Numerical simulation of hydrodynamics in downers using a CFD–DEM coupled approach

Experimental and Numerical Studies of Fine Quartz Single-Particle Sedimentation Based on Particle Morphology

The sedimentation characteristics of quartz particles affect their separation and settling dehydration processes. Particle morphology determines the sedimentation equilibrium velocity. In this paper, the sedimentation of a single quartz particle is characterized by employing experimental and CFD-DEM approaches. SEM served to examine quartz particles measuring 30–500 μm, and they exhibited flaky–blocky morphologies with an average long–middle axis ratio of 1.6. Consistent with the SEM-detected morphological features of the quartz particles, suggested here is a simpler drag coefficient model, followed by verification of the model with experimental data. The results show that the velocity of a quartz particle in the non-settling direction had a fluctuation of ±0.2 mm/s. The fluctuation reached 0.4 mm/s at varying settlement release angles. The order in which the particles reached sedimentation equilibrium velocity during the settlement process was double-cone, single-cone, and square when the initial velocity was greater than sedimentation equilibrium velocity. Furthermore, the long–middle axis ratio of quartz particles diminished as their equilibrium sedimentation velocities rose. Given that the quartz particles ranged from 30 to 50 μm in size, the long–middle axis ratio wielded no discernible effect on the sedimentation equilibrium velocity.

Numerical Analysis of Single-Particle Motion Using CFD-DEM in Varying-Curvature Elbows

Centrifugal pumps are the critical components in deep-sea mining. In order to investigate the particle motion in the curved channel of the impeller, three different types of curvature conform to blade profile to simplify the impeller design of pumps. A numerical study is conducted to investigate the flow field in a varying-curvature channel for solid-liquid two-phase flow. The flow of particles within the varying curvature channel is studied by combining the discrete element method (DEM) with computational fluid dynamics (CFD) and a comparison with Particle Image Velocimetry (PIV) test results. The results show that a polyhedral mesh with a small mesh number yields very accurate results, which makes it very suitable for CFD-DEM. Based on this method, the movement of a single particle is compared and analyzed, and the particle-motion law is obtained. The effects of the curvature ratio Cr and area ratio Ar on the motion law for a single particle are studied, and the simulation results are analyzed statistically. The results show that the effect of Cr on both the particle slip velocity and the turbulent kinetic energy only changes its strength, while the distribution law does not change significantly. Compared with the curvature ratio Cr, the area ratio Ar has a greater impact on the particles, and its distribution law becomes clearly different. As the area ratio Ar increases, the arc radius and length of the corresponding particle trajectory decrease.

Particle Lagrangian CFD Simulation and Experimental Characterization of the Rounding of Polymer Particles in a Downer Reactor with Direct Heating

Polypropylene (PP) powders are rounded at different conditions in a downer reactor with direct heating. The particles are fed through a single central tube, while the preheated sheath gas is fed coaxially surrounding the central aerosol jet. The influence of the process parameters on the quality of the powder product in terms of particle shape and size is analyzed by correlating the experimental results with the flow pattern, residence time distribution of the particles and temperature distribution predicted by computational fluid dynamics (CFD) simulations. An Eulerian–Lagrangian numerical approach is used to capture the effect of the particle size distribution on the particle dynamics and the degree of rounding. The simulation results reveal that inlet effects lead to inhomogeneous particle radial distributions along the total length of the downer. The configuration of particle/gas injection also leads to fast dispersion of the particles in direction of the wall and to particle segregation by size. Broad particle residence time distributions are obtained due to broad particle size distribution of the powders and the particles dispersion towards the wall. Lower mass flow ratios of aerosol to sheath gas are useful to reduce the particle dispersion and produce more homogenous residence time distributions. The particles’ residence time at temperatures above the polymer’s melting onset is determined from the simulations. This time accounts for the effective treatment (rounding) time of the particles. Clear correlations are observed between the numerically determined effective rounding time distributions and the progress of shape modification on the particles determined experimentally.

Wettability control on deformation: Coupled multiphase fluid and granular systems

Understanding of multiphase flow in porous media is important for a wide range of applications such as soil science, environmental remediation, energy resources, and CO_{2} sequestration. This phenomenon depends on the complex interplay between the fluid and solid forces such as gravitational, capillary, and viscous forces, as well as wettability of the solid phase. Such interactions along with the geometry of the medium give rise to a variety of complex flow regimes. Although much research has been done in the area of wettability, its mechanical effect is not well understood, and it continues to challenge our understanding of the phenomena on macroscopic and microscopic scales. In this paper, therefore, the effect of wettability on the deformation of porous media and fluid-fluid patterns is studied through a series of three-dimensional (3D) simulations. To this end, the discrete element method (DEM) and volume of fluid (VOF) are coupled to accurately model free-surface flow interaction in a cylindrical pack of spheres. The fluid-particle interactions are modeled by exchanging information between DEM and VOF, while the effect of wettability is considered to study how it controls fluid displacement. The results indicate that the drag force and deformation in the pack vary with the change in wettability and capillary number. To demonstrate the effect of both wettability and capillary number, a series of numerical experiments were conducted with two capillary numbers and three wettability conditions. Our results show that the drag force was greatest for near extreme wettability conditions, which resulted in a larger deformation.

Coupled fine-scale modeling of the wettability effects: Deformation and fracturing

Multiphase flow in porous media has been thoroughly studied over the years and its importance is encountered in several areas related to geo-materials. One of the most important parameters that control multiphase flow in any complex geometry is wettability, which is an affinity of a given fluid toward a surface. In this paper, we have quantified the effects of wettability on deformation in porous media, along with other parameters that are involved in this phenomenon. To this end, we conducted numerical simulations on a porous medium by coupling the exchanged forces between the fluid and solid. To include the effect of wettability in the medium, we used the Fictitious Domain methodology and coupled it with volume of fluid through which one can model more than one fluid in the system. To observe the effect of wettability on dynamic processes in the designated porous medium, such as deformation, particle-particle contact stresses, particle velocity, and injection pressure, a series of systematic computations were conducted where wettability is varied through five different contact angles. We found that wettability not only controls the fluid propagation patterns but also affects drag forces exerted on the particles during injection such that larger deformations are induced for particles with lower wettability. Our results are also verified against experimental tests.