Numerical Simulation of Fluid Flow and Heat Transfer in a DC Non-Transferred Arc Plasma Torch Operating Under Laminar and Turbulent Conditions

In this work, a magnetic fluid dynamics （MHD） model is used to simulate the electromagnetic field, heat transfer and fluid flow in a DC non-transferred arc plasma torch under laminar and turbulent conditions. The electric current density, temperature and velocity distributions in the torch are obtained through the coupled iterative calculation about the electromagnetic equations described in a magnetic vector potential format and the modified fluid dynamics equations. The fluid-solid coupled calculation method is applied to guarantee the continuity of the electric current and heat transfer at the interface between the electrodes and fluid. The predicted location of the anodic arc root attachment and the arc voltage of the torch are consistent with corresponding experimental results. Through a specific analysis of the influence of mass flow rates and electric current on the torch outlet parameters, the total thermal efficiency, thermal loss of each part, and the laws of the variation of outlet parameters with the variation of mass flow rates and electric current was obtained. It is found that operation under a laminar condition with a limited area of the anode could increase the total thermal efficiency of the torch.

Comparison of Reynolds average Navier-Stokes turbulence models in numerical simulations of the DC arc plasma torch

Five turbulence models of Reynolds average Navier-Stokes(RANS),including the standard k-ω model,the RNG k-e model taking into account the low Reynolds number effect,the realizable k-ω model,the SST k-ω model,and the Reynolds stress model(RSM),are employed in the numerical simulations of direct current(DC)arc plasma torches in the range of arc current from 80 A to 240 A and air gas flow rate from 10 m^3 h^-1 to 50 m^3 h^-1.The calculated voltage,electric field intensity,and the heat loss in the arc chamber are compared with the experiments.The results indicate that the arc voltage,the electric field,and the heat loss in the arc chamber calculated by using the standard k-ω model,the RNG k-ωmodel taking into account the low Reynolds number effect,and the realizable k-ω model are much larger than those in the experiments.The RSM predicts relatively close results to the experiments,but fails in the trend of heat loss varying with the gas flow rate.The calculated results of the SST k-ω model are in the best agreement with the experiments,which may be attributed to the reasonable predictions of the turbulence as well as its distribution.

Modelling Study on the Plasma Flow and Heat Transfer in a Laminar Arc Plasma Torch Operating at Atmospheric and Reduced Pressure

A modelling study is performed to investigate the characteristics of both plasma flow and heat transfer of a laminar non-transferred arc argon plasma torch operated at atmospheric and reduced pressure. It is found that the calculated flow fields and temperature distributions are quite similar for both cases at a chamber pressure of 1.0 atm and 0.1 atm. A fully developed flow regime could be achieved in the arc constrictor-tube between the cathode and the anode of the plasma torch at 1.0 atm for all the flow rates covered in this study. However the flow field could not reach the fully developed regime at 0.1 atm with a higher flow rate. The arc-root is always attached to the torch anode surface near the upstream end of the anode, i.e. the abruptly expanded part of the torch channel, which is in consistence with experimental observation. The surrounding gas would be entrained from the torch exit into the torch interior due to a comparatively large inner diameter of the anode channel compared to that of the arc constrictor-tube.

Applications of two electric arc plasma torches for the beneficiation of natural quartz

Experimental beneficiation processes of quartz concentrate in arc plasma torches of two different types and electric powers were studied. An emission scanning electron microscope and a universal laser analyzer were used to investigate the structures as well as the size distributions of grains and microparticles. Inductively coupled plasma–mass spectrometry was used to determine the chemical compositions of nonstructural solid-phase mineral impurities in quartz concentrate. Results related to the modified grains' structure and size distribution, the compositions of impurities, and the gas–liquid inclusions in the quartz concentrate were investigated. The total impurities concentrations in the processed grains were found to satisfy the IOTA-STD standard(industry standard for grading high quality fused quartz products). The optimal condition(i.e., the optimal specific plasma enthalpy) for the production of high-purity quartz in arc plasma torches was found to depend on the geological-genetic type and the structural and textural features(i.e., chemical composition and gas–liquid inclusions) of the quartz concentrate.

Three-Dimensional Numerical Modeling of an Ar-N_2 Plasma Arc Inside a Non-Transferred Torch

A three-dimensional numerical model is developed to study the behaviour of an argon-nitrogen plasma arc inside a non-transferred torch. In this model, both the entire cathode and anode nozzle are considered to simulate the plasma arc. The argon-nitrogen plasma arc is simulated for different arc currents and gas flow rates of argon. Various combinations of arc core radius and arc length, which correspond to a given torch power, are predicted. A most feasible combination of the same, which corresponds to an actual physical situation of the arc inside the torch, is identified using the thermodynamic principle of minimum entropy production for a particular torch power. The effect of the arc current and gas flow rate on the plasma arc characteristics and torch efficiency is explained. The effect of the nitrogen content in the plasma gas on the torch power and efficiency is clearly detected. Predicted torch efficiencies are comparable to the measured ones and the effect of the arc current and gas flow rate on predicted and measured efficiencies is almost similar. The efficiency of the torch, cathode and anode losses and core temperature and velocity at the nozzle exit are reported for five different cases.

Dual Torch Plasma Arc Furnace for Medical Waste Treatment

In this paper, characteristics of a treatment and operated at atmospheric pressure dual torch plasma arc used for hazardous waste are studied, and also compared with those of the multi-torch plasma arc and the single torch plasma arc. The dual torch plasma arc is generated between the cathode and anode with argon as the working gas. The temperature distributions of the plasma arc are measured using a spectroscope and line pair method with the assumption of local thermodynamic equilibrium （LTE） for the DC arc current I=100 A and argon flow rate Q = 15 slpm. The measurements show that the temperatures of the dual torch arc plasma in the regions near the cathode, the anode and the center point are 10,000 K, 11,000 K and 9,000 K, respectively. And the high temperature region of the multi torch plasma arc is of double or much wider size than that of a conventional dual torch plasma arc and single plasma torch. Based on the preceding studies, a dual torch plasma arc furnace is developed in this study. The measured gas temperature at the center region of the argon arc is about 11,000 K for the case of I=200 A and Q=30 slpm operated in atmosphere.

Comparative Observation of Ar,Ar-H_2 and Ar-N_2 DC Arc Plasma Jets and Their Arc Root Behaviour at Reduced Pressure

Results observed experimentally are presented, about the DC arc plasma jets and their arc-root behaviour generated at reduced gas pressure without or with an applied magnetic field. Pure argon, argon-hydrogen or argon-nitrogen mixture was used as the plasma-forming gas. A specially designed copper mirror was used for a better observation of the arc-root behaviour on the anode surface of the DC non-transferred arc plasma torch. It was found that in the cases without an applied magnetic field, the laminar plasma jets were stable and approximately axisymmetrical. The arc-root attachment on the anode surface was completely diffusive when argon was used as the plasma-forming gas, while the arc-root attachment often became constrictive when hydrogen or nitrogen was added into the argon. As an external magnetic field was applied, the arc root tended to rotate along the anode surface of the non-transferred arc plasma torch.

Experimental study on the jet characteristics of a steam plasma torch

Thermal steam plasma jet is promising for applications in environmental industries due to its distinctive characteristics of high enthalpy and high chemical reactivity. However, the performance of the steam plasma torch for its generation is limited by the problems of the large arc voltage fluctuation and serious erosion of the electrodes. In this study, a gas-stabilized steam plasma torch which can operate continuously and stably was designed. Experiments were conducted to reveal the effect of the different working parameters, including the anode diameter, the cooling water temperature, the arc current and the steam flow rate, on its Volt-Ampere characteristics, arc voltage fluctuation, thermal efficiency, jet characteristics and electrodes erosion. Results showed that the use of hot water to cool the electrodes can effectively prevent the condensation of steam on the inner wall of the electrodes, thus significantly reducing the arc voltage fluctuations and electrodes erosion. This is crucial for increasing the working life of the electrodes and ensuring long-term stability of the steam plasma torch. In addition, suitable anode diameter can greatly reduce the arc voltage fluctuation of the steam plasma torch and effectively improve the stability of the steam plasma jet. Furthermore, high arc current can effectively reduce the fluctuations of the arc voltage and increase the length and the volume of the steam plasma jet. Finally, using steam as the plasma forming gas can achieve higher thermal efficiency compared to air. An ideal thermal efficiency can be achieved by properly reducing the arc current and increasing the steam flow rate.

Discharge Characteristics of DC Arc Water Plasma for Environmental Applications

A water plasma was generated by DC arc discharge with a hafnium embedded rodtype cathode and a nozzle-type anode. The discharge characteristics were examined by changing the operation parameter of the arc current. The dynamic behavior of the arc discharge led to significant fluctuations in the arc voltage and its frequency. Analyses of the high speed image and the arc voltage waveform showed that the arc discharge was in the restrike mode and its frequency varied within several tens of kilohertz according to the operating conditions. The larger thermal plasma volume was generated by the higher flow from the forming steam with a higher restrike frequency in the higher arc current conditions. In addition, the characteristics of the water plasma jet were investigated by means of optical emission spectroscopy to identify the abundant radicals required in an efficient waste treatment process.

Diagnosis of Electron,Vibrational and Rotational Temperatures in an Ar/N2 Shock Plasma Jet Produced by a Low Pressure DC Cascade Arc Discharge

In this paper, a low pressure Ar/N2 shock plasma jet with clearly multicycle al- ternating zones produced by a DC cascade arc discharge has been investigated by an emission spectral method combined with Abel inversion analysis. Plasma emission intensity, electron, vi- brational and rotational temperatures of the shock plasma have been measured in the expansion and compression zones. The results indicate that the ranges of the measured electron temperature, vibrational temperature and rotational temperature are 1.1 eV to 1.6 eV, 0.2 eV to 0.7 eV and 0.19 eV to 0.22 eV, respectively, and it is found for the first time that the vibrational and rota- tional temperatures increase while the electron temperature decreases in the compression zones. The electron temperature departs from the vibrational and the rotational temperatures due to non-equilibrium plasma effects. Electrons and heavy particles could not completely exchange energy via collisions in the shock plasma jet under the low pressure of 620 Pa or so.

Prediction of Weld Bead Geometry in Plasma Arc Welding using Factorial Design Approach

The effect of various process parameters like welding current, torch height, welding speed and plasma gas flow rate on front melting width, back melting width and weld reinforcement of plasma arc welding on aluminum alloy is investigated by using factorial design approach. Variable polarity plasma arc welding is used for welding aluminum alloy. Trail experiments are conducted and the limits of the input process parameters are decided. Two levels and four input process parameters are chosen and experiments are conducted as per typical design matrix considering full factorial design. Total sixteen experiments are conducted and output responses are measured. The coefficients are calculated by using regression analysis and the mathematical models are constructed. By using the mathematical models the main and interaction effect of various process parameters on weld quality is studied.

直流电弧等离子体炬数值模拟与诊断

直流电弧等离子体炬内部物理过程复杂且具动态性,较难对其进行准确描述与深入研究,且其工作温度较高,其状态参数难以使用常规方式测量。针对直流电弧等离子体炬,建立流动、传热和电磁相互耦合的数值模型,基于Fluent软件对直流电弧等离子体炬进行三维数值模拟和特性分析,设计并搭建了一套热焓探针实验系统,完成对直流电弧等离子体炬射流参数的测量分析。结果表明:建立的数值模型模拟结果与实验测量结果吻合较好,误差在10%以内;炬内温度与速度最大值与工作气流量呈正相关,均出现在靠近阴极区域,且沿轴线逐渐降低;等离子体炬内高温区与高电流密度区重合。

大电流弧爆激波的改进等离子炬聚束性能研究

具有高温高压特性的大电流弧爆激波,在材料加工与军工领域有着巨大的应用前景。为实现定向热冲击,需要对弧爆激波聚束,通过改进等离子炬,设计了一种聚束原型机。采用等效电弧爆炸的方法,利用Autodyn-2D和高精度多物质求解器Euler-2D对9组设计方案进行数值模拟,分析了原型机的聚束管、管仰角和电极距离等对弧爆激波聚束性能的影响规律。研究结果表明:等离子炬通过加装聚束管改进后,能将弧爆激波射流速度与压强峰值分别提升300%、500%;管仰角γ对出口出处射流速度有很大的影响;弧倾角λ为45°时,聚束波的速度和能量最大;电极距离主要影响弧爆激波速度和压强的变化率。

Laminar Flow and Heat Transfer in a Circular Tube Located behind a D.C.Arc Plasma Torch

Modeling results are presented for the laminar flow and heat transfer within a circular tube connected coaxially with a d c arc plasma torch. In order to determine the correct boundary conditions at the tube inlet, the computational domain is extended to include both the circular tube and the arc plasma torch. Computational results show that the gas static pressure in the tube increases at first and then decreases slowly, while the heat flux to the tube wall decreases monotonically with increasing distance from the tube inlet. Comparison of some computed results with corresponding experimental data is also given.

直流电弧等离子体炬物理场的数值模拟研究

直流电弧等离子体炬内部温度较高,物理场情况复杂,较难进行实验研究,因此对等离子体炬内部物理场的研究一般采用基于磁流体动力学模型的数值模拟研究。以一种直流电弧等离子体炬为研究对象,在给定的电流大小以及工作气体流量条件下对其温度场、速度场等物理场进行了数值模拟研究,研究结果表明:在电流大小200 A、工作气体流量0.0014 kg/s的工作模式下,直流电弧等离子体炬射流在出口处中心温度可达到13000 K,出口最大流速可达到2400 m/s。高温等离子体的温度分布主要与电流密度的分布有关,其能量来源主要是电弧产生的焦耳热。台阶形的阳极结构主要对等离子体射流的流速产生影响。

提高锅炉等离子体火炬燃弧稳定性的参数调整方法研究

等离子体点火(也称等离子体火炬)已广泛应用于火力发电厂的锅炉点火,但由于系统复杂,工作环境恶劣,运行一段时间后容易出现起弧困难、频繁熄弧等问题。以某次点火过程中出现频繁熄弧问题为切入点,对等离子体火炬熄弧现象的数据进行了统计分析,研究提高燃弧稳定性的方法。结合简易电弧理论模型和试验数据,明确了电弧电压与轴向气压的强相关性,提出了定量评价燃弧质量的统计指标,并结合历史数据和正常设备数据对熄弧现象进行对比分析。研究发现,此次点火过程中火炬状态发生变化,在轴向气压未调整的情况下,出现电弧电压超过额定值的现象,导致了电源电压裕量不足,进而降低了燃弧稳定性。利用电弧电压与轴向气压的强相关性,通过拟合其线性关系可对电弧电压定量调整,调整后实现稳定燃弧。火炬的状态存在动态变化的现象,运行参数宜根据当前电弧特性动态调整,避免电压过高引发熄弧。研究结果可以为相关设备故障分析、提高点火装置运行管理水平和相关技术改造提供理论和方法参考。

外部磁场对直流电弧等离子体放电特性的影响及其机理

通过外部磁场驱动电弧旋转产生相对均匀的等离子体是一种可能的改进等离子体放电特性的有效手段。利用高速摄像技术和虚拟仪器技术,观察并测量了大气条件下、非均匀磁场驱动的直流电弧等离子体阳极弧根运动以及电弧电压波动。结果发现:相比无外部磁场,非均匀外部磁场驱动下的直流电弧等离子体在旋转力和稳弧力的作用下阳极弧根旋转,均匀性提高;其电弧电压波动幅度增大,放电模式发生改变;伏安特性曲线向上平移,电弧等离子体炬放电功率提高。另外,由于等离子体射流的高速运动而引起的等离子体射流在喷口处径向扩张,使等离子体射流横截面扩大,进一步提高了射流的均匀性。从结果中可以看出,外部磁场改善了直流电弧等离子体炬的基本特性,对直流电弧等离子体炬应用效率的提高具有重要的意义。

双阳极电弧等离子体炬的磁流体动力学分析

为了更好地研究直流电弧等离子体炬内的流动与传热,根据磁流体动力学(MHD)理论建立了等离子体电弧区的数学物理模型,采用磁矢量势A的方法来计算磁感应强度B的大小,利用通用软件FLUENT并进行二次开发,采用用户自定义函数(user defined function,UDF)加入磁流体动力学方程组中的源项和物性参数,并利用用户自定义标量方程(user defined scalar,UDS)的方法加入Maxwell方程组,采用SIMPLE算法对电弧区域进行了数值模拟。计算结果表明:等离子体炬内的弧电压随着气体质量流量的增加而增加;等离子体炬内的温度随着气体质量流量的增加而减小,而速度随着气体质量流量的增加而增加;出口处的温度和速度随径向距离的增加而减小,但温度减小的速率增加。这一结果可为实验提供理论指导和参考。

丝电弧等离子体强化超声速点火和燃烧

在总结国外关于丝电弧等离子体强化超声速点火和燃烧现状的基础上,分析了丝电弧等离子体强化超声速点火和燃烧的特点.基于等离子体点火强化超声速燃烧的基本原理,设计了4种丝电弧等离子体强化超声速点火和燃烧的电极布置方案,凹槽式燃烧室强化燃烧方案、平板式单排纵向放电强化燃烧方案、平板式双排横向放电强化燃烧方案和平板式多排纵向放电强化燃烧方案.对每种方案的优缺点进行了分析;设计了丝电弧等离子体强化超声速点火和燃烧的放电特性试验系统,并进行了初步的放电试验.

直流双阳极电弧等离子体炬的数值模拟

为了提高等离子体废物处理效率,根据磁流体动力学理论,利用计算流体力学软件FLUENT,采用磁矢量势的方法对直流双阳极非转移型电弧等离子体炬进行了二维轴对称数值模拟。计算中采用了SIMPLE算法。数值模拟得到了等离子体的温度、速度等分布。结果表明,等离子体的温度随着轴向距离的增加而减小,随弧电流增加而增加;其速度随着轴向距离的增加而先增大后减小,随弧电流增加而增加;等离子体炬出口处的温度和速度随着径向距离的增加而减小。这些结果与实验结果基本相符。