Stefan Pirker

Models, algorithms and validation for opensource DEM and CFD-DEM

We present a multi–purpose CFD–DEM framework to simulate coupled fluid–granular systems. The motion of the particles is resolved by means of the Discrete Element Method (DEM), and the Computational Fluid Dynamics (CFD) method is used to calculate the interstitial fluid flow. We first give a short overview over the DEM and CFD–DEM codes and implementations, followed by elaborating on the numerical schemes and implementation of the CFD–DEM coupling approach, which comprises two fundamentally different approaches, the unresolved CFD–DEM and the resolved CFD–DEM using an Immersed Boundary (IB) method. Both the DEM and the CFD–DEM approach are successfully tested against analytics as well as experimental data.

Parallel Resolved Open Source CFD-DEM: Method, Validation and Application

In the following paper the authors present a fully parallelized Open Source method for calculating the interaction of immersed bodies and surrounding fluid. Acombination of computational fluid dynamics (CFD) and a discrete element method (DEM) accounts for the physics of both the fluid and the particles. The objects considered are relatively big compared to the cells of the fluid mesh, i.e. they cover several cells each. Thus this fictitious domain method (FDM) is called resolved. The implementation is realized within the Open Source framework CFDEMcoupling (www.cfdem.com), which provides an interface between OpenFOAM® based CFD-solvers and the DEM software LIGGGHTS (www.liggghts.com). While both LIGGGHTS and OpenFOAM® were already parallelized, only a recent improvement of the algorithm permits the fully parallel computation of resolved problems. Alongside with a detailed description of the method, its implementation and recent improvements, a number of application and validation examples is presented in...

A Coarse-Grained Two-Fluid Model for Gas-Solid Fluidized Beds

Due to increasing computer power the numerical simulation of fluidized and moving beds has become feasible. However, while kinetic theory based CFD (Computational Fluid Dynamics) has become a valuable design tool for modeling pilot plant scale gas-solid fluidized bed reactors, a fully resolved simulation of industrial scale reactor is still nearly unfeasible. It is, therefore, common to use sub-grid models to account for the effect of the small unresolved structures on large resolved scales when using coarse grids. It is generally agreed that the influence of these small scales on the drag force is a key parameter in the prediction of the hydrodynamics of fluidized beds. We present a sub-grid drag modification dealing with the influence of heterogeneous structures on the drag force. It is assumed that these structures appear as distinct clusters of particles within an interstitial dilute particle phase. The clusters and the dilute phase itself consist of homogeneously distributed particles enabling the ap...

Recurrence CFD – A novel approach to simulate multiphase flows with strongly separated time scales

Abstract Classical Computational Fluid Dynamics (CFD) of long-time processes with strongly separated time scales is computationally extremely demanding if not impossible. Consequently, the state-of-the-art description of such systems is not capable of real-time simulations or online process monitoring. In order to bridge this gap, we propose a new method suitable to decouple slow from fast degrees of freedom in many cases. Based on the recurrence statistics of unsteady flow fields, we deduce a recurrence process which enables the generic representation of pseudo-periodic motion at high spatial and temporal resolution. Based on these fields, passive scalars can be traced by recurrence CFD. While a first, Eulerian Model A solves a passive transport equation in a classical implicit finite-volume environment, a second, Lagrangian Model B propagates fluid particles obeying a stochastic differential equation explicitly. Finally, this new concept is tested by two multiphase processes – a lab scale oscillating bubble column and an industrial scale steelmaking converter. Results of tracer distribution obtained by recurrence CFD are in very good agreement with full CFD simulations, while computational times are dramatically reduced. Actually, recurrence CFD is a promising candidate for online simulations of passive transport processes at full CFD resolution, which opens the door towards improved process monitoring.

Studies on Flow Characteristics at High-Pressure Die-Casting

The flow and filling characteristics during injection of liquid aluminum during high-pressure die-casting is studied threefoldly: a) analytically, b) experimentally and c) numerically. A planar jet of liquid aluminum is formed at the ingate due to its small width (≈O(10−3) m), its high aspect ratio (≈ 100) and high inlet velocity (up to 60 m/s). On the one hand, wavy disintegration of such a jet can inevitably lead to cold runs in the final casting. On the other hand, a high degree of atomization may strongly increase the porosity of the casting part. Both processes can highly reduce the mechanical stability of the product. Analytical investigations of Ohnesorge (or equivalently Weber) and Reynolds numbers show that the process of drop formation at the liquid planar free jet is dominated by atomization assuming an orifice nozzle geometry at the ingate. From a simple experimental investigation of an equivalent free jet of water, however, it is deduced that the process of drop formation can be changed to wavy disintegration by the nozzle geometry. Numerically, high-pressure die-casting is attacked by a Volume of Fluid approach. Although the drop formation at the phase interphase can not be captured by the numerical model since the drops are an order of magnitude smaller than feasible grid spacings, the global spreading of the free jet in the casting mold is well pictured by this first numerical simulation. In addition, a new approach is presented to detect cold runs at the final casting. Finally, the studies presented lead to an increased understanding of high pressure die casting and can help to improve the quality of casting products.

Resolving unsteady micro-scale atmospheric flows by nesting a CFD simulation into wide range numerical weather prediction models

The open boundary conditions for the CFD simulation of the micro- and meso-scale flow and temperature distribution around the Grimming mountain, Austria, are determined by an optimisation approach from interior observations. The numerical weather prediction model ALADIN–Austria provides wind speed and wind direction at those spatially arbitrarily defined observations. Furthermore, the plausibility of the resulting flow over the Grimming mountain is checked (a) by data of a ground station at the top of the Grimming mountain showing suitable correlation with the measurements. Besides, (b) the vertical turbulence profiles at the ground station are qualitatively compared to extensive studies covering the Askervein hill. In addition, (c) the wavelength of internal gravity waves obtained from the numerical CFD model is examined by analytic approximations at the Grimming mountain and by linear mountain wave theory at a mathematically idealised hill. Finally, the grid independence of the presented CFD model is shown.

Secondary Vortex Formation in Bifurcated Submerged Entry Nozzles: Numerical Simulation of Gas Bubble Entrapment

The submerged entry nozzle (SEN) flow behavior is crucial for continuous casting of slab steel since it controls the mold flow pattern. In this study, we focus on the bottom zone of a bifurcated SEN where the flow deflection determines the port outflow. By applying a hybrid finite volume and lattice Boltzmann-based turbulence model, the dynamic behavior of horizontally orientated secondary vortices is investigated. In addition to the pure liquid metal flow, gas bubbles are traced in both discrete and continuous way. Simulation results indicate the existence of highly turbulent secondary vortices in the deflection zone of a bifurcated SEN, which attract gas bubbles in form of bubble threads or continuous gas volumes at their rotational axes. In addition, cyclically detaching gas volumes are formed at the upper port region at higher gas flow rates. Numerical predictions agree well with observations from physical water–air models.

Numerical study and experimental validation of particle strand formation

Pneumatic conveying of spherical glass particles through a rectangular channel is studied by means of numerical simulation and compared with optical measurements. Thereby, a double-looping is placed in front of the straight channel in order to generate a particle strand at the bottom of the channel. Finally the profiles of particle velocity and volume concentration are measured by Particle Image Velocimetry (PIV). The corresponding numerical simulations are carried out with the Discrete Phase Model using the Fluent software package. Also some additional sub-models have been introduced in order to describe particle-wall collisions, particle-particle collisions and the influence of particle rotation.

A Passive Magnetically and Hydrodynamically Suspended Rotary Blood Pump

A combined hydrodynamic-magnetic bearing allows the design of rotary blood pumps that are not encumbered with mechanical bearings and magnets requiring sensors or electrical power. However, such pumps have so far needed very small and accurately manufactured gaps between rotor and housing to assure effective hydromagnetic bearing behavior. In order to use this concept in disposable pump heads, a design that allows larger rotor-housing gaps, and thus larger manufacturing tolerances, is needed. A pump with passive magnetic bearings and a gap between rotor and housing in the range of 0.5 mm was designed. Numerical simulations were performed to optimize the rotor geometry at low levels of shear stress. An experimental test stand was used to find a range of speeds and gap settings that resulted in low levels of vibration and useful pressure-flow relationships. Three different rotor geometries were tested using a viscosity-adjusted test fluid. Blood damage tests were conducted within the desirable range of speeds and gap settings. In this study stable pump performance was demonstrated at total gap widths between 0.3 and 0.7 mm at flows of 0-10 L/min, with afterloads up to 230 mm Hg. Best performance was achieved with rotors sliding on a fluid pillow between the rotor and the outer housing at a gap distance of 50 to 250 microm. The inner gap distance, between the rotor and the inner housing, could be as great as 500 microm. Hemolysis tests on the prototype within the chosen operating range showed lower values (NIH = 0.0029 +/- 0.0012 g/100 L) than the Biomedicus BP-80 pump (NIH = 0.0033 +/- 0.0011 g/100 L). In conclusion, it is possible to build rotary blood pumps with passive hydromagnetic bearings that have large gaps between their rotors and housings. Rotor behavior is sensitive to the position of the permanent magnetic drive unit. To minimize vibration and blood damage, the fluid gaps and the rotational speed have to be adjusted according to the desired operating point of the pump. Further study is needed to optimize the magnetic drive unit and to ascertain its ability to withstand inertial loads imposed by sudden movements and external shock.

CFD, a design tool for a new hot metal desulfurization technology

AbstractThispaperconsidersCFDmodellingofdesulfurizationcarriedoutinalargevesselcontaininghotmetalcoveredbyathicksyntheticslaglayer.Duringnitrogenstirringsulfurtransferstotheslag.Sulfurionsinthe slag have to be removed by oxidation (O 2 lance) to restore slag desulfurization capability. The mac-roscopic metallurgical reactions occurring during hot metal desulfurization and slag regeneration arestudiedbykineticlawsforpermanentandtransientphasecontact.Mechanicalmetal–slaginteractionsarecalculatedbyshearstressconsiderationsforstratifiedflows.Thepositionofthephaseinterfaceandtheslagsurface is obtained by an adaptive grid algorithm. Flow initiation by rising gas bubbles is simulated bymeansofanalgebraicdriftfluxmodel.Asaresultofthesesimulationsthefullythree-dimensionalflow-andtemperature fields in the slag and metal phase are obtained. Furthermore the variation of the time-dependent concentration fields of the main reactants can be observed. 2002 Elsevier Science Inc. Allrights reserved. Keywords:CFD simulation; Hot metal desulfurization; Slag regeneration; Metallurgical reactions