Spray drier simulation and air flow pattern studies

The literature pertaining to the key stages of spray drying has been reviewed in the context of the mathematical modelling of drier performance. A critical review is also presented of previous spray drying models. A new mathematical model has been developed for prediction of spray drier performance. This is applicable to slurries of rigid, porous crust-forming materials to predict trajectories and drying profiles for droplets with a distribution of sizes sprayed from a centrifugal pressure nozzle. The model has been validated by comparing model predictions to experimental data from a pilot-scale counter-current drier and from a full-scale co-current drier. For the latter, the computed product moisture content was within 2%, and the computed air exit temperature within 10oC of experimental data. Air flow patterns have been investigated in a 1.2m diameter transparent countercurrent spray tower by flow visualisation. Smoke was introduced into various zones within the tower to trace the direction, and gauge the intensity, of the air flow. By means of a set of variable-angle air inlet nozzles, a variety of air entry configurations was investigated. The existence of a core of high rotational and axial velocity channelling up the axis of the tower was confirmed. The stability of flow within the core was found to be strongly dependent upon the air entry arrangement. A probe was developed for the measurement of air temperature and humidity profiles. This was employed for studying evaporation of pure water drops in a 1.2m diameter pilot-scale counter-current drier. A rapid approach to the exit air properties was detected within a 1m distance from the air entry ports. Measured radial profiles were found to be virtually flat but, from the axial profiles, the existence of plug-flow, well-mixed-flow and some degree of air short-circuiting can be inferred. The model and conclusions should assist in the improved design and optimum operation of industrial spray driers.

The flow behaviour of shallow fluidised beds

The flow behaviour of shallow gas-fluidised beds was studied. experimentally using a rotational viscometer, and an inclined open channel. Initially, tests were carried out with the viscometer in order to establish qualitative trends in the flow properties of a variety of materials over a wide range of fluidising conditions. Also, a technique was developed which enabled quantitative viscosity data to be extracted from the experimental results. The flow properties were found to be sensitive to the size, size-range and density of the fluidised material, the type of distributor used, and the moisture content of the fluidising gas. Tests in beds up to 120 mm deep showed that the fluidity of the bed improves with reduction in depth; and indicated a range of flow behaviour from shear-thinning to Newtonian, depending chiefly on fluidising velocity .. Later, an apparatus was built which provided for a steady, continuous flow of fluidised material down an inclined open channel of 3m length x 0.15m square, up to a mass flowrate of 10 kg/s (35 ton/hr). This facility has enabled data to be obtained that is of practical value in industrial applications; which is otherwise difficult in view of the present limited understanding of the true mechanism of fluidised flow. A correlation has been devised, based on analogy with laminar liquid flow, which describes the channel flow behaviour with reasonable accuracy over the whole range of shear-rates used. 1he channeI results indicated that at low fluidiising velocities the flow was adversely affected by settlement of a stagnant layer of particles on to the distributor, which gave rise to increased flow resistance. Conversely, at higher fluidising velocities the resistance at the distributor appeared to be less than at the walls. In view of this, and also because of the disparity in shear-rates between the two types of apparatus, it is not possible as yet to predict exactly the flow behaviour in an open channel from small-scale viscometer tests.

Investigating viscous fluid flow in an internal mixer using computational fluid dynamics

This thesis presents an effective methodology for the generation of a simulation which can be used to increase the understanding of viscous fluid processing equipment and aid in their development, design and optimisation. The Hampden RAPRA Torque Rheometer internal batch twin rotor mixer has been simulated with a view to establishing model accuracies, limitations, practicalities and uses. As this research progressed, via the analyses several 'snap-shot' analysis of several rotor configurations using the commercial code Polyflow, it was evident that the model was of some worth and its predictions are in good agreement with the validation experiments, however, several major restrictions were identified. These included poor element form, high man-hour requirements for the construction of each geometry and the absence of the transient term in these models. All, or at least some, of these limitations apply to the numerous attempts to model internal mixes by other researchers and it was clear that there was no generally accepted methodology to provide a practical three-dimensional model which has been adequately validated. This research, unlike others, presents a full complex three-dimensional, transient, non-isothermal, generalised non-Newtonian simulation with wall slip which overcomes these limitations using unmatched ridding and sliding mesh technology adapted from CFX codes. This method yields good element form and, since only one geometry has to be constructed to represent the entire rotor cycle, is extremely beneficial for detailed flow field analysis when used in conjunction with user defined programmes and automatic geometry parameterisation (AGP), and improves accuracy for investigating equipment design and operation conditions. Model validation has been identified as an area which has been neglected by other researchers in this field, especially for time dependent geometries, and has been rigorously pursued in terms of qualitative and quantitative velocity vector analysis of the isothermal, full fill mixing of generalised non-Newtonian fluids, as well as torque comparison, with a relatively high degree of success. This indicates that CFD models of this type can be accurate and perhaps have not been validated to this extent previously because of the inherent difficulties arising from most real processes.

Chemical constituents associated with sewage settling velocity profiles

A methodology has been developed to measure the chemical constituents associated with the settling velocity fractions that comprise a wastewater settling velocity profile (SVP). 31 wastewater samples were collected from fifteen different catchments in England and Wales. For each catchment, settling velocity and associated chemical constituent profiles were determined. The results are mainly for Suspended Solids (SS), Chemical Oxygen Demand (COD), Phosphorus (P) and Total Kjeadahl Nitrogen (TKN), however these are supplemented by the results from 5 events for a suite of heavy metals. COD, P, Hg, Mn and Pb were found to be predominantly associated with the solid phase and TKN, Al, Cu and Fe with the liquor phase of the wastewater samples. The results in the thesis are expressed as mass of pollutant (g) per mass total SS (kg). COD and P were found to be mainly associated with the sinkers and had a particular affinity for solids with settling velocities in the range 0.9-9.03mm/sec. TKN was mainly associated with the soluble phase, however of the solids that did settle, a peak was found to be associated within the settling velocity range 0.9-9.03mm/sec. The relationships identified for COD and P were generally found to be unaffected by flow conditions and catchment characteristics. However, TKN was found to be affected by catchment type. Data on the distribution of heavy metals was limited, and no specific relationships with solids were identified. 16 mean pollutant profiles are presented in the thesis. Presentation of the data in this form will enable the results to be of use in the design of sedimentation devices to predict removal efficiencies for solids and associated pollutants. The findings of the research may also be applied to modelling tools to provide further characteristics on the solids that are modelled than is currently used. This would enhance the overall performance of tools used in integrated catchment modelling.

Osmotic flow in porous membranes:effects of electric charge

The electrostatic model for osmotic flow across a porous membrane in our previous study (Akinaga et al. 2008)" was extended to include the streaming potential, for solutes and pores of like charge and fixed surface charge densities. The magnitude of the streaming potential was determined to satisfy zero current condition along the pore axis. It was found that the streaming potential affects the velocity profiles of the pressure driven flow as well as the osmotic flow through the pore, and decreases their flow rates, particularly in the case of large Debye length relative to the pore radius, whereas it has little effect on the reflection coefficients of spherical solutes through cylindrical pores.

Bifurcation contrasts between plane Poiseuille flow and plane Magnetohydrodynamic flow

The stability characteristics of an incompressible viscous pressure-driven flow of an electrically conducting fluid between two parallel boundaries in the presence of a transverse magnetic field are compared and contrasted with those of Plane Poiseuille flow (PPF). Assuming that the outer regions adjacent to the fluid layer are perfectly electrically insulating, the appropriate boundary conditions are applied. The eigenvalue problems are then solved numerically to obtain the critical Reynolds number Rec and the critical wave number ac in the limit of small Hartmann number (M) range to produce the curves of marginal stability. The non-linear two-dimensional travelling waves that bifurcate by way of a Hopf bifurcation from the neutral curves are approximated by a truncated Fourier series in the streamwise direction. Two and three dimensional secondary disturbances are applied to both the constant pressure and constant flux equilibrium solutions using Floquet theory as this is believed to be the generic mechanism of instability in shear flows. The change in shape of the undisturbed velocity profile caused by the magnetic field is found to be the dominant factor. Consequently the critical Reynolds number is found to increase rapidly with increasing M so the transverse magnetic field has a powerful stabilising effect on this type of flow.

Reconstruction of an unsteady flow from incomplete boundary data:Part I. Theory

Purpose – To propose and investigate a stable numerical procedure for the reconstruction of the velocity of a viscous incompressible fluid flow in linear hydrodynamics from knowledge of the velocity and fluid stress force given on a part of the boundary of a bounded domain. Design/methodology/approach – Earlier works have involved the similar problem but for stationary case (time-independent fluid flow). Extending these ideas a procedure is proposed and investigated also for the time-dependent case. Findings – The paper finds a novel variation method for the Cauchy problem. It proves convergence and also proposes a new boundary element method. Research limitations/implications – The fluid flow domain is limited to annular domains; this restriction can be removed undertaking analyses in appropriate weighted spaces to incorporate singularities that can occur on general bounded domains. Future work involves numerical investigations and also to consider Oseen type flow. A challenging problem is to consider non-linear Navier-Stokes equation. Practical implications – Fluid flow problems where data are known only on a part of the boundary occur in a range of engineering situations such as colloidal suspension and swimming of microorganisms. For example, the solution domain can be the region between to spheres where only the outer sphere is accessible for measurements. Originality/value – A novel variational method for the Cauchy problem is proposed which preserves the unsteady Stokes operator, convergence is proved and using recent for the fundamental solution for unsteady Stokes system, a new boundary element method for this system is also proposed.

Gas-liquid-solid flow modelling in a bubble column

An alternative approach to the modelling of solid-liquid and gas-liquid-solid flows for a 5:1 height to width aspect ratio bubble column is presented here. A modified transport equation for the volume fraction of a dispersed phase has been developed for the investigation of turbulent buoyancy driven flows (Chem. Eng. Proc., in press). In this study, a modified transport equation has been employed for discrete phase motion considering both solid-liquid and gas-liquid-solid flows. The modelling of the three-phase flow in a bubble column was achieved in the following case: injecting a slug of solid particles into the column for 10 s at a velocity of 0.1 m s-1 and then the gas phase flow was initiated with a superficial gas velocity of 0.02 cm s-1. © 2003 Elsevier B.V. All rights reserved.

The modelling of buoyancy driven flow in bubble columns

Using the analogy between lateral convection of heat and the two-phase flow in bubble columns, alternative turbulence modelling methods were analysed. The k-ε turbulence and Reynolds stress models were used to predict the buoyant motion of fluids where a density difference arises due to the introduction of heat or a discrete phase. A large height to width aspect ratio cavity was employed in the transport of heat and it was shown that the Reynolds stress model with the use of velocity profiles including the laminar flow solution resulted in turbulent vortices developing. The turbulence models were then applied to the simulation of gas-liquid flow for a 5:1 height to width aspect ratio bubble column. In the case of a gas superficial velocity of 0.02 m s-1 it was determined that employing the Reynolds stress model yielded the most realistic simulation results. © 2003 Elsevier B.V. All rights reserved.

Regional variation in peripapillary retinal blood flow in primary open angle glaucoma:a follow-up study

Purpose: To investigate whether regional long-term changes in peripapillary retinal flow, measured by scanning laser Doppler flowmetry (SLDF), occur in patients with primary open angle glaucoma (POAG). Methods: 31 healthy volunteers (mean age: 65 8.3 years) and 33 POAG patients (mean age: 71.2 7.6 years) were followed up every 4 months for 16 months. Using SLDF, three images of the superior and inferior optic nerve head were obtained for each subject. A 1010-pixel frame was used to measure blood flow, volume and velocity in the four quadrants of the peripapillary retina. Central 24-2 visual field testing was carried out at each visit. Repeated measures analysis of covariance was used to assess change over time between the normal and POAG groups for the SLDF parameters. Univariate linear regression analysis for mean deviation and glaucoma change probability (GCP) analysis were used to identify visual field progression. Results: Blood volume, flow and velocity measured in the inferior nasal quadrant of the peripapillary retina decreased significantly over time for the POAG group compared to the normal group (p=0.0073, 0.0097, 0.0095 respectively). Overall, 2 glaucoma patients showed a significantly deteriorating MD slope, while 7 patients showed visual field progression with GPA. All of the patients progressing with GPA, showed change in the superior hemifield and, of those, 14% showed change in the inferior hemifield. Conclusion: Glaucoma patients showed a decrease in blood flow, volume and velocity in the inferior nasal peripapillary retina. A regional variation in microvascular retinal capillary blood flow may provide insight into the pathogenesis of glaucomatous optic neuropathy. Keywords: 331 blood supply • 554 retina • 624 visual fields