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Numerical Simulation of Metallic Solid Bridging Particles in A Fluidized Bed at High Temperature
Numerical Simulation of Metallic Solid Bridging Particles in A Fluidized Bed at High Temperature
Numerical Simulation of Metallic Solid Bridging Particles in A Fluidized Bed at High Temperature
2740
www.elsevier.comrlocaterpowtec
Abstract
High temperature fluidization of iron particles was investigated by numerical simulation based on the discrete element method DEM.
as a case study for metallic bridging. A model was developed for metallic solid bridging by surface diffusion mechanism including the
effect of surface roughness. The simulated fluidization behavior was highly time dependent, which is completely different from our
previous results for liquid bridging particles wT. Mikami, H. Kamiya, M. Horio, Chem. Eng. Sci. 53 1998. 1927.x. Both the amplitude of
pressure fluctuation and the absolute value of bed pressure drop decreased with time. These tendencies agreed well with the experimental
data of Mikami et al. wT. Mikami, H. Kamiya, M. Horio, Powder Techonol. 89 1996. 231.x although temperature and bed size were
different. Size and shape of agglomerates were much different for different surface roughness models. Hypha-shaped agglomerates were
more dominant in the case of the lowest cohesiveness three-microcontact-point model.. The size of agglomerates grown on the wall was
largest for the largest cohesiveness and smallest for the smallest cohesiveness. q 2000 Elsevier Science S.A. All rights reserved.
Keywords: Numerical simulation; Discrete element method; Surface diffusion; Iron particles; Agglomerate; Defluidization
1. Introduction
Metallic solid bridging is a well-recognized factor dominant in metallic fluidized bed processes such as iron oxide
reduction and silicon CVD if they are conducted in a
fluidized bed. Mikami et al. w1x carried out an experimental
investigation for a typical case of iron particles at high
temperatures and concluded that the neck growth of solid
bridging and the cohesion force between iron particles can
be predicted by the surface diffusion model of Kuczynskis
w2x sintering models. Although investigations into metallic
solid bridging fluidized beds have been conducted for
process developments w35x, and defluidization models
were recently proposed by Iwadate and Horio w6x and
Knight et al. w7x, no attempt has ever been made to
formulate the whole mechanism of agglomerating fluidization behavior of bridging metallic particles. Recently,
Mikami et al. w8x developed a simulation code SAFIRE.
based on the discrete element method DEM., considering
cohesion force by liquid bridging, and they successfully
simulated agglomerating fluidized bed behavior of wet
)
2. Theoretical analysis
2.1. Definition of time
Three kinds of time are used in the present model. The
first is the absolute time, t, starting from the beginning of
computation. The second is the time of neck growth, t neck ,
corresponding to each neck. When a neck is broken in a
collision, t neck for the neck is reset to zero. The third is the
0032-5910r00r$ - see front matter q 2000 Elsevier Science S.A. All rights reserved.
PII: S 0 0 3 2 - 5 9 1 0 9 9 . 0 0 2 2 4 - 7
28
x neck s
Et
E ui .
E xi
s 0.
1.
Momentum balance:
rf
E ui .
Et
q rf
E ui u j .
E xj
s y
Ep
E xi
y fi .
2.
d
dt
56gd 4
k BT
1r7
3
Ds a t neck
surface diffusion. ,
5.
x neck s
10gd 3
k BT
1r5
2
Dv a t neck
volume diffusion. ,
6.
between neck growth time t neck and neck radius x neck for
both the surface diffusion and the volume diffusion cases:
s ymg q Fpi q Fn q Ft q Fc ,
3.
7a .
T - 1180 K : for a y Fe . ,
7b .
1180 K - T : for g y Fe . .
7c .
Rotational motion:
I
dv
dt
s Ft rp ,
4.
where, m is the particle mass, Fpi is fluidparticle interaction force acting on a particle, g is gravity acceleration, Fn
is the normal component of the soft sphere contact interaction, Ft is the tangential component of the soft sphere
contact interaction, Fc is cohesive interaction force, I is
moment of particle inertia, v is angular velocity, and rp is
the radius of a particle. Eq. 4. is the corrected angular
momentum equation of Mikami et al. w8x i.e., the righthand side of Eq. 4. was written as < Ft < rp by mistake.. Fpi ,
Fn and Ft are defined in Appendix A. The expression for
Fc , the solid bridging force in the present investigation, is
derived in Section 2.3.3.
2.3. Model for solid bridging force
2.3.1. Mechanism of sintering
The surface diffusion and the volume diffusion mechanisms are the most significant ones in sintering of metal
powders. Kuczynski w2x derived the following relationships
29
30
8.
9.
where tq
neck is an increment of the modified neck growth
time from the beginning of a collision now taking place to
calculate the neck size given by:
tq
neck s t c
td ,Hertz
td ,Hooke
10 .
td ,Hooke s p
1r5
m2
a 2 r
11 .
12 .
a'
E dp
3 1 y n 2 .
13 .
t neck
/
t neck ,0
1r7
14 .
15 .
Fc s psneck
56gd 4
k BT
2r7
3
Ds a t neck
56gd 4
k BT
Ds
16 .
2r7
t neck
10
' Fc1
s 0.417Fc1
d2 x
dx
qh
d t c2
d tc
q kx s S F ,
Fc s 9psneck
56gd 4
k BT
Ds
/
10
17 .
x s exp y
2r7
t neck
s 1.25Fc1
F0
k
h
18 .
21 .
where h is damping coefficient, F is the sum of compression forces acting on two contacting particles. Assuming that F remains constant during an ongoing contact
i.e., F s F0 ., the general solution of Eq. 21. is given
as follows:
31
sy
2m
tc
/ (C q C
2
1
sin
(4 mk y h
2m
tc q b
/
22 .
2m
exp y
2m
q exp y
=cos
2
2
2m
tc
(4 mk y h
2m
tc q b
(4 mk y h
/ (C q C 2 m
(4 mk y h
2m
tc
2
1
2
2
tc q b ,
23 .
19 .
20 .
C1 s x 0 y
F0
k
C2 s
2 m 0 q h C1
(4 mk y h
24 .
32
exp y
q
2m
F0
k
tUc s
tUc
/(
2m
tUc q b
s 0,
4 mk y h
tm s
/
25 .
2m
(4 mk y h
yb y siny1
yt d - tUc - t d
tU1 is the time where the two particles are supposed to have
come into contact and tU2 is the time when they will
separate. From tU1 and tU2 , the time t m when the fictitious
of the two overlap reaches its maximum is calculated by:
C12 q C22
.,
tU1 q tU2
2
27 .
=sin
26 .
/(
(4 mk y h
2m
t m q b q S F.
Table 1
Computation conditions
Particles: steel shot
Number of particles
Particle density
Particle diameter
Young modulus
Poisson ratio
Tensile strength
Normal, sneck
Tangential, tneck
Lattice constant
Boltzman constant
Surface energy
28 .
Temperature
Viscosity
Density
Collision parameters
Restitution coefficient
Friction coefficient
Spring constant
Computational grid parameters
Number of fluid cells
Time step
Fluidized bed parameters
Column size
Distributor
Number of nozzles
Diameter of a nozzle
1273 K
2.29 = 10y5 Pa s
9.67 = 10y2 kgrm3
0.9
`
800 Nrm
21 = 82
1.00 = 10y6 s
0.0153 = 0.06 m
3
0.73 mm
33
34
K. Kuwagi et al.r Powder Technology 109 (2000) 2740
Fig. 5. Snapshots showing fluidization behavior of solid bridging particles without surface roughness.
Fig. 6. Snapshots showing fluidization behavior of solid bridging particles with surface roughness curvature radiuss10 mm, three microcontact points..
35
36
Surface
Smooth
7635
108 1.41%.
580 25.6%.
157 1.99%.
37
38
Table 3
Average number of contacting particles
Case
Surface
Contact points
Smooth
Average number
of bonds per a
primary particle
1.67
Rough
Three microcontact points
1.66
Rough
Nine microcontact points
1.81
4. Conclusions
The DEM code SAFIRE. developed for simulation of
agglomerating fluidized beds based on the soft sphere
interaction model was extended to the case of metallic
solid bridging particles. Surface roughness was considered
by introducing small grains on the surface of a particle. By
5. Nomenclature
A neck
a
Ds
D 0,s
dp
E
Es
Fc
Fn
Fpi
Frep
Ft
fi
g
I
k
kB
m
R
rg
rp
T
t
tc
tUc
t c1
39
x
x neck
Greek letters
a
DP
d
h
m
g
mf
n
rf
rp
sneck
tneck
v
' E d p r31 y n 2 .
Bed pressure drop Pa.
Lattice constant m.
Voidage y.
Damping coefficient y.
Friction coefficient y.
Surface tension Nrm.
Gas viscosity Pas.
Poissons ratio y.
Gas density kgrm3 .
Particle density kgrm3 .
Tensile strength of a neck Pa.
Shear strength of a neck Pa.
Angular velocity 1rs.
td,Hertz
td,Hooke
t neck
tq
neck
u0
u mf
u
Appendix A
Constitutive equations for fluidparticle and particle
particle interactions are as follows.
A.1. Fluidparticle interaction
For a cell being in a dense condition - 0.8., the
well-known pressure drop equation of Ergun w17x is used
to estimate the force acting on unit volume, f i :
f i s 150
2
1 y . mf u y .
q 1.75 1 y .
d p2
rf u y . < u y <
dp
29 .
40
ft
dp
y
Vp (
fi
30 .
n
where n is the number of particles in a fluid cell and Vp is
the volume of a particle. For a cell being in the dilute
condition ) 0.8., the modified Stokes-type single particle drag force Wen and Yu w18x. is used for the force Fpi,l
acting on particle l in a cell i:
p
Fpi ,l s CXD r f 2 u y l . < u y l < d p2 ,
31 .
8
n
dx
CXD s y4 .65 C D ,
CD s
24
Ft s m < Fn <
d xt
d tc
xt
< xt <
35 .
36 .
h s 2g 'km , g s
ln e .
2
ln e . q p 2
37 .
References
Re - 1000,
Re G 1000,
33 .
where Re s r f d p < u y l <.rmf , d p is the particle diameter, C D is the drag coefficient for an isolated single
particle, CXD is the modified drag coefficient, and l is the
velocity of particle l. The summation of the force acting
on all particles l s 1n. in a fluid cell i is adopted for
Fpi,l in the fluid dynamic calculation.
w1x
w2x
w3x
w4x
w5x
w6x
w7x
w8x
w9x
Fn s k n D x n y hn
Ft s k t D x t y ht
32 .
l q 0.15Re 0.687 .
Re
C D s 0.44
And the tangential contact force of soft sphere interaction is given by:
34 .
w10x
w11x
w12x
w13x
w14x
w15x
w16x
w17x
w18x