Numerical simulation of flash reduction in a drop tube reactor with variable temperatures

A computational fluid dynamics(CFD)model was developed to accurately predict the flash reduction process,which is considered an efficient alternative ironmaking process.Laboratory-scale experiments were conducted in drop tube reactors to verify the accuracy of the CFD model.The reduction degree of ore particles was selected as a critical indicator of model prediction,and the simulated and experimental results were in good agreement.The influencing factors,including the particle size(20–110μm),peak temperature(1250–1550°C),and reductive atmosphere(H_(2)/CO),were also investigated.The height variation lines indicated that small particles(50μm)had a longer residence time(3.6 s)than large particles.CO provided a longer residence time(~1.29 s)than H_(2)(~1.09 s).However,both the experimental and analytical results showed that the reduction degree of particles in CO was significantly lower than that in H2 atmosphere.The optimum experimental particle size and peak temperature for the preparation of high-quality reduced iron were found to be 50μm and 1350°C in H2 atmosphere,and40μm and 1550°C in CO atmosphere,respectively.

Undercooling and solidification of Ni_(77)P_(23) alloy in a 52-m drop tube

This paper applies techniques of containerless processing, drop tube and glass fluxing, to undercool and solidify Ni77P23 alloys. Different diameter spheres were collected at the bottom of a 52-m long drop tube. Both crystalline and amorphous phase were formed in various size specimens due to the different cooling rate. The variation of partial undercooling with bulk undercooling is calculated for the Ni77P23 alloys. The deep undercooling and rapid solidification behaviour of Ni77P23 melts has been analysed with respect to microstructure formation and transition during fluxing and 52-m drop process of undercooled melts.

Microstructure of Pd_(77.5)Au_6Si_(16.5) Alloy Droplet Solidified in a Drop Tube Process

The microstructure development of Pd77.5Au6Si16.5 alloy droplet solidified in a drop tube process was studied. It was found that two distinct microstructures, i.e. (Pd,Au)3Si primary phase and Pd+(Pd,Au)3Si eutectic can be obtained when the droplet diameter is within the range between 2.3~0.4 mm. The morpologies of the (Pd,Au)3Si developed from dendrite trunk-like with single branching only into dendrite cluster-like with ternary branching with the decrease of the droplet diameter. When the droplet diameter is about 0.25 mm, the primary phase (Pd,Au)3Si almost disappears and the microstructure mainly shows Pd+(Pd,Au)3Si eutectic. The morphology of the eutectic transforms from fiber-like to plate-like with the decrease of the droplet diameter in the range between 2.3-0.25 mm. When the droplet diameter is about 0.19 mm, the microstructure is only the single phase of Pd solid solution

Rapid solidification of steel droplets with different carbon contents in drop tube

Rapid solidification is regarded as being an effective method to refine the microstructure and reduce or eliminate the segregation of alloying elements.In this study the microstructures of rapid solidified carbon steel droplets (cooled in silicone oil) with different C contents by drop tube processing were observed.The volumes of droplets were set to be 2 mm×2 mm×2 mm (TM) and 5 mm×5 mm×5 mm (FM).For most samples,the microstructures are nearly the same from the surface to the center region.The microstructures of the FM samples with higher C content are much finer than those of the TM samples,which is the opposite of the situation with the lower C content samples.The distribution of C along the diameter of each sample was detected.The segregation of C was observed in TM samples with higher C contents while not in FM samples.This is regarded as relating to recalescence and the diffusion of C atoms during the solidification process.

Rapid solidification of Al-18%Si hypereutectic alloy in drop tube

The drop tube technique was performed to achieve rapid solidification of undercooled Al 18%Si hypereutectic alloy. The droplets ranging from 60～1 000 μm in diameter were obtained. The regular polygonal primary Si and lamellar eutectic homogeneously distribute on α (Al) matrix in the droplets larger than 500 μm. While in the droplets smaller than 500 μm the five star primary Si was found, which is often accompanied by some spherical eutectic grains. The different morphologies of primary Si are due to varied undercoolings. Scanning electron microscopy suggests that the spherical eutectic grain is composed of anomalous eutectic in its core and lamellar eutectic radiating outside from its periphery. Such eutectic microstructure is presumed to be the result of combining large undercooling, microgravity with containerless processing during free fall. [

Segregation of C and P in Steel Droplets Solidified in Drop Tube

The properties of steels can be improved by adding appropriate amount of alloying elements.However,the quality and properties of steels may be affected due to the segregation of the alloying elements.Rapid solidification was regarded to be an effective method to reduce or eliminate the segregation of alloying elements.While in this paper,the segregation of C and P was also observed in rapid solidified carbon steel droplets (in silicon oil) by drop tube processing.The distributions of alloying elements in 0.2m drop tube samples were similar to those in 50m drop tube samples.While in both 0.2m and 50m drop tube,the segregation of C and P was quite different when the contents of the samples were varied,the segregation profiles were discussed in detail.The microstructures of 50m droplet samples were a little finer than those of 0.2m droplet samples.The solidification speed was approximately the same from the surface to the center of each sample.In high-C samples,the microstructure was also corresponding to the distribution of C.

Heat transfer of micro-droplet during free fall in drop tube

To explore the heat transfer of micro-droplet during free fall in the drop tube, the falling velocity and microgravity level are calculated. The Newtonian heat transfer formulation is coupled with the classical heat conduction equation to predict the heat transfer process within micro-droplet. Based on the numerical solution by finite difference method with implicit Euler scheme,the temporal evolution of thermal information inside micro-droplet is obtained including the temperature distribution, cooling rate, temperature difference and gradient. To quantitatively reveal the mechanism how the various factors affect the heat transfer of micro-droplet, the effects of physical properties of liquid metal and cooling gas as well as the micro-droplet size are studied.As the important indicators of heat transfer process, the cooling rate and temperature difference are acquired to systematically investigate the relationship between thermophysical properties and heat transfer process of different metallic micro-droplets.

Morphologies of Fe-66.7 at.%Si alloy solidified in a drop tube

Solidification of 0.1―1.0 mm diameter droplets of Fe-66.7 at.%Si alloy was achieved in a 3 m drop tube. The XRD, EDS, and SEM measurements reveal that all the droplets are composed of the primary phase α and the α+ε eutectic. With decreasing droplet diameter, the growth mode of the primary phase α changes from faceted to nonfaceted growth and the eutectic changes from needle-like to anomalous eutectic. In addition, the width of the primary phase α decreases with decreasing droplet size. The different cooling rates and undercooling levels corresponding to the samples with different sizes are responsible for the morphology changes. The cooling rates of the samples with different diameters during free fall were calculated and their effects on the microstructure formation were discussed. This kind of transition is also found inside the same sample, which is due to the larger cooling rate on the surface than at the center.

High undercooling and rapid dendritic growth of Cu-Sb alloy in drop tube

Droplets of Cu-20%Sb hypoeutectic alloy has been rapidly solidified in drop tube within the containerless condition. With the decrease of droplet diameter, undercooling increases and the microstructures of primary copper dendrite refines. Undercooling up to 207 K (0.17 TL) is obtained in experiment. Theoretic analysis indicated that, because of the broad temperature range of solidification, the rapid growth of primary copper dendrite is controlled by the solutal diffusion. Judging from the calculation of T0 curve in the phase diagram, it is shown that the critical undercooling of segregationless solidification is △T0=474 K. At the maximum undercooling of 207 K, the growth velocity of primary copper phase exceeds to 37 mm/s, and the distinct solute trapping occurs.

Investigation of microgravity effect on solidification of medium-low-melting-point alloy by drop tube experiment

The solidification microstructure of Al-Ni, Al-Cu, Ag-Cu, Al-Pb and Cu-Co alloys quenched in silicone oil before and after free fall in evacuated 50 m drop tube were investigated contrastively. The effect of microgravity on the solidification process of medium-low-melting-point eutectic, monotectic and peritectic alloys were ana-lyzed and discussed. The results indicated that the effects of microgravity on the eutectic cell shape, the pattern in eutectic cell and the inter-eutectic spacing were different for different types of eutectic systems; the size distribution of Pb particles in Al-5wt% Pb monotectic alloy was significantly changed by microgravity; and the shape of retained primary α-Co phase in Cu-10wt%Co peritectic alloy was also changed by microgravity. These results are beneficial for people to further identify and analyze the solidification behavior of multiphase alloys under microgravity.

Containerless solidification of Zr_(41)Ti_(14)Cu_(12.5)Ni_(10)Be_(22.5) glass-forming alloy in drop tube

Droplets of Zr41Ti14Cu12.5Ni10Be22.5 glass forming alloys with different sizes are solidified in a drop tube containerless processing. Glass transition behavior, crystallization kinetics, and the phase evolution during annealing of the Zr41Ti14Cu12.5Ni10Be22.5 glassy spheres are investigated. The experimental results indicate that the apparent activation energy of the glass transition (Eg=435.5 kJ/mol), and the activation energy of the main crystallization reaction (Ep1 = 249.6 kJ/mol) are obviously different from those of bulk glass samples prepared by water quenched (Eg=559.1 kJ/mol and Ep1=192.5 kJ/mol). The difference is discussed in the view point of the atomic configuration of the liquid state of the metallic glass and nucleation mechanism.

Two Phase Pressure Drop Performance of Refrigerant in a Small Horizontal Smooth Tube with 2.5 mm inside Diameter

Two-phase flow pressure drop measurements were made during the phase change heat transfer process of R22 in a small horizontal smooth tube with 2.5 mm inside diameter. Conclusions can be drawn that the quality corresponding to the pressure gradient peak value of small tubes became higher than that of large tubes. The effect of quality to pressure drop becomes weak as the mass flux increases. The experiment data were compared with the predicated values of the state-of-the-art correlations from the open literature. The comparisons between the data and the predictions indicate that most of the state-of-the-art correlations fails to predict the experimental data. Chisholm model shows a relatively better predictive ability than the other empirical correlations although it has a mean deviation of 26.7%. But the predicated values of Chisholm model are lower by 50% than the experimental data when the quality becomes larger.

Experimental Study on Heat Transfer and Pressure Drop of Micro-Sized Tube Heat Exchanger

A micro-sized tube heat exchanger(MTHE) was fabricated, and its performance in heat transfer and pressure drop was experimentally studied. The single-phase forced convection heat transfer correlation on the sides of the MTHE tubes was proposed and compared with previous experimental data in the Reynolds number range of 500—1 800. The average deviation of the correlation in calculating the Nusselt number was about 6.59%. The entrance effect in the thermal entrance region was discussed. In the same range of Reynolds number, the pressure drop and friction coefficient were found to be considerably higher than those predicted by the conventional correlations. The product of friction factor and Reynolds number was also a constant, but much higher than the conventional.

Pressure Drop of Liquid–Solid Two-Phase Flow in the Vertical Tube Bundle of a Cold-Model Circulating Fluidized Bed Evaporator

A cold-model vertical multi-tube circulating fluidized bed evaporator was designed and built to conduct a visualization study on the pressure drop of a liquid–solid two-phase flow and the corresponding particle distribution.Water and polyformaldehyde particle(POM)were used as the liquid and solid phases,respectively.The effects of operating parameters such as the amount of added particles,circulating flow rate,and particle size were systematically investigated.The results showed that the addition of the particles increased the pressure drop in the vertical tube bundle.The maximum pressure drop ratios were 18.65%,21.15%,18.00%,and 21.15%within the experimental range of the amount of added particles for POM1,POM2,POM3,and POM4,respectively.The pressure drop ratio basically decreased with the increase in the circulating flow rate but fluctuated with the increase in the amount of added particles and particle size.The difference in pressure drop ratio decreased with the increase in the circulating flow rate.As the amount of added particles increased,the difference in pressure drop ratio fluctuated at low circulating flow rate but basically decreased at high circulating flow rate.The pressure drop in the vertical tube bundle accounted for about 70%of the overall pressure drop in the up-flow heating chamber and was the main component of the overall pressure within the experimental range.Three-dimensional phase diagrams were established to display the variation ranges of the pressure drop and pressure drop ratio in the vertical tube bundle corresponding to the operating parameters.The research results can provide some reference for the application of the fluidized bed heat transfer technology in the industry.

煤粉掺氨空气分级燃烧排放特性及炉内过程烟气特性试验

以往针对氨煤掺烧研究多集中在数值模拟及小型试验炉,大型试验炉上多为技术可行性的点工况试验。在一台50 kW自持燃烧下行试验炉中在不同工况下针对燃煤掺氨燃烧产物的排放和过程分布特性展开研究,重点分析了不同掺氨比例、燃尽风率及运行氧量的影响。为充分了解氨与煤燃烧过程中对NO生成的贡献,针对纯氨燃烧进行一系列试验。试验结果表明,空气分级燃烧可大幅降低燃煤掺氨燃烧NO的排放,掺氨比例为10%~90%时NO排放质量浓度在170~215 mg/m^(3),同纯煤燃烧NO排放质量浓度处于同一水平;最佳燃尽风比率维持在38%附近,继续增大燃尽风比率不会进一步降低NO排放,反而会导致燃烧不充分等负面影响。纯氨燃烧利用空气分级技术可以很好地控制出口NO浓度,但纯氨燃烧稳定性远不及氨煤掺混燃烧,运行氧浓度较低时易出现氨逃逸现象。燃煤掺混氨燃烧既可解决氨燃烧困难、出口NO排放浓度过高的问题,又可减少燃煤CO_(2)排放,是一项极具潜力的技术路线。

非均匀散热管对中冷器流动均匀性的影响

为了解决中冷器内部气体流动均匀性差的问题,提出了非均匀散热管中冷器。基于非均匀散热管设计了非均匀散热管中冷器,采用计算流体力学(CFD)方法对非均匀散热管中冷器的内部流动均匀性进行了研究。结果表明:在不改变中冷器气室的情况下,使用非均匀散热管能有效提高中冷器内部流动均匀性;非均匀散热管中冷器与传统中冷器相比,均匀性系数提高2.45%~3.51%,中冷器整体压降增加约7%。

R513A在水平螺纹管内冷凝换热性能与压降

为研究R513A在内螺纹管中的冷凝换热性能与流动特性,通过实验对R513A在外径为12.7 mm和9.52 mm的光滑管和内螺纹管中的冷凝换热系数和压降进行分析,实验工况为:质量流速50—270 kg/(m^(2)·s),冷凝温度33、35、38、40℃。结果表明:R513A与R134a在光滑管内的冷凝换热系数差值为-18.8%—-25.5%,在螺纹管内差值为-5.5%—0.8%,螺纹管对于R513A的管内冷凝换热效果的增强更为显著;R513A的压降比R134a低5.6%—17.8%;随着管径的减小,R513A的管内冷凝换热系数和压降均增大。Oliver关联式对所测试螺纹管的管内冷凝换热系数的预测精度最高,平均误差值约为14.56%;对于管内压降的预测,所选关联式的计算结果与部分实验值存在较大误差;新拟合的压降关联式对R513A在内螺纹管内冷凝的压降预测结果较好,95.32%的数据点在30%误差线之内。

水平管内高黏油水环输送减阻特性分析

随着人们对于石油资源需求的日益加深,常规原油逐渐枯竭。稠油的使用会成为一种趋势,世界稠油地质储量丰富,占全球石油剩余储量的70%,具有巨大的开发潜力和广阔的市场前景,但稠油自身具有黏度高、分子量大、流动性差的特点,这些性质为稠油的输送带来了极大的困难与挑战。因此,加快我国稠油输送技术及相关理论的研究创新是适应未来趋势变化的客观要求,是经济有效地开发输送稠油资源的必然选择。本文采用水环输送法对稠油水平管流减阻,用以探究水环包裹下的稠油水平管流阻力特性,分析入口含水率(5%~80%)、油(0.65~1.57m^(3)/h)、水(0.09~2.13m^(3)/h)相流量对于水环润滑减阻效果以及稠油流型的影响,自主设计水环输送稠油实验环道,引入有效粗糙度k*,建立环状流压降预测修正模型,分析讨论流型特征及形成环状流时的油水流量范围,结果表明:在一定条件下形成的水环能够有效地对稠油输送进行减阻;水环可以有效润滑管壁;修正后的压降预测模型与实验值对比相对误差介于±10%,RMSE=0.02,水环输送压降仅占纯油输送压降的0.01~0.24;油相流量较高时应注意水相流量,避免过大导致输油效率η以及减阻率DR下降。

R410A水平三维强化管蒸发换热实验

针对传热管内蒸发换热特性,开展了R410A在铜及不锈钢光管和涟漪纹管管内换热特性的实验研究,分析了部分流型对管内蒸发的换热机理。实验工况:饱和温度为6℃,制冷剂质量流速为100~200 kg·(m^(2)·s)^(-1),干度范围0.1~0.9。验证了光滑管内的流型,结果与Wojtan流型图的预测具有较好的一致性。实验结果表明:蒸发换热系数随质量流速增加而增加。换热系数与流型相关。压降主要取决于质量流速和干度。与光滑管相比较,传热强化率为1.27~1.96,沸腾压降增加了11%~36%。