Shibo Kuang

Discrete particle simulation of particle–fluid flow: model formulations and their applicability

The approach of combining computational fluid dynamics (CFD) for continuum fluid and the discrete element method (DEM) for discrete particles has been increasingly used to study the fundamentals of coupled particle–fluid flows. Different CFD–DEM models have been used. However, the origin and the applicability of these models are not clearly understood. In this paper, the origin of different model formulations is discussed first. It shows that, in connection with the continuum approach, three sets of formulations exist in the CFD–DEM approach: an original format set I, and subsequent derivations of set II and set III, respectively, corresponding to the so-called model A and model B in the literature. A comparison and the applicability of the three models are assessed theoretically and then verified from the study of three representative particle–fluid flow systems: fluidization, pneumatic conveying and hydrocyclones. It is demonstrated that sets I and II are essentially the same, with small differences resulting from different mathematical or numerical treatments of a few terms in the original equation. Set III is however a simplified version of set I. The testing cases show that all the three models are applicable to gas fluidization and, to a large extent, pneumatic conveying. However, the application of set III is conditional, as demonstrated in the case of hydrocyclones. Strictly speaking, set III is only valid when fluid flow is steady and uniform. Set II and, in particular, set I, which is somehow forgotten in the literature, are recommended for the future CFD–DEM modelling of complex particle–fluid flow.

Numerical Simulation of the Interaction Between Supersonic Oxygen Jets and Molten Slag-Metal Bath in Steelmaking BOF Process

The impinging of multiple jets onto the molten bath in the BOF steelmaking process plays a crucial role in reactor performance but is not clearly understood. This paper presents a numerical study of the interaction between the multiple jets and slag–metal bath in a BOF by means of the three-phase volume of fluid model. The validity of the model is first examined by comparing the numerical results with experimental measurement of time-averaged cavity dimensions through a scaled-down water model. The calculated results are in reasonably good agreement with the experimental data. The mathematical model is then used to investigate the primary transport phenomena of the jets-bath interaction inside a 150-ton commercial BOF under steelmaking conditions. The numerical results show that the cavity profile and interface of slag/metal/gas remain unstable as a result of the propagation of surface waves, which, likely as a major factor, governs the generation of metal droplets and their initial spatiotemporal distribution. The total momentum transferred from the jets into the bath is consumed about a half to drive the movement of slag, rather than fully converted as the stirring power for the metal bath. Finally, the effects of operational conditions and fluid properties are quantified. It is shown that compared to viscosity and surface tension of the melts, operating pressure and lance height have a much more significant impact on the slag–metal interface behavior and cavity shape as well as the fluid dynamics in the molten bath.

Computational study on the behaviours of supersonic jets and their impingement onto molten liquid free surface in BOF steelmaking

Abstract A mathematical model is proposed to study the impingement of multiple supersonic jets onto the free surface of the liquid bath containing molten slag and metal in a steelmaking converter by means of volume of fluid (VOF) approach. The applicability of the proposed model is verified by the good agreement with measured and calculated results. The model is then used to study the jet hydrodynamic behaviours such as jet profile, impact force, penetration depth and impact area, as well as time-dependent evolution of cavity, with respect to temperature, operating pressure and lance height. The results show that the temperature effect on total impact force is negligible but significant for penetration depth and impact area. A semi-empirical correlation is used to describe penetration depth under the steelmaking condition of high temperature. It is also shown that the proposed model can reproduce the splashing phenomenon on the bath surface. On propose un modèle mathématique pour étudier l’impact de jets supersoniques multiples à la surface libre du bain liquide contenant de la scorie et du métal fondus dans un convertisseur de production d’acier, au moyen de l’approche du Volume de Fluide (VOF). On vérifie l’applicabilité du modèle proposé par l’agrément entre les résultats calculés et les résultats mesurés. On utilise ensuite le modèle pour étudier les comportements hydrodynamiques du jet, comme le profil du jet, la force de choc, la profondeur de pénétration et la superficie de l’impact, ainsi que l’évolution de la cavité en fonction du temps par rapport à la température, à la pression d’opération et à la hauteur de la lance. Les résultats montrent que l’effet de la température sur la force totale de choc est négligeable mais qu’il est important pour la profondeur de pénétration et pour la superficie de l’impact. On utilise une corrélation semi-empirique pour décrire la profondeur de pénétration pour la production d’acier à température élevée. On montre également que le modèle proposé peut reproduire le phénomène d’éclaboussement à la surface du bain.

LBM-LES Simulation of the Transient Asymmetric Flow and Free Surface Fluctuations under Steady Operating Conditions of Slab Continuous Casting Process

Transient flow structures in a continuous casting mold can strongly influence the slag entrainment in liquid steel and the bubbles capture in the initial solidified shell, both of which are associated with the quality of the final product. This paper presents a numerical study of the turbulent flow with a top free surface in the continuous casting mold at a meso-scale level by a three-dimensional combined approach of Free Surface Lattice Boltzmann Method and Large Eddy Simulation (FSLBM-LES). The validity of the model is verified by the good agreement between the calculated results and the measurements from various water experiments in terms of the flow velocity and free surface profile. The mathematical model is then used to reveal the transient and spatiotemporal asymmetric characteristics associated with the transient flow field and the free surface fluctuation, although the steady state operation is considered during the continuous casting process. The results show that the locations of the jets of liquid steel from the two out ports of the Submerged Entry Nozzle (SEN) always fluctuate alternatively within a certain range, and periodically deviate from the design angle of the SEN within the same time period. The oscillating behavior of the jets promotes the asymmetric flow patterns and multi-scale vortices at both sides of the SEN. By introducing the Q-criterion in the results analysis, the formation, development, and shedding of the coherent structure (CS) of the turbulent flow are quantitatively characterized. The interaction between the transient flow patterns and the fluctuations of the top free surface as well as the evolution of the transient profile and velocities of the free surface are also demonstrated. The results obtained from the current study suggest that the FSLBM-LES model offers a promising way to study the complex flows and related transfer phenomena in the continuous casting process.

Numerical study of the influence of particle friction on horizontal pneumatic conveying

Material properties are of great importance to pneumatic conveying. This paper presents a numerical study of the effect of particle friction coefficient on flow transition mode in horizontal pneumatic conveying in terms of the combined approach of computational fluid dynamics and discrete element method (CFD-DEM), facilitated with periodic boundary condition for solid and gas phases in the flow direction. The numerical results show that when gas velocity is varied, the change in particle friction coefficient leads to three typical flow transition modes, including Model I (dilute-phase only), Model II (smooth transition from dilute-phase, to unstable, finally to slug flow), and Model III (smooth transition from dilute-to dense-phase).

Numerical Investigation of Novel Oxygen Blast Furnace Ironmaking Processes

Oxygen blast furnace (OBF) ironmaking process has the potential to realize “zero carbon footprint” production, but suffers from the “thermal shortage” problem. This paper presents three novel OBF processes, featured by belly injection of reformed coke oven gas, burden hot-charge operation, and their combination, respectively. These processes were studied by a multifluid process model. The applicability of the model was confirmed by comparing the numerical results against the measured key performance indicators of an experimental OBF operated with or without injection of reformed coke oven gas. Then, these different OBF processes together with a pure OBF were numerically examined in aspects of in-furnace states and global performance, assuming that the burden quality can be maintained during the hot-charge operation. The numerical results show that under the present conditions, belly injection and hot charge, as auxiliary measures, are useful for reducing the fuel rate and increasing the productivity for OBFs but in different manners. Hot charge should be more suitable for OBFs of different sizes because it improves the thermochemical states throughout the dry zone rather than within a narrow region in the case of belly injection. The simultaneous application of belly injection and hot charge leads to the best process performance, at the same time, lowering down hot-charge temperature to achieve the same carbon consumption and hot metal temperature as that achieved when applying the hot charge alone. This feature will be practically beneficial in the application of hot-charge operation. In addition, a systematic study of hot-charge temperature reveals that optimal hot-charge temperatures can be identified according to the utilization efficiency of the sensible heat of hot burden.

Numerical Investigation of the Inner Profiles of Ironmaking Blast Furnaces: Effect of Throat-to-Belly Diameter Ratio

The inner profile of iron making blast furnace (BF) is of significant importance to reactor performance. However, its determination lacks any sound theoretical and empirical base. This paper presents a numerical study of the multiphase flow and thermochemical behaviors inside BFs with different inner profiles by a multi-fluid process model. The validity of the model is first confirmed by various applications. It is then used to study the effect of throat-to-belly diameter ratio (RD) with respect to productivity, burden distribution pattern, and softening-melting temperature of ferrous materials. The results show that when RD increases, the fuel rate increases at relatively low productivities; however, it initially decreases to a minimum and then increases at relatively high productivities. This performance against RD to some degree varies with either burden distribution pattern or softening-melting temperature of ferrous materials. Optimum RD can be identified with relatively small coke rate and minimum fluctuations of global performance and in-furnace states. The analysis of the in-furnace states reveals that the flow and thermochemical behaviors above the cohesive zone are drastically deteriorated with increasing productivity for BFs with relatively small RD, leading to different variation trends of fuel rate.

Numerical study of vertical pneumatic conveying: Effect of friction coefficient

This paper presents a numerical study of vertical pneumatic conveying by a combined approach of computational fluid dynamics for gas phase and discrete element method for solid phase. The effects of friction coefficient on the flows in regard with particle flow patterns and their transition, reverse flow, and gas pressure behavior are qualified. The forces acting on particles are analyzed in detail to understand the underlying mechanisms.

A Reaction Method for Estimating Gibbs Energy and Enthalpy of Formation of Complex Minerals

A bstractNew and updated thermodynamic data for simple binary compounds are readily available from both experimental measurements and theoretical calculations. Based on these available data, an approach is proposed to predict Gibbs energies and enthalpies of formation for complex minerals of metallurgical, chemical, and other industrial importance. The approach assumes that complex minerals are formed from binary composite oxides, which in turn, are formed from individual pure oxides. The validity of this approach is examined by comparing the calculated values of Gibbs energies and enthalpies against the experimentally measured ones reported in literature. The results show that for typical complex minerals with available experimental data, the calculated results exhibit an average residual of 0.51 pct for Gibbs energies and 0.52 pct for enthalpies, compared to the experimental results. This new approach thus correlates well with experimental approaches and can be applied to most of the complex minerals.

Flow Regimes in Vertical Pneumatic Conveying

This paper presents a numerical study of the flow regimes in a vertical pipeline by a combined approach of discrete element model for solid phase and computational fluid dynamics model for gas phase. Two typical cases, i.e. the transports of glass beads when Solid Loading Ratio (SLR)u2009=u20090.5∼3.4 and polyethylene pellets when SLRu2009=u20097.3–33.0 are considered. The results show that in both cases, the phase diagrams featured with the flow transition between the dense‐phase flow and dilute‐phase flow can be produced. In the transport of glass beads, only the dispersed flow regime is observed. However, both the slug flow regime and the dispersed flow regime are observed in the transport of polyethylene pellets. These results satisfactorily agree with the experiments.