cfd modelling of the flow inside an lc refiner cost fp1005 / sig 43 meeting, 24-26.x.2012, trondheim...
TRANSCRIPT
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 1
CFD Modelling of the Flow Inside an LC Refiner
Dariusz Asendrych, Grzegorz KondoraCzęstochowa Univ. of Technology, Poland
A joint meeting
COST Action FP1005Fibre suspension flow modelling - a key for innovation & competitiveness in the pulp &
paper industry
ERCOFTAC SIG 43Fibre suspension flows
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 2
Introduction / Motivation
Numerical model Simplified / full geometry Boundary conditions Governing equations
Results
Simplified geometry - Diverging grooves Full geometry - General flow pattern
Summary / Perspectives
Outline
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 3
plate disc refiner Geometry – assumptions
simplified
• neglected housing axisymmetric outlet (instead of point outlet)
• neglected axial part of inlet, radial inlet applied
• periodicity of discs geometry - single-segment (30 degrees of angular extent - 1/12)
full
• 12 segments• housing• single-pipe outlet
typical refiner filling
LC refiner
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 4
simplified filling
inlet - VELOCITY INLET
outlet - PRESSURE OUTLET
PERIODIC B.C.
INTERFACE for sliding meshes
• geometry and mesh - GAMBIT
• mesh: 6 / 24 mln cells
• FLUENT 6.3 / 13
Boundary conditions
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 5
• pulp suspension treated as a single-phase continuum (N-S, continuity)
• flow character assumed to be laminar (confirmed by simulation results)
• pulp modelled as either Newtonian or non-Newtonian fluid
• fibre-fibre and fibre-wall interactions are neglected - main goal was to analyze the LC refining hydraulics
or
Governing equations
0U
UUUU 2p
t
γf
where - rate of deformation tensorγ
constμ
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 6
softwood pulp, Cm = 4%, fibre lenght = 1400 μm, diameter = 26 μm
ln(l/d) = 3,986 ln(μr) = 5,91 μr = 370
μpulp = μr · μwater = 370 · 0,001003 = 0,371 Pa·s
Newtonian fluid - constant apparent viscosity
Pulp material properties
source:Radoslavova, Silvy, Roux, 1996,,TAPPI Papermakers Conf., Philadelphia
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 7
reverse flows in stator disc
enhanced internal circulation
General flow pattern
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 8
αdiv = 0.0 deg
αdiv = 0.25 deg
αdiv = 0.50 deg
Diverging grooves
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 9
intensification of reverse flow
Diverging grooves
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 10
Diverging grooves
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 11
• mass flux exiting stator grows
• power consumption decreases
Diverging grooves
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 12
Full refiner simulation
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 13
•housing includedhousing included
•pipe outletpipe outlet
•12 segments12 segments
collectoroutlet pipe
inlet
outlet
Full refiner geometry model
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 14
Velocity magnitude
rotor
stator
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 15
Pressure distribution
p[bar]
7
6
5
4
3
2
1
0
rotor
stator
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 16
Pressure distribution
5
4
3
2
1
p[bar]
r* [-]
5
4
3
2
1
p[bar]
r*
0
1
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 17
Pressure distribution
p[bar]
7
6
5
4
3
2
1
0
gap
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 18
LC refiner flow model - Fox et al.
Fox, T.S., Brodkey, R.S. Nissan, A.H., 1979, TAPPI J., 62 (3)
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 19
Pressure distribution - CFD vs Fox et al.
0 1 2 3 4 5 6 7 [bar]
exit region
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 20
Mass flux at filling outlet
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 21
Mass flux at filling outlet
full refiner single-segment refiner
2
1
0
-1
-2
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 22
Flow reversals in stator
full refiner
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 23
Simplified geometry model• qualitative agreement with experimental observation - adequate numerical model
• divergent grooves: modify pressure distribution and enhance flow reversals no energy penalty - improved flow quality
Summary / Perspectives
Full geometry model• circulation / exit regions - analogy to Fox et al.
• existence of the backflows in the stator
• mass flow rate distributions stongly non-uniform and rotor position dependent
General• no fibres included...
• CFD can really help - useful tool in process optimisation
• time consuming simulations
• ongoing simulations / data processing for varying conditions
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 24
Thank You for Your Attention
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 25
Re is low enough to justify the assumption about laminar flow character
gap groove
Reynolds number - Laminar vs Turbulent
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 26
Investigated parameters:
• succesive ratio• interval count at the cross-section• interval count along the groove
Grid tests
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 27
simulation
literature
velocity vectors axial velocity
[Lumiainen] - LDA [Fox et al.]
• refiner grooves occupied by spiral vortices• tertiary flows (momentum exchange between discs)
• good qualitative agreement
CFD vs experiment
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 28
source [Ventura et al.]
II - 2nd invariant o D
)(f II
II
)D(fD - deformation rate tensor
non-Newtonian pulp model
i
IIii )/texp(A)D(
refining regime
istan
Pulp material properties
CFD Modelling of the Flow Inside an LC RefinerCOST FP1005 / SIG 43 meeting, 24-26.X.2012, Trondheim 29
Solution monitoring
progressing solution (time step No)
mass flux at selected groove outlet