While advances in Computational Fluid Dynamics have increased our understanding of single phase ow, the development of improved

simulation tools for multiphase ow and mixing demands further research into basic phenomena, says Professor Bengt Andersson

Improving the tools for better ow simulation

Part of a series of wider advances in the
Computational Fluid Dynamics eld, ow simulation tools have grown increasingly sophisticated and accessible over recent years, to a point where they are now widely used in the commercial sector. Specic computer programmes are now capable of simulating the interaction between liquids and gases at the boundary between the two states, bringing real benets to companies from across the commercial spectrum, including those from the aerospace, automotive and chemical industries. However, there is a lower limit to Computational Fluid Dynamics (CFD) in terms of the cell size it can simulate, which in turn can have a negative impact on the accuracy of the eventual tool. As such all phenomena smaller than the computational cells themselves must be modelled if precision is to be improved, an area that Professor Bengt Andersson of Chalmers University of Technology in Sweden is working to address. If for example you have a 10 cubic metre reactor then typically you will divide it into 1 million cells. In these circumstances each cell will be 10 millilitres in size, meaning that everything which happens on that scale has to be modelled. We need good models to describe this, the development of which is the focus of my research, he says. There are a number of factors to take into account in this work, including not only the behaviour of individual chemical agents, but also how they are likely to respond to the presence of other reactants. If you have two competitive reactions one fast and one slow then which reaction will occur earlier? asks Andersson. With the fast reaction the reactant will be consumed quite quickly, so after a short while there will be

Turbulent velocity perpendicular to main ow in a pipe at Re=16000 colored with axial vorticity ranging from -150 s-1 to 150 s-1

Concentration of species Sc=100 in turbulent boundary layer perpendicular to ow no reactant present, because the diusion is slow. This means that the slow reaction can then start to dominate. In order to understand that kind of process you need quite an accurate model to describe the mixing between the reactants.

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Basic phenomena

An understanding of basic phenomena is crucial to the wider goal of developing models suciently accurate to be used on large scales. Many of the simulations for large industrial projects like chemical reactors currently rely on relatively crude approximations of transport between the gas, liquid and solid states, and any inaccuracies can have knock-on eects further down the line, particularly in terms of the overall energy eciency of the eventual reactor. Commercial companies are correspondingly keen to understand the nature of liquid ow in ever-greater detail, a context in which Anderssons research into mass transfer in turbulent boundary layers takes on real practical signicance. If you have a large tank reactor and only have laminar ow then it will take a long time for the elements to mix together and generate a reaction. In this kind of situation we often want to induce turbulence so as to generate a chemical reaction. Viscosity usually acts as a stabilising force, but if the inertia or ow is very high then the viscosity might not be sucient to dampen instabilities. So its likely to become turbulent, he says. This kind of research has long informed product design, yet an improved understanding of turbulence and viscosity levels, and how they can be modied, can still bring real improvements to the performance of everyday applications. Sometimes you want to supress turbulence and sometimes you want to enhance turbulance. Central heating systems work through the distribution of hot water. We want the pressure drop associated with this distribution to be low, and then it can be decreased further by adding elements which increase the viscosity. Laminar ow up to higher velocities will mean a lower pressure drop, but if you have turbulence then the pressure drop will be much higher, explains Andersson. In chemical reactors we need good mixing and high velocities to enhance turbulence. However, if you have a very high velocity then the residence time will be very short, which will have an eect on the way the elements mix: will those elements have time to react if you have very high velocity? In addressing these kinds of questions Andersson builds on a core recognition that turbulence in mass transport is not random, but rather has a clearly dened structure, and that using only average turbulent quantities can lead to inaccuracies in the model. The development of accurate ow simulation tools thus demands that the size, lifetime and velocity distribution

Break-up of a liquid low viscous high surface tension drop (dodecane) in water

Break-up of high viscous low surface tension drop (octanol) in water

Coalescence of two bubbles

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EU Research

of small-scale phenomena be taken into account, and while the analysis of turbulent eddies turbulence indicators range from micrometers to meters in large chemical reactors is enormously complex, Andersson is condent that it will bring tangible benets. Understanding the structure of turbulence will help us understand the basic phenomena that occur in chemical reactors, he stresses. With the project also studying the breakup and coalescence of bubbles and drops, and utilising sophisticated experimental techniques, they are well-placed to develop models reecting the complexities of ow dynamics. Indeed, the use of high-speed, microscope-equipped cameras, planar laser induced uorescence (PLIF), and particle image velocimetry (PIV), allows for unprecedented levels of analytical depth. You need to introduce energy to form turbulent eddies; turbulent eddies attract energy from velocity gradients. In the case

of data, advances in computational power mean companies today can use ow simulation tools to gain data within a reasonable timeframe. Car manufacturers in particular recognise that simulation tools are a cheaper way of testing prototypes than conventional means, which has helped the project attract interest from across the commercial spectrum, and not just the automotive sector. We have Scania, Volvo, Saab and VolvoCars automotive companies in our competence centre. They dont want ready solutions, they want the basic understanding. We provide manufacturers with simulation tools which they can then use to develop products themselves. We have also been involved with a large project with Alfa Laval where they developed completely new chemical reactors, which they now sell on the commercial marketplace. They had some clever ideas about how to design the reactor so that it would generate turbulence

At a glance
Full Project Title
Sub-grid modelling of Turbulent Flows

Project Funding Swedish Science Council Contact Details

Project Coordinator, Professor Bengt Andersson Department of Chemical and Biological Engineering Chalmers University of Technology Goteborg Sweden T: +46 (0) 317 723 026 E: Per-Olof.Grande@med.lu.se W: www.chalmers.se/chem/EN/divisions/ chemical-reaction

Turbulence is of great interest to industry;

better combustion will allow the

the chemical industry will benet from higher

automotive and energy industries to reduce fuel consumption, while

yields and reduced use of raw materials
at lower velocities, says Andersson. While the commercial relevance of his work is undeniable, Anderssons research agenda is in no way limited by commercial interests, and includes a number of fundamental questions.We focus more on generic issues in the ow dynamics eld than specic problems, and work across a diverse range of areas, he continues. One large project, for which Im about to recruit one assistant professor and some PhD students, involves looking at instantaneous measurements of turbulence. I will introduce bubbles and drops into the turbulent eddys, or around the turbulent eddys, and follow the way they move around it. How are they attracted into the eddys? How are they broken up, what role does the velocity gradient and shear rate play? The question of mixing is also extremely important, how do you get the dierent compounds to be entrained into the turbulent eddys? These are the areas Im trying to move into now. Professor Bengt Andersson

of pipes, velocity gradients are located close to walls, at the furthest point from its centre, says Andersson. Turbulence is mostly generated close to boundary layers or between phases mainly solid and uid phases and when we understand turbulence we will also be better able to benet from it. This is of great interest to industry,in general; better combustion will allow the automotive and energy industries to reduce fuel consumption, while the chemical industry will benet from higher yields and reduced use of raw materials You lose a lot of engine power if you have a downstream pressure drop. Our understanding of basic phenomena can help reduce turbulence and pressure drop, although in general we are aiming for the opposite.

Project Coordinator
Professor Bengt Andersson, born in 1947, did his PhD in Chemical Reaction Engineering at Chalmers University 1977. He has divided his research between computational uid dynamics, CFD, and automotive catalysis in Competence Center for Catalysis. He was board member of the Science Council for Engineering Sciences 1999-2000 and chairman for Chemical Engineering in the Swedish Science Council 2007-2008.

Commercial links

This approach has developed in direct response to commercial needs, and while it still takes time to process large volumes

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experimental techniques, they are wellplaced to develop models reecting the complexities of ow dynamics. Indeed, the use of high-speed, microscope-equipped cameras, planar laser induced uorescence (PLIF), and particle image velocimetry (PIV), allows for unprecedented levels of analytical depth. You need to introduce

ready solutions, they understanding. We prov with simulation tools wh use to develop product have also been involved w with Alfa Laval where completely new chemica they now sell on

Turbulence is of great interest to indu better combustion will allow the

automotive and energy indu to reduce fuel consumption,

energy to form turbulent eddies; turbulent eddies attract energy from velocity gradients. In the case of pipes, velocity gradients are located close to walls, at the furthest point from its centre, says Andersson. Turbulence is mostly generated close to boundary layers or between phases mainly solid and uid phases and when we understand turbulence we will also be better able to benet from it. This is of great interest to industry,in general; better combustion will allow the automotive and energy industries to reduce fuel consumption, while the chemical industry will benet from higher yields and reduced use of raw materials You lose a lot of engine power if you have a downstream pressure drop. Our understanding of basic phenomena can help reduce turbulence and pressure drop, although in general we are aiming for the opposite.

the chemical industry will benefit from

yields and reduced use of raw mat

Commercial links
This approach has developed in direct response to commercial needs, and while it still takes time to process large volumes

marketplace. They had about how to design the would generate turbu velocities, says Ander commercial relevance undeniable, Anderssons in no way limited by com and includes a number questions. We focus mor in the ow dynamics problems, and work acro of areas, he continues. for which Im about to re professor and some PhD looking at instantaneous turbulence. I will intro drops into the turbulent the turbulent eddys, an they move around it. How into the eddys? How ar what role does the velo shear rate play? The que also extremely importan the different compound into the turbulent eddy areas Im trying to move

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