Fluid Mechanics and Heat-Transfer Operations Combination Involved in Urea Unit of Fertilizer Complex

Fertilizer plants are most complex plants in the world (Rashid et al., 2013, Process Safety Progress) and its good opportunity to learn science from operations involved in these plants. Fluid mechanics and heat transfer operations combination involved in fertilizer complexes are explored in this article.

Investigation on heat-transfer-coefficient between aluminum alloy and organic/inorganic sand mold based on inverse method

A kind of cylinder sand mold was designed to investigate the heat-transfer-coefficients (HTCs) between aluminum alloy and organic/inorganic binder bonded sand mold during the solidification processes. Temperature during the solidification process was recorded and input into the simulation software. The inverse model of MAGMA was used to calculate the HTC based on the actual temperature. Results show that the temperature of the inorganic sand mold increased faster than the organic sand mold;while the temperature of the casting part with the inorganic sand mold decreased faster. The optimal HTCs between Al and the organic/ inorganic sand mold are confirmed to be 300 to 700 and 1000 to 1800 W·m^-2·K^-1, respectively, along with the change of solid-liquid phase line. The simulated temperature curves show the same trend as the measured ones. The maximum deviation between the two temperature curves are 17.32℃ and 18.77℃ for castings by inorganic and organic sand molds.

Interfacial heat-transfer between A356-aluminium alloy and metal mould

The interfacial heat-transfer coefficient at casting/mould interface is a key factor that impacts the simulation accuracy of solidification progress.At present,the simulation result of using available data is comparatively different from the practice.In the current study,the methods of radial heating and electricity measurement under steady-state condition were employed to study the nature of interfacial heat-transfer between A356 Aluminum alloy and metal mould.The experimental results show that the interfacial heat-transfer between A356 Aluminum alloy and the outer mould drops linearly with time while that of A356 aluminum alloy and the inner mould increases with time during cooling.The interfacial heat-transfer coefficient between A356 aluminum alloy and mould is inversely proportional to the electrical resistance.

Heat-transfer model on the improvement of continuous casting slab temperature

A heat transfer model on the solidification process has been established onthe basis of the technical conditions of the slab caster in No.3 steel works of Wuhan Iron & SteelCorporation, and the temperature field in the solidifying slab was calculated which was verified bythe measured slab surface temperature. The influences of the main operating factors includingcasting speed, spray cooling patterns, superheat of melt and slab size on the solidification processwere analyzed and the means of enhancing the slab temperature was brought forward. Raising thecasting speed to 1.3 m/min, controlling the flowrate of secondary cooling water and improving thecooling pattern at the lower segments of secondary cooling zone could improve the slab temperatureeffectively. And the increasing the superheat is adverse to the production of high temperature slab.

Numerical simulation of the drag and heat-transfer characteristics around and through a porous particle based on the lattice Boltzmann method

Porous particle flow is universal in nature and industry.However,in previous numerical simulations,porous particles have usually been assumed to be solid.It is necessary to study the flow and heat-transfer characteristics around porous particles because they are greatly different from those of impermeable particles.In this study,two-dimensional steady flow and heat transfer around and through a porous particle with a constant temperature placed in a cold fluid were numerically investigated.The effects of the Reynolds number(Re)and Darcy number(Da)on the flow and heat-transfer characteristics were investigated in detail.The investigated ranges of the parameters were 10≤Re≤40 and 10^(−6)≤Da≤10^(−2).It is sophisticated to simulate porous particles with traditional simulation methods because of their complicated structure.Therefore,the lattice Boltzmann method was used to solve the generalized macroscopic governing equations because of its simplicity.The drag coefficient decreased with increasing Re or Da,but the decrease was not prominent in the range 10^(−6)≤Da≤10^(−4).The heat-transfer efficiency of the front surface was much stronger than that of the rear surface.The heat-transfer efficiency between the particle and the fluid increased with increasing Re or Da.However,for 10^(−6)≤Da≤10^(−4),the increase was not prominent and the heat-transfer enhancement ratio was slightly larger than one.Furthermore,the effect of Da became more prominent at larger Re.In addition,new correlations for the drag coefficient and surface-averaged Nusselt number were obtained based on the simulated results.

Time-accurate CFD conjugate analysis of transient measurements of the heat-transfer coefficient in a channel with pin fins

Heat-transfer coefficients(HTC)on surfaces exposed to convection environments are often measured by transient techniques such as thermochromic liquid crystal(TLC)or infrared thermography.In these techniques,the surface temperature is measured as a function of time,and that measurement is used with the exact solution for unsteady,zero-dimensional(0-D)or one-dimensional(1-D)heat conduction into a solid to calculate the local HTC.When using the 0-D or 1-D exact solutions,the transient techniques assume the HTC and the free-stream or bulk temperature characterizing the convection environment to be constants in addition to assuming the conduction into the solid to be 0-D or 1-D.In this study,computational fluid dynamics(CFD)conjugate analyses were performed to examine the errors that might be invoked by these assumptions for a problem,where the free-stream/bulk temperature and the heat-transfer coefficient vary appreciably along the surface and where conduction into the solid may not be 0-D or 1-D.The problem selected to assess these errors is flow and heat transfer in a channel lined with a staggered array of pin fins.This conjugate study uses three-dimensional(3-D)unsteady Reynolds-averaged Navier-Stokes(RANS)closed by the shear-stress transport(SST)turbulence model for the gas phase(wall functions not used)and the Fourier law for the solid phase.The errors in the transient techniques are assessed by comparing the HTC predicted by the time-accurate conjugate CFD with those predicted by the 0-D and 1-D exact solutions,where the surface temperatures needed by the exact solutions are taken from the time-accurate conjugate CFD solution.Results obtained show that the use of the 1-D exact solution for the semi-infinite wall to give reasonably accurate“transient”HTC(less than 5%〇relative error).Transient techniques that use the 0-D exact solution for the pin fins were found to produce large errors(up to 160%relative error)because the HTC varies appreciably about each pin fin.This study also showed that HTC measured by transient techniques could differ considerably from the HTC obtained under steady-state conditions with isothermal walls.

η_m FOR THE HEAT-TRANSFER LAW q∞△1/T

Curzon and Ahlborn considered firstly the irreversibility of heat-transfer in the Carnot cycle, and derived the efficiency of a Carnot cycle at maximum power

Experimental study of heat-transfer coefficient of Al-Zn-Mg-Cu ultra-thick hot plate during multi-stage quenching

Experiments were conducted to investigate the cooling manner of an ultra-thick hot aluminum alloy plate during multistage quenching. Cooling curves and heat flux curves of different rapid quenching flux varied from 23 to 40 L min^(-1) and were analyzed in detail. In this investigation, cooling process was divided into the following four steps:(I) starting step,(II) rapid cooling step,(III) slow cooling step, and(IV) stopping step. Based on the curves, the calculation method for surface transfer coefficient was provided, and the effects of coefficient on surface temperature and quenching flux were discussed. Results showed that the transfer coefficient disagreed with heat flux and that it is a nonlinear function of surface temperature. The highest coefficient was observed not in the rapid cooling step with the largest heat flux but in the slow cooling step with lower heat flux. The coefficient increased with surface temperature ranging from 480 to 150°C, and a coefficient peak appeared in the temperature range of 150–100°C. The coefficient also increased with quenching flux. Finally, a simulation was performed using the finite element method to verify the reliability of the coefficient results, which showed good agreement with the measurement values.

基于六水氯化钙的单相变材料热二极管的实验研究

基于相反传热方向上相变程度不同引起的传热形式和系数差异设计的相变材料热二极管被认为是有潜力的热管理器件.然而多种材料的使用或仅依靠数值模拟的研究使其结构复杂或理想化,降低了其实际应用的可能性.因此,本文结合材料固液相变和自然对流过程的传热形式和传热系数变化,提出了一个仅含有CaCl_(2)·6H_(2)O单相变材料的简单热二极管结构,并制备了相应的器件,搭建了稳态热通量测试系统用于实验研究,其测量结果与文献记载值相近,具有良好的准确度,实验研究了冷热端温差和正反传热方向对热二极管热整流效果的影响规律.结果表明:热二极管的热通量随冷热源温差的减小而降低,正向和反向分别沿逆重力和重力方向时,热整流比最高可达1.58,最佳冷源温度范围为20-25℃,接近室温,所提出的相变材料热二极管结构在建筑节能和热管理等方面具有一定的应用潜力.

4种用于温室除湿的亲水翅片管蒸发器热湿传递性能分析

温室冬季高效除湿需求已经成为制约中国温室产业高质量发展的技术难题之一。为了提高温室用冷冻除湿系统中亲水翅片管蒸发器的热湿传递性能,该研究建立了低温高湿工况下平翅片、带涡产生器平翅片、波纹翅片、开缝翅片4种亲水翅片管蒸发器空气侧的数值传热模型,采用蒸发器的换热量Q、努塞尔特数Nu、摩擦因子f、单位翅片面积析湿量和强化传热因子JF等评价参数,对比分析了低温高湿工况下4种亲水翅片管蒸发器空气侧热湿传递性能。结果表明,与平翅片相比,带涡产生器平翅片、波纹翅片、开缝翅片空气侧的Nu、Q和f均高于平翅片,且开缝翅片的Q和f在相同条件下均最大;4种翅片的f随入口风速的增大而大幅度减小,而相对湿度对f的影响较小;单位翅片面积析湿量均随入口风速和相对湿度的增大而增大,波纹翅片的除湿能力最优;在入口风速1~4 m/s和相对湿度80%~95%条件下,波纹翅片管蒸发器的JF因子平均值最大,其热性能最优;在冬季寒冷地区低温高湿的温室中,推荐选用波纹亲水翅片管蒸发器对温室内空气进行除湿。该研究可为温室低温高湿环境下除湿系统用亲水翅片管蒸发器的设计与应用提供参考。

影响工业还原罐内铝热法炼镁过程还原效率的因素

在工业还原罐内进行铝热还原炼镁试验,分析影响还原效率的因素。结果表明:结晶镁的氧化和燃烧以及原料混合不均匀是导致还原效率降低的主要原因;原料混合不均匀导致贫铝区和MgO剩余,促进生成12CaO·7Al_(2)O_(3)和CaO·Al_(2)O_(3);对于富铝区域,MgO和CaO同时被还原,生成Mg_(2)Ca相。辐射传热和化学反应吸热是影响还原速率的关键因素;提高加热温度能够迅速提高球团层的温度,进而使球团获得足够的反应速度;此外,球团中含镁量越高,需要的反应时间越长。

铝车轮铸造模具水冷界面换热系数反算求解

铝车轮低压铸造过程中,模具温度场是影响铝液凝固的重要因素。水冷作为铸造模具的主要冷却方式,对模具温度场的影响机理仍不明晰,有待深入研究。本文以铝车轮铸造模具的边模水冷模块为研究对象,设计水冷降温实验并采集水冷过程中的模具温度数据。通过ProCAST及ANSYS分析冷却水流动状态,以实测温度数据为基础进行软件反求解,基于Beck非线性估算法,建立界面换热数值模型。通过对比分析两种界面换热系数求解方式,并正向求解以验证两种求解方式的准确性,以期为铝车轮低压铸造模拟验证提供数据支撑,有望获取冷却水与模具的真实换热系数,并揭示其传热行为和换热机理。

航天器用界面导热填料应用状态接触传热系数分析

为解决航天器用RKTL-DRZ-2型导热脂及RKTL-DRNJ-1型导热凝胶2种新开发导热填料无实际应用状态下接触传热系数数据的问题,采用试验方法对其接触传热系数进行研究,得到在航天器上设备典型尺寸及不同固定螺钉分布情况下的接触传热系数。试验结果表明:在相同安装状态下,与目前常用的RKTL-DRZ-1型导热脂相比,RKTL-DRZ-2型导热脂对界面接触传热性能改善效果较好,RKTL-DRNJ-1型导热凝胶较差。此外,获取了保证导热填料填充效果的实施经验,并给出了导热填料的选用建议。试验分析结论可应用于选用导热填料时的航天器热设计及热控实施。

磁场诱导矩形通道内铁磁流体流动及强化传热

为深入研究外加磁场作用下矩形通道中铁磁流体的流动及换热性能,基于有限体积法对其进行数值仿真计算。分析铁磁流体在不同雷诺数Re、磁场强度B下对努塞尔数Nu及流体阻力系数f的影响,重点对比3种热边界条件下磁场诱导铁磁流体旋流流动的特点、强化传热效果及综合强化性能。结果表明:当外加磁场作用于铁磁流体时,由于磁场-流场-温度场的协同作用,3种热边界条件下,矩形通道内的铁磁流体均产生不同结构的旋流流动,明显强化其传热效果,且施加的磁场强度越大,强化传热效果越好,综合性能更优。在研究范围内,通过对3种热边界条件的比较,四面受热、上下两面受热和底面受热的综合强化因子最大值分别达到了1.372、2.277、2.299。

基于床层传热的皮江法炼镁过程优化

球团在还原罐内传热导致的温度梯度是限制皮江法还原反应的关键因素.本文采用数值方法研究了球团尺寸、装料方式、还原罐外壁温度等因素对床层温度分布、还原率分布的影响.结果表明:在球团直径为22.3 mm、还原时间相同时能够获得最大的还原率;生产过程中应尽量提高还原罐外壁温度;床层中心区域温度低,还原反应速率慢,反应滞后;通过中心留空的方法能够有效缩短还原周期,提高原料利用率;以单位体积、单位时间镁的产量为依据,对于内径为270 mm的还原罐,当中心留空区域的直径小于27 mm时,可获得最大生产效率.

基于场协同理论的热空气吹掠型太阳能蒸馏器对流传热性能优化分析

以热空气吹掠型太阳能蒸馏器为研究对象,利用数值模拟结果和均匀设计法分析蒸馏器内流动与传热场协同角的变化规律和影响因素。结果表明,影响场协同角的主要因素是热空气进口速度,热空气进口温度和水温的影响不显著。在蒸馏水温30~70℃、进口空气温度40~90℃,进口空气速度为8 m/s时平均传热场协同角最小,为73.14°,传热系数最大,可达到同等条件下自然对流传热系数的4倍。

微尺度下润湿性表面对双气泡传热特性的影响

为探究混合润湿表面双气泡生长过程的特点和传热特性,利用格子Boltzmann方法研究混合润湿性表面不同因素对生长和传热过程的影响规律。结果表明:对于纯润湿性表面,随着润湿性的降低,气泡成核时间减少,气泡脱离表面时间呈增加趋势,双气泡生长过程的平均热流密度呈减少趋势。混合表面可以实现相比纯润湿性表面更高的脱离频率和更好的换热效果,混合润湿表面整体脱离频率在(L_(q)/△x)>0.37(△x<30)时呈增加趋势,在(L_(q)/△x)≤0.37(△x≥30)时呈降低趋势;同一距离L_(q)/△x不同疏水尺寸的脱离频率在(L_(q)/△x)>0.37(△x<30)时呈先降低后增加趋势,在(L_(q)/△x)≤0.37(△x≥30)时呈增加趋势;同一距离L_(q)/△x不同疏水尺寸的平均热流密度在(L_(q)/△x)>0.37(△x<30)时呈降低趋势,L_(s)=3(L_(s)/L_(q)=0.27)是最佳换热尺寸,在(L_(q)/△x)≤0.37(△x≥30)时呈先增加后降低趋势,L_(s)=5(L_(s)/L_(q)=0.45)为最佳换热尺寸。

冷却通道对引射器红外辐射特性影响的研究

为降低燃气轮机排气系统中的引射器排气温度,从而减少排出燃气的红外辐射强度,本文提出了一种具有冷却通道的亚音速引射器结构,并提出了评价冷却通道引射器的综合系数。在原有的引射器喷嘴内增加冷却通道,使冷气直接与主流中心位置的高温气体掺混,破坏排气包覆性分布,达到提高主流温度均匀性、降低中心温度的目的。本文运用数值模拟的方法,研究引射器内冷却通道数量、冷却通道进深和排气通道的排布对引射器内阻力特性、换热特性、出口温度分布特性的综合影响。研究结果表明:单排冷却通道排布时,通道数量与换热特性成正比,与阻力损失成反比;双排冷却通道排布时,阻力损失降低。双排12通道引射器可有效降低出流总温,均匀主流温度,综合系数最高。

三维变形管MVR蒸发器用于纤维素生产末端废水零排放项目

蒸发器的换热性能对机械蒸汽再压缩(MVR)系统投资及运行均有着重要影响。MVR蒸发器的管内传热与压降性能在基于三维变形管和直圆管的情况下存在明显差异。建立了考虑盐水浓度修正的三维变形管MVR蒸发器性能准则关联式,设计一套用于纤维素生产末端废水零排放项目的新型蒸发器。应用实践表明,相对于传统直圆管的MVR蒸发器,基于三维变形管的新型MVR蒸发器节材节能效果显著,其在节省29%换热面积的情形下仍能完全满足工程实际需要。在现场调研期间MVR系统处理每吨废水的压缩机耗电量在18.81~23.78 kW∙h之间,体现出新型蒸发器高能效的技术特性,极具应用推广价值。