Sparking concepts! TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider) Konrad Uebel | [email protected]| www.tu-freiberg.de 6 th OpenFOAM® Workshop PSU, Pennsylvania, USA, 13 th – 16 th of June 2011 Modeling high viscosity slag flows in entrained flow gasifiers using a Volume of Fluid (VOF) approach K. Uebel*, D. Messig, B. F.W. Gschaider, C. Hasse, B. Meyer
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1 1 Sparking concepts!
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
6th OpenFOAM® Workshop PSU, Pennsylvania, USA, 13th – 16th of June 2011 Modeling high viscosity slag flows in entrained flow
gasifiers using a Volume of Fluid (VOF) approach K. Uebel*, D. Messig, B. F.W. Gschaider, C. Hasse, B. Meyer
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Contains carbon and ash (Si, Fe, Ca, Na, K) - Products:
- Synthesis gas (mainly H2, CO) - Slag (residue, but necessary for process)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Importance of slag modeling: - wall protection in gasifier, closed slag film necessary - Radiant cooler (exhaust heat steam generating system) → Fouling, plugging and corrosion
interSlagFoam Motivation
Therefore simulation of slag flow behavior important
near wall region radiant cooler
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Neglected physics: - No gas phase reactions in iSF - No velocity and turbulence backcoupling
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Modeling of viscosity essential for slag flow simulation - Different models already implemented - Urbain, Kalmanovitch-Frank, Random Model for testing - Model coefficients depending on slag composition (phases)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Device for slag flow measurement in laboratory scale
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
Mesh information: - 40,000 hexahedral cells - Size: Ø 25 cm, length 100 cm
- Fully 3D test case for slag flow and source term behavior
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Animations of slag layer formation and downstream flow
viscosity behavior under different temperatures
slag flow and velocity magnitude/ profile
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Mesh deformation due to fouling done with dynamicMesh
- Example: simpleFoam calculation on quarter cylinder case - based on „static“ condition of slag flow - backcoupling via deformed mesh
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- First results for slag layer formation and slag flow
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
- Future goal: - Simulation of slag flow behavior of complete entrained flow
gasifiers with radiant cooler
TU Bergakademie Freiberg | Chair of Energy Process Engineering and Chemical Engineering Chair of Numerical Thermo-Fluid Dynamics | ICE Strömungsforschung GmbH (Bernhard Gschaider)
The results described above were obtained in the research project TEIMAB. The project was supported with the public funding by the German Federal Ministry of Education and Research. (Project ID 040201012) This research is also supported in the framework of Virtuhcon (Project ID 040201030)