigation of the fluid flow in an isolated rotor-stator system with a peripheral opening

This paper deals with an experimental, theoretical and numerical study of a turbulent flow with separated boundary layers between a rotor and a stator. The system is not subjected to any superimposed radial flow. The periphery of the cavity is opened to the atmosphere so that the solid body rotation for infinite discs is not always observed. Emphasis was placed on develop- ment of an asymptotic approach and a step-by-step method to compute the radial distribution of the core swirl ratio and the static pressure on the stator side. The theory also includes the radial and axial velocities in the core region. The numerical simulation has been conducted with the commercial CFD code Fluent 6.1. The k- SST turbulence model is used, with the assumption of 2D-axisymmetric and steady flow. CFD validations have been performed by comparison of the numerical results with the corresponding theoretical results. Numerical and experimental results are in good agreement with analytical solutions.

Effect of windage heating on a micro high-speed rotor-stator cavity

The main objective of this work is to investigate the effect of windage heating on the micro high-speed rotor-stator cavity.The influences of centrifugal force and spacing on the windage heating are analyzed with and without the change of gap ratio respectively.The results demonstrate that there is no difference in the flow structure between micro and large-scale rotorstator cavities at the same rotational Reynolds number and gap ratio.However,the windage heating induced by the larger centrifugal force and smaller spacing brings the different heat transfer laws for the micro rotor-stator cavity.The larger centrifugal force weakens the local heat transfer near the rotor periphery.Such influence can be strengthened at higher rotational Reynolds numbers and lower rotor excess temperatures.Besides,the smaller spacing further enhances the windage heating and reduces the average heat transfer especially under the condition of lower gap ratio.The findings of this work contribute to the design of rotor-stator cavity utilized in the micro rotating machinery.

Numerical Simulation of Rotor-stator Interactions in a Transonic Compressor Stage

A numerical method is developed for the simulation of rotor\|stator interactions in a compessor or turbine stage. This method solves quasi\|three\|dimensional Navier\|Stokes equations by an implicit high\|resolution finite volume approach.A fully conservative method is designed to compute the inviscid and viscous fluxes at the interface of rotor and stator grids. Numerical results of rotor\|stator interactions in a transonic compressor stage are presented. The mechanism of rotor\|stator interactions in this compressor stage is discussed in terms of the computational results.

无刷双馈电机研究综述与展望

无刷双馈电机具有结构可靠、变频器容量小等优势,非常适合灵活运行于防爆、易燃等特殊或极端工况,近年来受到广泛关注。该文根据无刷双馈电机的基本工作原理,明确了该类电机的命名原则与规范名称;总结了现有定转子方案的结构及性能特点,综合考虑性能指标与结构工艺,提出了转子双套绕组的发展方向;梳理了无刷双馈电机的稳态等效电路模型及基于各类数学模型的优化设计方法,针对现存难以完整考虑不同转速工况性能的不足,阐明了利用新型同步-异步相串联等效电路进行优化设计的思路;对比分析了经典及新近出现的无刷双馈电机控制系统拓扑和控制策略特点,面向典型电动、发电工况建立了完整的电机及控制系统。最后,对无刷双馈电机的上述理论研究问题及工业应用的发展方向进行了总结阐述,为该类电机的深入研究及加快推广应用提供参考和指导。

三代压水堆核主泵关键部件制造及工艺研究进展

核主泵作为反应堆冷却剂系统中唯一高速旋转的设备,其正常运行对于整个核电站的安全至关重要.长期以来,核主泵制造的安全性与可靠性一直是中国核电技术发展的“卡脖子”难题.近年来,得益于国家对核电技术基础研究的大力投入,以及依托重大课题项目的推进,中国三代压水堆核主泵国产化进程在各个方面都取得了重大成果.文中从核主泵制造及工艺的角度,深入剖析叶轮、泵壳、定子、转子、屏蔽套、密封、轴承等关键部件的发展历程,并针对各部件的材料选择、加工、装配工艺、检测方法及技术体系等进行详细分析,总结了中国核主泵的制造进度及难点.最后,结合当前核主泵制造的现状,提出中国核主泵制造发展的相关建议,这对中国核电事业的国产化进程具有重要意义.

分流叶片对液力透平压力脉动的影响

为揭示分流叶片对低比转速液力透平性能的影响,以一台低比转速离心泵(n_(s)=33)反转作液力透平为例,设计出4种不同分流叶片数的叶轮(复合叶轮),通过CFX软件对原始叶轮和4种复合叶轮进行数值模拟并对比分析。结果表明,4种新模型在最优工况下效率和水头均有所提高,其中当分流叶片数Z=6+6时液力透平的性能最佳,在最优工况下效率、水头分别提高了2.23%、6.83%;叶轮内压力分布更加均匀;叶轮进口漩涡区域减弱;内部各个监测点压力系数、脉动幅值均小于原始模型,说明分流叶片可以降低液力透平内部的压力脉动、提升透平机组运行的稳定性。研究结果可为低比转速液力透平性能提升提供参考。

基于代理模型的双气隙混合转子低速大转矩同步电机优化设计

为解决常规低速大转矩电机普遍存在体转矩密度低、永磁体用量多等问题,提出了一种双气隙混合转子低速大转矩同步电机拓扑结构。然而,该种电机结构相对复杂、设计参数多、优化难度大,对此提出了一种基于代理模型的双气隙混合转子低速大转矩同步电机高效优化设计方法。首先,以提高输出转矩与降低转矩脉动为优化目标,对电机的参数进行敏感性分析,实现了在保证代理模型精确度的基础上精简优化变量。然后,为提高该种电机多目标优化设计的精确度和效率,同时缩短优化周期,提出了一种序贯子空间与模式搜索算法相结合的优化算法对电机进行优化处理。最后通过有限元仿真与实验方法验证了所构建代理模型的精确性、合理性和优化方法的有效性、先进性。