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SIMULATING THE BLISTER TAP HOLE CONCEPT DESIGNUSING CHT CAPABILITIES IN STAR-CCM+ V5.02.009
Bateman Engineering Projects, Pyro Technologies, SA
2011 STAR European Conference: 22 & 23 March, Netherlands
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CONTENTS
• Current Blister Tap Hole:
• Numerical CFD Models (x4).
• Conclusions.
• Bull Nose Blister Tap Hole:
• Numerical CFD Models (x3).
•
Conclusions.
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Current SiC insert blister tap hole configuration
(oxygen fuel burner effect included).
1. Steady state simulation – clay in tap hole with the Oxygen Fuel
Burner (OFB) off. Results not shown. Aim: Establish the initial
conditions for the subsequent transient runs.
2. Transient simulation – clay in tap hole with the OFB on (duration =
37 minutes). Determine the OFB heat flux required to incite the 6thermocouple positions to correspond with the measured thermo-
couple values (benchmark).
3. Transient simulation – blister flowing in tap hole with the OFB on
(duration = 62 minutes). Simulate the transient tapping process to
correspond with measured thermocouple values / trends.
4. Transient simulation – clay in tap hole with the OFB off (duration =
62 minutes). Simulate the cool-down cycle after transient tapping
to correspond with measured thermocouple values / trends.
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Current Blister Tap Hole – Thermocouple Positions
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Clay in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
T1T2
T3T4
T5T6
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Clay in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
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Clay in Tap Hole – Temperature (OFB off)
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Clay in Tap Hole – Temperature (OFB off)
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BTH7 – Summary of OFB on / OFB off conditions
• Measured- & predicted CFD temperaturevalues at the end of each transient cycle:
Measured vs.
Predicted
T1
[° C]
T2
[° C]
T3
[° C]
T4
[° C]
T5
[° C]
T6
[° C]
T/C (clay & OFB on) 242.3 91.3 50.5 43.4 47.7 64.7
CFD (clay & OFB on) 242.5 142.0 98.9 81.2 78.4 89.8
T/C (blister & OFB on) 990.3 882.2 825.3 801.4 745.0 798.8
CFD (blister & OFB on) 961.7 911.3 963.9 971.1 906.3 923.8
T/C (clay & OFB off) 399.4 431.8 438.9 478.8 460.9 529.6
CFD (clay & OFB off) 355.7 389.8 426.5 446.0 451.8 463.9
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Current Blister Tap Hole – Conclusions
• Differences in measured vs. predicted values attributed to:
• Thermocouple positions & measurements maybe not exactly thesame in the SiC insert (on-site vs. models).
• Temperature CFD results are higher due to constant thermal materialproperties in all directions (isotropic).
• Thermal resistances between region interfaces not incorporated inthe numerical models (conjugate heat transfer).
• However: Trends of graphs predicted more or less correctly for eachtransient stage.
• Next step: Apply oxygen fuel burner boundary condition to the newbull nose blister tap hole concept. Predict thermal behaviour beforeactual installation earlier this year (March 2011).
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Bull Nose High Alumina insert blister tap hole configuration
(oxygen fuel burner effect included).
1. Steady state simulation – clay in tap hole with the OFB off (results
not shown). Establish the initial conditions for the subsequent
transient runs.
2. Transient simulation – blister flowing in tap hole with the OFB on
(duration = 62 minutes). Simulate the transient tapping process to
determine the increase in the maximum monitored SG Iron bull
nose- & steel can temperatures.
3. Transient simulation – clay in tap hole with the OFB off (duration =
62 minutes). Simulate the cool-down cycle after transient tapping
to determine the decrease in the maximum monitored SG Iron bull
nose- & steel can temperatures.
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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)
SG Iron Bull Nose
Steel Frame & Can
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Clay in the Tap Hole – Temperature (OFB off)
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Clay in the Tap Hole – Temperature (OFB off)
SG Iron Bull Nose
Steel Frame & Can
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BTH8 – Summary of OFB on / OFB off conditions
• Predicted CFD temperature values at the endof each transient cycle:
Maximum Temperatures for: SG Iron
[° C]
Steel Can
[° C]
High
Alumina
[° C]
CFD (blister & OFB on) 483.5 386.1 1394.2
CFD (clay & OFB off) 242.2 362.4 502.8
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Bull Nose Blister Tap Hole – Conclusions
• Maximum monitored temperature value in the SG Iron bull nose withthe OFB on just short of 500 °C after an hour of blister tapping withconstant heat flux = 34.8 kW/m² on the front face.
• Maximum monitored temperature value in the steel can hot facetapered tip just short of 390 °C after an hour of blister tapping(Thermal cycling / induced stresses not investigated).
• Front of the High Alumina insert much hotter with the OFB on, albeitonly locally around the tap hole exit.
• All the regions monitored (SG Iron, Steel & High Alumina) heat-upduring the tapping cycle within acceptable operating limits.
• Cool-down cycle with the clay plug; after an hour the SG Iron cooleddown to halve the maximum value when the OFB was on. The SteelCan cooled down by 24 °C, which is less sensitive to either tappingor plugged conditions.
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QUESTIONS?
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