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Formation and Dispersion of Ropes in Pneumatic Conveying: Ali Yilmaz, Edward K. Levy
Formation and Dispersion of Ropes in Pneumatic Conveying: Ali Yilmaz, Edward K. Levy
168185
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Abstract
In this study, the solid flow nonuniformities which develop in lean phase upward flow in a vertical pneumatic conveying line
following a horizontal-to-vertical elbow were investigated. Laboratory experiments were conducted in 154 and 203 mm I.D. test sections
using pulverized-coal particles 90% less than 75 mm. for two different 908 circular elbows having pipe bend radius to pipe diameter
ratios of 1.5 and 3.0. The experiments covered a range of conveying air velocities and solids mass loadings. Experimental measurements
of time-average local particle velocities, concentrations, and mass fluxes were obtained using a fiber-optic probe which was traversed
over the cross-section of the pipe. The measurements indicate a continuous rope-like structure forms within the elbow. The rope maintains
its continuous structure until it disintegrates into large discontinuous clusters at downstream locations. Comparisons of the results of CFD
simulations of turbulent gas-particle flow and time-average experimental data were used to explain rope formation and dispersion. The
CFD simulations, based on the Lagrangian particle-source-in-cell method, predict a denser particle rope as the nondimensional radius of
curvature R r D . is increased, agreeing with trends in experimental data. The individual effects of secondary flows and turbulence on
axial dispersion of the rope were studied computationally and the results show both mechanisms are important. q 2001 Elsevier Science
S.A. All rights reserved.
Keywords: Pneumatic conveying; Elbows; Rope flow; Clusters; Fiber optic probe; CFD Modeling of turbulent gas-particle flows
1. Introduction
Pneumatic conveying of solids has wide ranges of
application in the chemical, food processing, pharmaceutical, cement and power industries. In coal-fired boilers,
pulverized coal is pneumatically conveyed in large diameter pipes 400 to 800 mm I.D.. with conveying velocities
of 20 to 30 mrs and with solids loading ratios of 0.33 to 1.
As the mixture of air and pulverized coal make a turn
within an elbow, pulverized-coal particles form a rope-like
structure because of inertial effects. A particle rope, which
carries most of the conveyed material in a small portion of
the pipe cross-section, acts as a third phase in the pneumatic conveying line, with lower particle velocities and
relatively high particle concentration. Roping causes a
variety of operational difficulties in coal-fired boilers and
affects the ability to control NO x emissions and limit
efficiency loss due to unburned carbon in the ash.
0032-5910r01r$ - see front matter q 2001 Elsevier Science S.A. All rights reserved.
PII: S 0 0 3 2 - 5 9 1 0 0 0 . 0 0 3 1 9 - 3
169
2. Experimental
2.1. Pneumatic coneying test facility
The pneumatic conveying test facility consists of two
6.1-m-long horizontal pipes and a 3.35-m-long vertical
pipe as well as two 908 elbows see Fig. 1.. The pipes are
made of schedule 40 carbon steel pipe 0.154 m I.D... A
cyclone is used to separate the coal particles from the air.
The collected coal particles are fed to the hopper by a
rotary airlock. A screw feeder feeds the recycled material
into the pneumatic conveying line. This completes one
cycle in the continuous operation of coal flow in the
system. The air flow leaving the cyclone discharges to the
atmosphere after passing through an Aget Model FT-40
bag filter assembly, where fine particles down to 0.3 mm
are captured. The length of the first horizontal run was
selected by performing an acceleration length calculation
according to Yangs unified theory w60x. As a result, a fully
accelerated gassolid flow prevailed at the inlet to the
horizontal to vertical elbow for all test conditions. The
vertical sections 154 and 203 mm I.D.. were made of
modular parts to make it possible to fit different elbows
into the system. During the experiments for the larger pipe
170
Table 1
Particle size distribution of pulverized coal
Diameter mm.
Weight %.
)125
106125
90106
7590
6375
4563
- 45
1.5
11.0
17.9
16.7
13.1
20.1
19.7
mately 200 times. Sieve analyses performed on the samples showed no significant attrition for the time period
covered. The weight mean diameters of the pulverized-coal
samples fluctuated in the range of 70 to 76 mm, most
likely due to random variations in sampling and sieving.
2.2. Fiber optic probe
A reflective fiber-optic measurement system was used
to simultaneously measure the particle velocity and mass
concentration. Fig. 2 shows the instrument, which consists
of two similar optical probes, and the detail of a singleprobe configuration used in the present study. Two glass
fibers were used in each probe: one of the fibers is used to
send light from a light emitting diode LED. into the
gas-particle flow region, while the other fiber transfers the
reflected light onto the detector area of a silicon photodiode. Local particle velocities are measured using the
cross-correlation technique; that is, the flight time of particles from the upstream probe to the downstream probe was
estimated using the cross-correlation function:
Ct . s
H u t. u tqt .dt
T 0
1
1.
tmax
2.
a calibration procedure was developed to convert the particle flow signal intensities Ip . into a particle mass concentration Cp . as follows:
Cp s KIpn
3.
4.
3. Experimental results
The majority of the experiments were performed to
understand rope flow dispersion characteristics in the verti-
1
Note: The Stokes number is defned as: St s tA rt t ., where the term
tA rp d p2 .r18m .. is the particle aerodynamic response time and t t is the
particle transit time through the measuring volume.
171
172
Fig. 4. Effect of solids loading ratio m .: a. particle velocity profiles, b. particle concentration profiles one pipe diameter upstream of elbow inlet plane.
173
Fig. 7. a. Effect of elbow radius of curvature and b. effect of solids loading ratio m . on local particle velocity and concentration profiles along the pipe
diameter in the x direction at zrD s 1, 5, 9, and 17 for two 908 circular elbows. Results obtained using fiber-optic probe.
4. Numerical modeling
Lagrangian particle tracking along with a Renormalization Group RNG. k y e turbulence model was used to
simulate turbulent gas-particle flows through the elbows.
The objective of the numerical simulations was to study
rope formation and dispersion phenomena and compare the
numerical results with trends observed in the time-averaged experimental data.
In the Lagrangian particle tracking approach, the interaction between the gas phase and particulate phase is
treated using the particle-source-in-cell method of Crowe
et al. w9x. This method was founded on the idea of treating
particles as sources of mass, momentum, and energy to the
gaseous phase w36x. For the present study, only the momentum source term due to the particles is considered. After
particles are randomly injected at the inlet with a finite
number of starting locations and with a finite number of
particle sizes at each starting location, Newtons second
law of motion is used to find the velocity of every particle
in the flow domain. Integration of the particle velocities
174
d
xp
s Up
6.
dt
and the equation of particle motion which is generally
written as w7x
mp
dUp
s FD q FB q FOTHERS
7.
dt
Eq. 7. describes the balance of forces acting on the
particle as it moves along its trajectory. The term on the
left side is the inertia force acting on the particle due to its
acceleration and the right-hand side terms are the external
forces acting on the particle. The most influential
force
acting on the particle is the viscous drag force FD exerted
by the continuous phase. This force is predicted with the
aid of the standard drag coefficient C D and relative
velocity between the particle and the carrier fluid UR ;
1
FD s p d p2 r C D < UR < UR
8.
8
175
Fig. 9. Axial variation of a. peak particle concentration in pipe cross-section and b. particle velocity at locations where peak particle concentration
prevails for RrD s 1.5 and 3.0 elbows D s 0.154 m..
24
Re p
1 q 0.15Rep0.687 .
for Re p F 1000
9.
Re p s
r < UR < d p
m
10 .
Fig. 10. Comparison of rope dispersion behaviors for two different pipe diameters D s 0.154 and 0.2027 m. RrD s 1.5 and comparable flow
conditions..
176
UR s U q
u 4 y Up
12 .
13 .
where Cm is a turbulence model constant, k is the turbulent kinetic energy, and e is the energy dissipation rate.
The eddy life time is computed in a manner similar to
Shuen et al. w45x by
1
te s Ler 2 kr3 .
14 .
//
15 .
ts
rp d p
<C
3 r <U
R
D
16 .
s 1y
2r
D
1r7
17 .
e inlet s
3 Uinlet
2
18 .
10
3r2
k inlet
19 .
0.3 D
/
dm
20 .
177
Fig. 11. a. Numerical grid for a 908 circular elbow and b. detail of
numerical grid for pipe cross-section.
Table 2
Numerical grid resolution
Geometry
Elbow R r Ds1.5.
Elbow R r Ds 3.0.
Elbow R r Ds 5.0.
Vertical pipe
Grid1
Grid2
NH
NB
NV
NCR
NTOTAL
20
40
40
40
18
22
44
60
80
110
110
110
110
224
333
333
333
333
26,432
57,276
64,602
69,930
36,630
178
Fig. 12. History of changes in mass source residuals for two simulations performed for RrD s 1.5 and 3.0 elbows..
Ncell
< R M ,i <
is1
m
air
Fd
21 .
S iq1,S i
i
iq1
Sfiq1
,p s Sf ,p P 1 y g . q Sf ,pcalculated . P g
22 .
Table 3
Geometries and physical properties for the simulations
Case
Simulation geometry
Type
1
908 Elbow
2
908 Elbow
3
908 Elbow
4
Vertical pipe
D: Inside pipe diameter
R: elbow radius of curvature
Particles
Air
D m.
RrD
L H rD
L V rD
Density kgrm3 .
Temp. K.
0.154
0.154
0.154
0.154
1.5
3.0
5.0
5
5
5
20
20
20
20
1680
300
1680
300
1680
300
1680
300
L H : Length of horizontal pipe
L V : Length of vertical pipe
Pressure kPa.
2.0
2.0
2.0
2.0
179
Fig. 13. Secondary flow patterns for RrD s 1.5 elbow at zrD s 0.5: a. single-phase flow solution, b. gas-particle flow solution Uo s 30 mrs and
m s 0.33..
ate under-relaxation factor must be used to obtain a converged solution. The convergence strategy employed in
this study is a global one and it does not guarantee a
converged solution at all local points in the flow geometry.
4.4. CFD results and discussions
CFD simulations were performed for three different
elbow geometries with nondimensional elbow radii of
curvature RrD of 1.5, 3.0, and 5.0 and conveying air
velocities Uo of 20 and 30 mrs. All of the simulations
were for the lowest solids loading case m s 0.33. for
which experimental measurements were available for comparison. The CFD simulations were used to study both the
rope formation process and the individual effects of secondary flows and flow turbulence on rope dispersion
downstream of the elbow exit. Table 3 summarizes the
information on the flow geometries and on the air and
particle physical properties.
' k . in the x direction: comparison of CFD results for two elbows RrD s 1.5 and 3.0..
2
3
180
Fig. 15. Numerical simulation results showing the rope formation within
three 908 circular elbows with R r Ds1.5, 3.0, and 5.0.
CFD model w21x. Fig. 17 compares CFD results and experimental data on particle concentration profiles in the x
direction at different angular positions from the elbow
inlet. The particle concentration progressively increases at
the outer wall with increasing u for the case of CFD
results. However, experimental data show that peak particle concentration reaches a maximum somewhere around
u s 678, agreeing LDV measurements performed by Kliafas and Holt w26x.
4.6. Rope dispersion
A particle rope created by an elbow starts dispersing
once it exits the elbow due to secondary flows and turbulence and possibly due to gas-particle flow instabilities.
CFD predictions showed rather rapid rope dispersion within
three to four pipe diameters downstream of the elbow exit
plane zrD s 0.. This dispersion characteristic is accompanied by a rapid decrease in the intensity of secondary
flows and turbulence levels between zrD s 0 and 5. Fig.
18 compares CFD predictions with experimental data on
the rope formation and dispersion processes for the RrD
s 1.5 elbow. Fig. 18 also shows the effects of grid resolution and number of computational particles modeled on the
CFD results. Increasing the grid resolution and number of
computational particles did not change the overall rope
dispersion behavior.
Rope dispersion characteristics were found to be very
different for the RrD s 1.5 and 3.0 elbows as discussed in
the experimental part of this study. Ropes formed within
the RrD s 1.5 elbow moved towards the center of pipe
181
Fig. 19. Comparison of CFD results and experimental data on rope dispersion for a. RrD s 1.5 and b. RrD s 3.0 elbows at different zrD distances.
182
Fig. 21. Particle concentration contours showing the effects of a. turbulence and b. secondary flows on particle dispersion RrD s 1.5, Uo s 30 mrs and
m s 0.33..
symbols
Pipe cross-section area m2 .
Cross correlation function V 2 .
Standard drag coefficient .
Particle mass concentration c p s rp 1 y e ..,
kgrm3 .
c p,max Max. particle concentration within pipe cross-section kgrm3 .
c po
Average particle concentration c po s m
Yp orUo .,
3
kgrm .
dp
Weight mean particle diameter m.
D
Inside pipe diameter m.
De
Dean number De s 2DR Re ., .
e
Coefficient of restitution .
f
Sampling frequency Hz.
Io
Mean signal intensity without particles V .
Mean signal intensity with particles V .
Im
Ip
Mean signal intensity difference Im y Io ., V .
k
Turbulence kinetic energy m2rs 2 .
K, n
Particle concentration calibration constants c p s
K Ip . n .
L
Optical distance between fiber-optic probes m.
LrD
Axial dimensionless distance to the inlet of elbow
.
Le
m
a
m
p
m
Yp
m
Yp o
N
Ncell
P
R
R M, i
Re p
s
Sf
Sf , p
St
te
tR
t tr
T
uX
< uX <
< uXp <
u1 , u 2
U
Up
U
o
UR
V
W
xrD
x, y
z
zrD
183
Greek Letters
d
Convergence tolerance Eq. 21., .
e
Turbulence dissipation rate m2rs 3 . and Voidage
e s 1 y VprVT ., .
1 y e . Particle volume concentration c p s rp 1 y e ..,
.
g
Under-relaxation factor for particle source terms
.
m
Fluid viscosity kgrm s. and solids loading ratio
.
mt
Turbulence viscosity kgrm s.
r
Gas phase density kgrm3 .
ra
Air density kgrm3 .
184
rp
s
s2
t
tA
tmax
tt
u
w20x
w21x
w22x
w23x
w24x
w25x
w26x
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