Professional Documents
Culture Documents
College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210096, China
School of Energy and Environment, Southeast University, Nanjing 210096, China
a r t i c l e in f o
a b s t r a c t
Article history:
Received 23 January 2009
Received in revised form
9 October 2009
Accepted 21 December 2009
Available online 4 January 2010
A kineticfrictional model, which treats the kinetic and frictional stresses in an additive manner, was
incorporated into the two uid model based on the kinetic theory of granular ow to simulate three
dimensional ow behaviors of dense phase pneumatic conveying of pulverized coal in horizontal pipe.
The kinetic stress was modeled by the kinetic theory of granular ow, while the friction stress is from
the combination of the normal frictional stress model proposed by Johnson and Jackson [1987.
Frictionalcollisional constitutive relations for granular materials, with application to plane shearing.
Journal of Fluid Mechanics 176, 6793] and the modeled frictional shear viscosity model proposed by
Syamlal et al. [1993. MFIX documentation and theory guide, DOE/METC94/1004, NTIS/DE94000087.
Electronically available from http://www.mx.org], which was modied to t experimental data. For
the solid concentration and gas phase Reynolds number was high, the gas phase and particle phase
were all treated as turbulent ow. The experiment was carried out to validate the prediction results by
three kinds of measurement methods. The predicted pressure gradients were in good agreement with
experimental data. The predicted solid concentration distribution at cross section agreed well with
electrical capacitance tomography (ECT) image, and the effects of supercial velocity on solid
concentration distribution were discussed. The formation and motion process of slug ow was
demonstrated, which is similar to the visualization photographs by high speed video camera.
Crown Copyright & 2009 Published by Elsevier Ltd. All rights reserved.
Keywords:
Kinetic theory
Pneumatic conveying
Dense phase
Friction stress
Slug ow
1. Introduction
High pressure and large-scale entrained bed gasication
technology is one of the promising coal gasication technologies
for IGCC, indirect coal liquefaction, chemical fertilizer, hydrogen
production and fuel cell, etc, while dense phase pneumatic
conveying of pulverized coal at high pressure is one of the most
important techniques in coal gasication process. Due to the
inherent complexity of dense phase pneumatic conveying in
horizontal pipe, numerical simulation can provide valuable
insights into particle ow process, which are difcult to be
obtained from experiments.
In the framework of Eulerian approach, the solid phase was
commonly modeled with the kinetic theory of granular ow,
which was adopted by some authors (Lun et al., 1984; Sinclair and
Jackson, 1989; Ocone et al., 1993; Benyahia et al., 2000) to
simulate various gas solid ows. In the past few decades, the
dilute ow had been simulated with success based on the classic
Corresponding author.
0009-2509/$ - see front matter Crown Copyright & 2009 Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.ces.2009.12.025
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
2501
or the solid concentration could not be the criteria. When the gas
phase was insufcient to support all the particles in suspension, it
was regarded as dense phase conveying. That is to say, stratied ow,
slug ow and plug ow were all regarded as dense phase ow.
Because of the requirement of the gasier, the solid feeding was truly
continuous in our experiments. It was different from the plug ow,
which was separated by the gas phase. In experiments, the solids
loading ratio ranged from 7.54 to 15.26 and the solid concentration
was between 0.16 and 0.33. The solids loading ratio was not very
large. Compared with the pneumatic conveying at atmospheric
pressure, the transport pressure was much larger and ranged from
2.6 to 3.3 MPa. For example, when the transport pressure was
2.6 MPa, the gas density and the gas mass ow rate were 26 times
larger than those at atmospheric pressure. So the solids loading ratio
became less. But on the other hand, the ratio of solid mass ow rate to
gas volume ow rate was between 239 and 506 kg/m3 and the solid
mass ux was over 2100 kg/(m2s). These data showed the advantages
of our experimental setup. In our simulations, we focused on that
how to describe the deposited particles and the suspended particles
simultaneously.
There were almost no detailed published data on solid
concentration distribution in horizontal pipe, due to not only
their spatial and temporal complexities but also practical
difculties of the measurement. Differential pressure transducers
were usually used to measure the pressure drop; however, the
ow information was over-simplied. Traditionally, the ow
instabilities presented in the dense ow have been investigated
by the use of photography. This enabled extracting the shape of
the ow structures, but it must be remembered that particles can
remain in each others shadows and the data interpretation is
difcult (Jaworski and Dyakowski, 2002). Moreover, no information was available on the internal structure of the ow such as
solid volume fraction distribution. It is worth noting that the
Electrical Capacitance Tomography (ECT) becomes a promising
technique to overcome these weaknesses in recent years. In order
to validate the simulation results, three kinds of measurement
methods were employed to get more useful information in
experiments.
Only a few researches (Geldart and Ling, 1990; Chen et al.,
2007; Liang et al., 2007; Pu et al., 2008) on dense phase pneumatic
conveying at high pressure have been reported in the literatures
so far. Among them, little work on simulation of slug ow in
horizontal pipe was reported. Here a kineticfrictional model,
which was revised according to the pressure gradients from
experiments, was attempted to predict the slug ow for dense
phase pneumatic conveying at high pressure. In dense phase
pneumatic conveying in horizontal pipe at high pressure, the
average solid concentration was up to 30% at the pressure of
3.3 MPa in a conned space with high transport velocity. Thus it is
necessary to consider both kinetic stress and frictional stress. At
the same time, the particle phase and the gas phase were all
treated as turbulent ow due to high gas phase Reynolds and solid
concentration. Further details can be founded in literatures
(Zheng et al., 2001; Pu et al., 2008).
A kineticfrictional model, which considered the kinetic and
frictional stresses of the particle phase and the turbulence
interaction between gas phase and particle phase, was incorporated into the two uid model based on the kinetic theory of
granular ow to simulate three dimensional ow behaviors of
dense phase pneumatic conveying of pulverized coal in horizontal
pipe. The kinetic stress was based on the kinetic theory of
granular ow. For frictional stress, a normal frictional stress
model proposed by Johnson and Jackson (1987) and the modied
frictional shear viscosity model proposed by Syamlal et al. (1993)
were used, which was modied to t experimental data. The
experiments were carried out to validate the prediction results.
ARTICLE IN PRESS
2502
2. Experimental setup
The experiment apparatus used in this study is illustrated in
Fig. 1. The pulverized coal with average particle diameter of
37 mm and real density of 1350 kg/m3 was conveyed between two
pressurized hoppers (3) via a 53 m long and 10 mm inside
diameter pipe. As conveying gas, the nitrogen was introduced
into the system via a header (7) connected with sixteen nitrogen
cylinders (8) and then divided into three parts: pressurizing gas
(4), uidizing gas (5) and supplemental gas (6). The pressurizing
gas (4) was to maintain the stabilization of pressure in the
sending hopper. The uidizing gas (5) uidized the pulverized
coal at the bottom of the sending hopper, and then drove the
pulverized coal into the conveying pipe. The supplemental gas (6)
was used to adjust the nitrogen ow rate in a wide range and
prevent pipe from blockage to guarantee continuous transport of
pulverized coal. The pressure in the receiving hopper was
controlled by motor-driven valve (1). Each of the three nitrogen
ow rates was measured and controlled by a metal rotor ow
meter. The dosing hopper (3) was suspended on three load cells
(2), by which the pulverized coal mass ow rate was measured.
The EJA 430A differential pressure transducers (11) were used to
measure the pressure drops of sections in horizontal pipe, vertical
pipe and two bends. A computer data acquisition system was
employed to record the data of ow rates and pressure drops.
The ECT sensor consists of eight equally spaced sensing
electrodes of 10 mm long, is shown schematically in Fig. 2 (a).
The sensor pipe is made of quartz glass with 20 mm outer
diameter. The ECT sensor can provide dynamic information on the
spatial distribution of the composite permittivity of the gas solid
phase at 40 frames per second. From the permittivity data, the
14
Fig. 2. (a) Schematic of the ECT sensor and (b) visualization section.
3. Hydrodynamic model
The model adopted is based on the fundamental concept of
interpenetrating continua for multiphase mixtures. It is assumed
that different phases can be present at the same time in the same
computational volume. The fundamental equations of mass,
momentum, and energy conservation are solved for each
considered phase. The emerging kinetic theory of granular ow
provides a physical motivation for such an approach. Appropriate
constitutive equations have to be specied in order to describe
the physical and rheological properties of each phase and to close
the conservation equations.
3.1. Gas phase
3
2
Computer
13
@
ag rg r ag rg vg 0
@t
1
1
12
10
@
ag rg vg r ag rg vg vg ag rpg r sg bvg vs ag rg g
@t
2
1
10
where, mg,eff is the effective gas phase viscosity and I is the unit
tensor.
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
Res Z1000
ag rg ds jvs vg j
mg
Ys
1=2
Ys
1=2
p
2
10rs ds Ys p
4
1 1 ess as g0;ss
5
961 ess g0;ss
fsg 3bYs
Table 2
Frictional stress model.
ss sks sfs
Table 1
Kinetic theory of granular ow closures
Res o1000
2503
1=n1 )
p
f
f
mf p p
nn1
pc
2as S s : S s Ys =d2s
8 p
>
3
<
r vs 4 0
2 sin f
>
: 1:03r v o 0
s
"
#n1
r vs
p
pf 1p
pc
2n sin f Ss : Ss Ys =d2s
8 24
10
>
as;max r as
10 as;max as
>
>
>
< a amin r
s
s
amin
o as o as;max
pc F
s
> as;max as s
>
>
>
:0
a r amin
n
ARTICLE IN PRESS
2504
Ug
Gg
eg;in 2k3=4
=kD
g;in
ml;t
m
ra bU l U i i;t rai
al sl l
ai si
11
m
@
e
ai ri ei r ai ri U i ei r ai i;t rei i C1e ai Gk;i C2e ai ri ei
se
ki
@t
m
m
e
C3e i bCli kl Cil ki bU l U i l;t ral bU l U i i;t rai
ki
al sl
ai si
12
where Ui is the phase-weighted velocity, and Gk,i is the generation
of turbulent kinetic energy. The gas or particle phase turbulent
viscosity is dened as
mt;i ri Cm
k2i
ei
13
17
as;in
16
m
@
ai ri ki r ai ri U i ki r ai i;t rki ai Gk;i ai ri ei
sk
@t
14
15
pD2 =4
vsz;in
In the kinetic theory of granular ow, the granular temperature describes the particleparticle collisions and is introduced as
a measure of single particle velocity uctuation. Actually, particle
cluster is one of the most signicant features in dense phase
pneumatic conveying. Thus it is necessary to consider both smallscale uctuation due to particleparticle collision and large-scale
particle uctuation due to particle turbulence (Pu et al., 2008).
Gas/particle turbulent kinetic energy and turbulent kinetic energy
dissipation rate equation (i= gas, solid, l ai) are given by
60 Ug
12r=D1=7
49 1as;in
Ms
18
as;in rs pD2 =4
Ms
Mg
rs
rg
Ms
rs
!1
19
ks;in 0:004v2s;in
20
3=4
es;in 2ks;in
=kD
21
Ys;in 0:004v2s;in
22
p
p
a p
a
3
3
prs g0;ss j s
Ys jvsw j2
prs g0;ss 1e2w s Y3=2
6
4
as;max
as;max s
24
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
P
jR j
PCV F o d
CV jFj
25
16
16
Ms = 0.167kg/s
prediction
experimental data
prediction
2505
12
12
8
Ug (m/s)
10
12
10
12
Ug (m/s)
Fig. 3. Pressure gradient vs. supercial velocity: (a) transport pressure 3.3 MPa and (b) transport pressure 2.6 MPa.
Fig. 4. Solid volume fraction distribution at cross section and central vertical plane (a) ECT image of solid volume fraction, (b) solid volume fraction contours simulated and
(c) solid volume fraction contours simulated at central vertical plane.
ARTICLE IN PRESS
2506
Symbol
Values
Units
Psend
Prec
Ms
D
Ug
ds
ess
ew
3.6
2.8
0.227
10
6.37
80
0.8
0.6
0.02
28.5
0.55
MPa
MPa
kg/s
F0
F
as,max
mm
m/s
mm
dimensionless
dimensionless
dimensionless
dimensionless
5.50E-01
5.21E-01
4.92E-01
4.63E-01
4.34E-01
4.05E-01
3.76E-01
3.47E-01
3.18E-01
2.89E-01
2.61E-01
2.32E-01
2.03E-01
1.74E-01
1.45E-01
1.16E-01
8.68E-02
5.79E-02
2.89E-02
1.00E-06
5.50E-01
5.21E-01
4.92E-01
4.63E-01
4.34E-01
4.05E-01
3.76E-01
3.47E-01
3.18E-01
2.89E-01
2.61E-01
2.32E-01
2.03E-01
1.74E-01
1.45E-01
1.16E-01
8.68E-02
5.79E-02
2.89E-02
1.00E-06
Ug = 4.82m/s
Ug = 8.15m/s
5.50E-01
5.21E-01
4.92E-01
4.63E-01
4.34E-01
4.05E-01
3.76E-01
3.47E-01
3.18E-01
2.89E-01
2.61E-01
2.32E-01
2.03E-01
1.74E-01
1.45E-01
1.16E-01
8.68E-02
5.79E-02
2.89E-02
1.00E-06
Ug = 9.52m/s
Fig. 5. Prediction of solid volume fraction at different supercial velocity: (a) Ug = 4.82 m/s, (b) Ug =8.15 m/s and (c) Ug = 9.52 m/s.
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
in Fig. 4b, the cross section can be divided into three parts: the
dilute regime (a), the intermediate regime (b) and the dense
regime (c). The dilute regime (a) locates at the upper part of the
pipe, where the particles experience short and fast collisions.
The dense regime (c) locates at the lower part of the pipe, where
the particle concentration is high and the particles experience
enduring contacts giving rise to frictional stress. For horizontal
pneumatic conveying in a conned volume, the intermediate
regime (b) is typically expected to exist at the interface between
the dense regime and the dilute regime, where both collision and
frictional stresses might be present. It is commonly believed that
there exists erce mass and momentum exchange of particle
phase both between the intermediate regime and the dilute
regime and between the intermediate regime and the dense
regime. Some particles in the dilute regime enter into
the intermediate regime due to gravity, at the same time some
particles in the intermediate regime enter into the dilute regime
due to particleparticle collisions or dragging by gas. The same
case happens between the intermediate regime and the dense
regime. It also can be founded that there are no clear boundaries
among these regimes. It indicates that the particle movement in
the pipe is very complex and affected by many factors. Fig. 4c
shows the simulated solid volume fraction contours at central
vertical plane. From the picture, it can be seen that the ow type
predicted belongs to stratied ow.
Fig. 5 shows the predicted solid volume fraction contours at
different supercial velocity. Here the solid mass ow rate is
0.177 kg/s with the particle diameter of 37 mm, the supercial gas
velocity Ug is 4.82 m/s, 8.15 m/s and 9.52 m/s, respectively. It is
clearly observed that as the supercial velocity increases, the
settled layer becomes thinner, which ts common sense. Two
factors may contribute to the phenomenon. For the solid mass
ow rate constant, the particle velocity increases with the
supercial velocity increasing. It leads to the solid volume
fraction decrease. On the other hand, the gas velocity
uctuations become stronger at higher supercial velocity,
which enhances the mass and momentum exchange of particle
phase between the dilute regime and dense regime and leads to
the settled layer decrease.
result, it is impossible to comprehensively validate the predictions of the model, and so it is decided to compare the similarity
between the characteristics of the predicted ow eld and the
experimentally determined ow elds. Thus, a qualitative
comparison is presented.
1.2
1.0
as/as,in
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
Time(s)
1.0
1.2
1.4
2507
1.6
ARTICLE IN PRESS
2508
Pulverized coal is fed into the pipe inlet during a time interval
of 0.3 s. During that period, a long slug with high particle layer is
formed near the pipe inlet in Fig. 7. After the rst 0.3 s, only gas
ow enters into the pipe inlet. Thus, a long slug built articially
during the rst 0.3 s of the numerical simulation is formed. As
time proceeds, the slug moves from the right to the left (t= 0.3
0.7 s). Finally the slug moves away from the pipe (t = 0.71.0 s). In
addition, moving slug leaves a thinner layer behind it and short
afterwards the layer is carried away by gas until the pipe becomes
empty (t= 1.11.5 s).
Fig. 8 shows the pressure history at Z =2500 mm. The pressure
at Z =2500 mm keeps constant until the slug does not arrive
10000
Pressure (Pa)
8000
6000
4000
2000
0
0.0
0.2
0.4
0.6
0.8
Time (s)
1.0
1.2
1.4
1.6
direction
t = 0s
t = 0.016s
t = 0.032s
t = 0.048s
t = 0.064s
t = 0.08s
Fig. 7. (Continued)
t = 0.096s
Fig. 9. Visualization photos of single slug ow in the horizontal pipe with high
speed camera.
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
2509
(t =00.4 s). When the forehead of the slug arrives the pressure
begins to increase (t = 0.40.7 s), then the pressure reaches a
constant value when the tail of the slug leaves (t =0.70.8 s). After
the slug arrives at the outlet of the pipe, the pressure begins to
decrease with the outow of the slug (t= 0.81.5 s). The simulation
results are similar to the description of the pressure change of
single slug by Fan (2002).
During the initial visualization test it was difcult to get the
clear photographs in the horizontal visualization section for the
pulverized coal with a diameter of 37 mm because of its strong
wall adhesion. In order to eliminate the particlewall adhesion,
the pulverized coal with a diameter of 300 mm was used. Fig. 9
shows a series of seven photographs illustrating a passage of
single slug through the visualization section in the horizontal
pipe. By comparing Fig. 9 with Fig. 7, it can be seen that the
simulation results are similar to the characteristics of the
experimental ow elds. As the slug passes through the pipe
gradually, there is a thin layer left behind, as seen in Fig. 9
(t =0.096 s) which is similar to the prediction results in Fig. 7
t =1.1 s.
1.6
1.4
as/as,in
1.2
Fig. 11. Prediction of slug ow movement over central vertical plane.
1.0
0.8
5. Conclusions
0.6
0.4
0.0
0.1
0.2
0.3
0.4
0.5 0.6
Time (s)
0.7
0.8
0.9
1.0
ARTICLE IN PRESS
2510
Direction
t = 0s
t = 0.016s
t = 0.032s
t = 0.048s
Fig. 12. High speed camera visualization of slug ow in the horizontal pipe.
for friction stress. The gas phase and particle phase were treated
as turbulent ow, respectively. The experiment was carried out to
validate the prediction results. The solid concentration distribution at cross section was obtained and compared with the
measurement by ECT. Then the effects of supercial velocity on
solid concentration distribution were discussed. The formation
and motion process of slug ow was simulated and compared
with the photographs by high speed camera. Simulation results
are in good agreement with experimental data. Based on the
presented results, the following conclusions may be drawn:
ARTICLE IN PRESS
W. Pu et al. / Chemical Engineering Science 65 (2010) 25002512
Notation
CD
ds
D
ess
ew
g0,ss
g
Gg
Gk,i
kg
ks
kYs
M
n
pc
pf
pg
pks
Res
Ss
Ug
Ui
vg
vs
Acknowledgments
drag coefcient, dimensionless
diameter of solid particle, m
pipe inside diameter, m
particleparticle collision restitution coefcient,
dimensionless
particlewall collision restitution coefcient,
dimensionless
radial distribution function, dimensionless
gravitational constant, m s 2
the gas volume ow rate, m3 s 1
generation of turbulent kinetic energy of phase i,
kg m 1 s 3
gas phase turbulent kinetic energy, m2s 2
solid phase turbulent kinetic energy, m2s 2
transport coefcient of pseudo-thermal energy,
kg m 1 s 2
solid mass ow rate, kg s 1
exponent on the shape of yield surface,
dimensionless
critical state pressure, N m 2
frictional pressure in solid phase, N m 2
gas phase pressure, N m 2
kinetic pressure in solid phase, N m 2
particle Reynolds number, dimensionless
particle strain rate tensor, s 1
supercial velocity, m s 1
phase-weighted velocity of phase i, m s 1
gas velocity, m s 1
solid velocity, m s 1
Greek letters
ag
as
b
gYs
e
Ys
lks
mf
mg
mg,eff
mks
rg
rs
sg
ss
sfs
sks
us
f
f0
Fsg
Subscripts
g
s
max
min
2511
gas phase
solid phase
maximum
minimum
ARTICLE IN PRESS
2512
Sinclair, J.L., Jackson, R., 1989. Gas-particle ow in a vertical pipe with particle
particle interactions. A.I.Ch.E. Journal 35, 14731486.
Srivastava, A., 2001. Dense-phase gassolid ows in circulating uidized beds.
Ph.D. Thesis, Deptartment of Chemical Engineering, Princeton University.
Srivastava, A., Sundaresan, S., 2003. Analysis of a frictional-kinetic model for gas
particle ow. Powder Technology 129, 7285.
Sundaresan, S., 2000. Modeling the hydrodynamics of multiphase ow reactors:
current status and challenges. A.I.Ch.E. Journal 46, 11021105.
Syamlal, M., Rogers, W.A., OBrien, T.J., 1993. MFIX documentation and theory
guide, DOE/METC94/1004, NTIS/DE94000087. Electronically available from
/http://www.mx.orgS.
Tardos, G.I., 1997. A uid mechanistic approach to slow, frictional ow of powders.
Powder Technology 92, 6174.
Tardos, G.I., McNamara, S., Talu, I., 2003. Slow and intermediate ow of frictional
bulk powder in the coquette geometry. Powder Technology 131, 2339.
Tsuji, T., Yabumoto, K., Tanaka, T., 2008. Spontaneous structures in threedimensional bubbling gas-uidized bed by parallel DEM-CFD coupling
simulation. Powder Technology 184, 132140.
Tsuji, Y., Tanaka, T., Ishida, T., 1992. Lagrangian numerical simulation of plug ow
of cohesionless particles in a horizontal pipe. Powder Technology 71,
239250.
Van Wachem, B.G.M., Schouten, J.C., Van den Bleek, C.M., 2001. Comparative
analysis of CFD models of dense gassolid systems. A.I.Ch.E. Journal 47,
10351051.
Van Wachem, B.G.M., Almstedt, A.E., 2003. Methods for multiphase computational
uid dynamics. Chemical Engineering Journal 96, 8198.
Yang, D.Y., 2008. Study on electrical capacitance tomography with thick pipeline in
gas/solid two-phase ow. Ph.D. Thesis, Southeast University.
Zheng, Y., Wang, X.T., Zhen, Q., Wei, F., Jin, Y., 2001. Numerical simulation of the
gasparticle turbulent ow in riser reactor based on k-e-kp-ep two-uid model.
Chemical Engineering Science 56, 68136822.
Zhu, H.P., Zhou, Z.Y., Yang, R.Y., Yu, A.B., 2008. Discrete particle simulation of
particulate systems: a review of major applications and ndings. Chemical
Engineering Science 63, 57285770.
Zhu, H.P., Zhou, Z.Y., Yang, R.Y., Yu, A.B., 2007. Discrete particle simulation of
particulate systems: theoretical developments. Chemical Engineering Science
62, 33783392.
Zhu, K.W., Wong, C.K., Rao, S.M., Wang, C.H., 2004. Pneumatic conveying of
granular solids in horizontal and inclined pipes. A.I.Ch.E. Journal 50,
17291745.