Experimental and discrete element simulation studies of bell-less charging of blast furnace

This thesis presents an experimental study and numerical study, based on the discrete element method (DEM), of bell-less charging in the blast furnace. The numerical models are based on the microscopic interaction between the particles in the blast furnace charging process. The emphasis is put on model validation, investigating several phenomena in the charging process, and on finding factors that influence the results. The study considers and simulates size segregation in the hopper discharging process, particle flow and behavior on the chute, which is the key equipment in the charging system, using mono-size spherical particles, multi-size spheres and nonspherical particles. The behavior of the particles at the burden surface and pellet percolation into a coke layer is also studied. Small-scale experiments are used to validate the DEM models.

Fluid dynamic modelling and simulation of circulating fluidized bed reactors: importance of the interface turbulence transfer

The main objective of this work is to analyze the importance of the gas-solid interface transfer of the kinetic energy of the turbulent motion on the accuracy of prediction of the fluid dynamic of Circulating Fluidized Bed (CFB) reactors. CFB reactors are used in a variety of industrial applications related to combustion, incineration and catalytic cracking. In this work a two-dimensional fluid dynamic model for gas-particle flow has been used to compute the porosity, the pressure, and the velocity fields of both phases in 2-D axisymmetrical cylindrical co-ordinates. The fluid dynamic model is based on the two fluid model approach in which both phases are considered to be continuous and fully interpenetrating. CFB processes are essentially turbulent. The model of effective stress on each phase is that of a Newtonian fluid, where the effective gas viscosity was calculated from the standard k-epsilon turbulence model and the transport coefficients of the particulate phase were calculated from the kinetic theory of granular flow (KTGF). This work shows that the turbulence transfer between the phases is very important for a better representation of the fluid dynamics of CFB reactors, especially for systems with internal recirculation and high gradients of particle concentration. Two systems with different characteristics were analyzed. The results were compared with experimental data available in the literature. The results were obtained by using a computer code developed by the authors. The finite volume method with collocated grid, the hybrid interpolation scheme, the false time step strategy and SIMPLEC (Semi-Implicit Method for Pressure Linked Equations - Consistent) algorithm were used to obtain the numerical solution.

Direct Simulation Monte Carlo Method Applied to Aerothermodynamics

An axisymmetric supersonic flow of rarefied gas past a finite cylinder was calculated applying the direct simulation Monte Carlo method. The drag force, the coefficients of pressure, of skin friction, and of heat transfer, the fields of density, of temperature, and of velocity were calculated as function of the Reynolds number for a fixed Mach number. The variation of the Reynolds number is related to the variation of the Knudsen number, which characterizes the gas rarefaction. The present results show that all quantities in the transition regime (Knudsen number is about the unity) are significantly different from those in the hydrodynamic regime, when the Knudsen number is small.

Wind tunnel simulation of atmospheric boundary layer flows

The present work shows how thick boundary layers can be produced in a short wind tunnel with a view to simulate atmospheric flows. Several types of thickening devices are analysed. The experimental assessment of the devices was conducted by considering integral properties of the flow and the spectra: skin-friction, mean velocity profiles in inner and outer co-ordinates and longitudinal turbulence. Designs based on screens, elliptic wedge generators, and cylindrical rod generators are analysed. The paper describes in detail the experimental arrangement, including the features of the wind tunnel and of the instrumentation. The results are compared with experimental data published by other authors and with naturally developed flows.

Simulation of wind powered hydraulic heating system

The objective of this master’s thesis was to design and simulate a wind powered hydraulic heating system that can operate independently in remote places where the use of electricity is not possible. Components for the system were to be selected in such a way that the conditions for manufacture, use and economic viability are the as good as possible. Savonius rotor was chosen for wind turbine, due to its low cut in speed and robust design. Savonius rotor produces kinetic energy in wide wind speed range and it can withstand high wind gusts. Radial piston pump was chosen for the flow source of the hydraulic heater. Pump type was selected due to its characteristics in low rotation speeds and high efficiency. Volume flow from the pump is passed through the throttle orifice. Pressure drop over the orifice causes the hydraulic oil to heat up and, thus, creating thermal energy. Thermal energy in the oil is led to radiator where it conducts heat to the environment. The hydraulic heating system was simulated. For this purpose a mathematical models of chosen components were created. In simulation wind data gathered by Finnish meteorological institute for 167 hours was used as input. The highest produced power was achieved by changing the orifice diameter so that the rotor tip speed ratio follows the power curve. This is not possible to achieve without using electricity. Thus, for the orifice diameter only one, the optimal value was defined. Results from the simulation were compared with investment calculations. Different parameters effecting the investment profitability were altered in sensitivity analyses in order to define the points of investment profitability. Investment was found to be profitable only with high average wind speeds.

Large-eddy simulation of wind flows over complex terrains for wind energy applications

Wind energy has obtained outstanding expectations due to risks of global warming and nuclear energy production plant accidents. Nowadays, wind farms are often constructed in areas of complex terrain. A potential wind farm location must have the site thoroughly surveyed and the wind climatology analyzed before installing any hardware. Therefore, modeling of Atmospheric Boundary Layer (ABL) flows over complex terrains containing, e.g. hills, forest, and lakes is of great interest in wind energy applications, as it can help in locating and optimizing the wind farms. Numerical modeling of wind flows using Computational Fluid Dynamics (CFD) has become a popular technique during the last few decades. Due to the inherent flow variability and large-scale unsteadiness typical in ABL flows in general and especially over complex terrains, the flow can be difficult to be predicted accurately enough by using the Reynolds-Averaged Navier-Stokes equations (RANS). Large- Eddy Simulation (LES) resolves the largest and thus most important turbulent eddies and models only the small-scale motions which are more universal than the large eddies and thus easier to model. Therefore, LES is expected to be more suitable for this kind of simulations although it is computationally more expensive than the RANS approach. With the fast development of computers and open-source CFD software during the recent years, the application of LES toward atmospheric flow is becoming increasingly common nowadays. The aim of the work is to simulate atmospheric flows over realistic and complex terrains by means of LES. Evaluation of potential in-land wind park locations will be the main application for these simulations. Development of the LES methodology to simulate the atmospheric flows over realistic terrains is reported in the thesis. The work also aims at validating the LES methodology at a real scale. In the thesis, LES are carried out for flow problems ranging from basic channel flows to real atmospheric flows over one of the most recent real-life complex terrain problems, the Bolund hill. All the simulations reported in the thesis are carried out using a new OpenFOAM® -based LES solver. The solver uses the 4th order time-accurate Runge-Kutta scheme and a fractional step method. Moreover, development of the LES methodology includes special attention to two boundary conditions: the upstream (inflow) and wall boundary conditions. The upstream boundary condition is generated by using the so-called recycling technique, in which the instantaneous flow properties are sampled on aplane downstream of the inlet and mapped back to the inlet at each time step. This technique develops the upstream boundary-layer flow together with the inflow turbulence without using any precursor simulation and thus within a single computational domain. The roughness of the terrain surface is modeled by implementing a new wall function into OpenFOAM® during the thesis work. Both, the recycling method and the newly implemented wall function, are validated for the channel flows at relatively high Reynolds number before applying them to the atmospheric flow applications. After validating the LES model over simple flows, the simulations are carried out for atmospheric boundary-layer flows over two types of hills: first, two-dimensional wind-tunnel hill profiles and second, the Bolund hill located in Roskilde Fjord, Denmark. For the twodimensional wind-tunnel hills, the study focuses on the overall flow behavior as a function of the hill slope. Moreover, the simulations are repeated using another wall function suitable for smooth surfaces, which already existed in OpenFOAM® , in order to study the sensitivity of the flow to the surface roughness in ABL flows. The simulated results obtained using the two wall functions are compared against the wind-tunnel measurements. It is shown that LES using the implemented wall function produces overall satisfactory results on the turbulent flow over the two-dimensional hills. The prediction of the flow separation and reattachment-length for the steeper hill is closer to the measurements than the other numerical studies reported in the past for the same hill geometry. The field measurement campaign performed over the Bolund hill provides the most recent field-experiment dataset for the mean flow and the turbulence properties. A number of research groups have simulated the wind flows over the Bolund hill. Due to the challenging features of the hill such as the almost vertical hill slope, it is considered as an ideal experimental test case for validating micro-scale CFD models for wind energy applications. In this work, the simulated results obtained for two wind directions are compared against the field measurements. It is shown that the present LES can reproduce the complex turbulent wind flow structures over a complicated terrain such as the Bolund hill. Especially, the present LES results show the best prediction of the turbulent kinetic energy with an average error of 24.1%, which is a 43% smaller than any other model results reported in the past for the Bolund case. Finally, the validated LES methodology is demonstrated to simulate the wind flow over the existing Muukko wind farm located in South-Eastern Finland. The simulation is carried out only for one wind direction and the results on the instantaneous and time-averaged wind speeds are briefly reported. The demonstration case is followed by discussions on the practical aspects of LES for the wind resource assessment over a realistic inland wind farm.

Flow in porous media of oil-water systems

Fluid flow behaviour in porous media is a conundrum. Therefore, this research is focused on filtration-volumetric characterisation of fractured-carbonate sediments, coupled with their proper simulation. For this reason, at laboratory rock properties such as pore volume, permeability and porosity are measured, later phase permeabilities and oil recovery in function of flow rate are assessed. Furthermore, the rheological properties of three oils are measured and analysed. Finally based on rock and fluid properties, a model using COMSOL Multiphysics is built in order to compare the experimental and simulated results. The rock analyses show linear relation between flow rate and differential pressure, from which phase permeabilities and pressure gradient are determined, eventually the oil recovery under low and high flow rate is established. In addition, the oils reveal thixotropic properties as well as non-Newtonian behaviour described by Bingham model, consequently Carreau viscosity model for the used oil is given. Given these points, the model for oil and water is built in COMSOL Multiphysics, whereupon successfully the reciprocity between experimental and simulated results is analysed and compared. Finally, a two-phase displacement model is elaborated.

Design and Simulation of High-Speed Rotating Electrical Machinery

Global energy consumption has been increasing yearly and a big portion of it is used in rotating electrical machineries. It is clear that in these machines energy should be used efficiently. In this dissertation the aim is to improve the design process of high-speed electrical machines especially from the mechanical engineering perspective in order to achieve more reliable and efficient machines. The design process of high-speed machines is challenging due to high demands and several interactions between different engineering disciplines such as mechanical, electrical and energy engineering. A multidisciplinary design flow chart for a specific type of high-speed machine in which computer simulation is utilized is proposed. In addition to utilizing simulation parallel with the design process, two simulation studies are presented. The first is used to find the limits of two ball bearing models. The second is used to study the improvement of machine load capacity in a compressor application to exceed the limits of current machinery. The proposed flow chart and simulation studies show clearly that improvements in the high-speed machinery design process can be achieved. Engineers designing in high-speed machines can utilize the flow chart and simulation results as a guideline during the design phase to achieve more reliable and efficient machines that use energy efficiently in required different operation conditions.

Dynamic modeling and simulation of the airflow cleaning device

The objective of the work is to study the flow behavior and to support the design of air cleaner by dynamic simulation.In a paper printing industry, it is necessary to monitor the quality of paper when the paper is being produced. During the production, the quality of the paper can be monitored by camera. Therefore, it is necessary to keep the camera lens clean as wood particles may fall from the paper and lie on the camera lens. In this work, the behavior of the air flow and effect of the airflow on the particles at different inlet angles are simulated. Geometries of a different inlet angles of single-channel and double-channel case were constructed using ANSYS CFD Software. All the simulations were performed in ANSYS Fluent. The simulation results of single-channel and double-channel case revealed significant differences in the behavior of the flow and the particle velocity. The main conclusion from this work are in following. 1) For the single channel case the best angle was 0 degree because in that case, the air flow can keep 60% of the particles away from the lens which would otherwise stay on lens. 2) For the double channel case, the best solution was found when the angle of the first inlet was 0 degree and the angle of second inlet was 45 degree . In that case, the airflow can keep 91% of particles away from the lens which would otherwise stay on lens.

Une nouvelle méthode smoothed particle hydrodynamics : simulation des interfaces immergées et de la dynamique Brownienne des molécules avec des interactions hydrodynamiques

Dans cette thèse, nous présentons une nouvelle méthode smoothed particle hydrodynamics (SPH) pour la résolution des équations de Navier-Stokes incompressibles, même en présence des forces singulières. Les termes de sources singulières sont traités d'une manière similaire à celle que l'on retrouve dans la méthode Immersed Boundary (IB) de Peskin (2002) ou de la méthode régularisée de Stokeslets (Cortez, 2001). Dans notre schéma numérique, nous mettons en oeuvre une méthode de projection sans pression de second ordre inspirée de Kim et Moin (1985). Ce schéma évite complètement les difficultés qui peuvent être rencontrées avec la prescription des conditions aux frontières de Neumann sur la pression. Nous présentons deux variantes de cette approche: l'une, Lagrangienne, qui est communément utilisée et l'autre, Eulerienne, car nous considérons simplement que les particules SPH sont des points de quadrature où les propriétés du fluide sont calculées, donc, ces points peuvent être laissés fixes dans le temps. Notre méthode SPH est d'abord testée à la résolution du problème de Poiseuille bidimensionnel entre deux plaques infinies et nous effectuons une analyse détaillée de l'erreur des calculs. Pour ce problème, les résultats sont similaires autant lorsque les particules SPH sont libres de se déplacer que lorsqu'elles sont fixes. Nous traitons, par ailleurs, du problème de la dynamique d'une membrane immergée dans un fluide visqueux et incompressible avec notre méthode SPH. La membrane est représentée par une spline cubique le long de laquelle la tension présente dans la membrane est calculée et transmise au fluide environnant. Les équations de Navier-Stokes, avec une force singulière issue de la membrane sont ensuite résolues pour déterminer la vitesse du fluide dans lequel est immergée la membrane. La vitesse du fluide, ainsi obtenue, est interpolée sur l'interface, afin de déterminer son déplacement. Nous discutons des avantages à maintenir les particules SPH fixes au lieu de les laisser libres de se déplacer. Nous appliquons ensuite notre méthode SPH à la simulation des écoulements confinés des solutions de polymères non dilués avec une interaction hydrodynamique et des forces d'exclusion de volume. Le point de départ de l'algorithme est le système couplé des équations de Langevin pour les polymères et le solvant (CLEPS) (voir par exemple Oono et Freed (1981) et Öttinger et Rabin (1989)) décrivant, dans le cas présent, les dynamiques microscopiques d'une solution de polymère en écoulement avec une représentation bille-ressort des macromolécules. Des tests numériques de certains écoulements dans des canaux bidimensionnels révèlent que l'utilisation de la méthode de projection d'ordre deux couplée à des points de quadrature SPH fixes conduit à un ordre de convergence de la vitesse qui est de deux et à une convergence d'ordre sensiblement égale à deux pour la pression, pourvu que la solution soit suffisamment lisse. Dans le cas des calculs à grandes échelles pour les altères et pour les chaînes de bille-ressort, un choix approprié du nombre de particules SPH en fonction du nombre des billes N permet, en l'absence des forces d'exclusion de volume, de montrer que le coût de notre algorithme est d'ordre O(N). Enfin, nous amorçons des calculs tridimensionnels avec notre modèle SPH. Dans cette optique, nous résolvons le problème de l'écoulement de Poiseuille tridimensionnel entre deux plaques parallèles infinies et le problème de l'écoulement de Poiseuille dans une conduite rectangulaire infiniment longue. De plus, nous simulons en dimension trois des écoulements confinés entre deux plaques infinies des solutions de polymères non diluées avec une interaction hydrodynamique et des forces d'exclusion de volume.

Numerical simulation of tunnel fires using preconditioned finite volume schemes

This article is concerned with the numerical simulation of flows at low Mach numbers which are subject to the gravitational force and strong heat sources. As a specific example for such flows, a fire event in a car tunnel will be considered in detail. The low Mach flow is treated with a preconditioning technique allowing the computation of unsteady flows, while the source terms for gravitation and heat are incorporated via operator splitting. It is shown that a first order discretization in space is not able to compute the buoyancy forces properly on reasonable grids. The feasibility of the method is demonstrated on several test cases.

Numerical Simulation of Flows at Low Mach Numbers with Heat Sources

This work is concerned with finite volume methods for flows at low mach numbers which are under buoyancy and heat sources. As a particular application, fires in car tunnels will be considered. To extend the scheme for compressible flow into the low Mach number regime, a preconditioning technique is used and a stability result on this is proven. The source terms for gravity and heat are incorporated using operator splitting and the resulting method is analyzed.

Verfahren zur echtzeitfähigen Simulation dynamischer Emissionsverläufe ausgewählter Schadstoffe von Ottomotoren

Im Rahmen dieser Arbeit werden Modellbildungsverfahren zur echtzeitfähigen Simulation wichtiger Schadstoffkomponenten im Abgasstrom von Verbrennungsmotoren vorgestellt. Es wird ein ganzheitlicher Entwicklungsablauf dargestellt, dessen einzelne Schritte, beginnend bei der Ver-suchsplanung über die Erstellung einer geeigneten Modellstruktur bis hin zur Modellvalidierung, detailliert beschrieben werden. Diese Methoden werden zur Nachbildung der dynamischen Emissi-onsverläufe relevanter Schadstoffe des Ottomotors angewendet. Die abgeleiteten Emissionsmodelle dienen zusammen mit einer Gesamtmotorsimulation zur Optimierung von Betriebstrategien in Hybridfahrzeugen. Im ersten Abschnitt der Arbeit wird eine systematische Vorgehensweise zur Planung und Erstellung von komplexen, dynamischen und echtzeitfähigen Modellstrukturen aufgezeigt. Es beginnt mit einer physikalisch motivierten Strukturierung, die eine geeignete Unterteilung eines Prozessmodells in einzelne überschaubare Elemente vorsieht. Diese Teilmodelle werden dann, jeweils ausgehend von einem möglichst einfachen nominalen Modellkern, schrittweise erweitert und ermöglichen zum Abschluss eine robuste Nachbildung auch komplexen, dynamischen Verhaltens bei hinreichender Genauigkeit. Da einige Teilmodelle als neuronale Netze realisiert werden, wurde eigens ein Verfah-ren zur sogenannten diskreten evidenten Interpolation (DEI) entwickelt, das beim Training einge-setzt, und bei minimaler Messdatenanzahl ein plausibles, also evidentes Verhalten experimenteller Modelle sicherstellen kann. Zum Abgleich der einzelnen Teilmodelle wurden statistische Versuchs-pläne erstellt, die sowohl mit klassischen DoE-Methoden als auch mittels einer iterativen Versuchs-planung (iDoE ) generiert wurden. Im zweiten Teil der Arbeit werden, nach Ermittlung der wichtigsten Einflussparameter, die Model-strukturen zur Nachbildung dynamischer Emissionsverläufe ausgewählter Abgaskomponenten vor-gestellt, wie unverbrannte Kohlenwasserstoffe (HC), Stickstoffmonoxid (NO) sowie Kohlenmono-xid (CO). Die vorgestellten Simulationsmodelle bilden die Schadstoffkonzentrationen eines Ver-brennungsmotors im Kaltstart sowie in der anschließenden Warmlaufphase in Echtzeit nach. Im Vergleich zur obligatorischen Nachbildung des stationären Verhaltens wird hier auch das dynami-sche Verhalten des Verbrennungsmotors in transienten Betriebsphasen ausreichend korrekt darge-stellt. Eine konsequente Anwendung der im ersten Teil der Arbeit vorgestellten Methodik erlaubt, trotz einer Vielzahl von Prozesseinflussgrößen, auch hier eine hohe Simulationsqualität und Ro-bustheit. Die Modelle der Schadstoffemissionen, eingebettet in das dynamische Gesamtmodell eines Ver-brennungsmotors, werden zur Ableitung einer optimalen Betriebsstrategie im Hybridfahrzeug ein-gesetzt. Zur Lösung solcher Optimierungsaufgaben bieten sich modellbasierte Verfahren in beson-derer Weise an, wobei insbesondere unter Verwendung dynamischer als auch kaltstartfähiger Mo-delle und der damit verbundenen Realitätsnähe eine hohe Ausgabequalität erreicht werden kann.

FastAero – A Precorrected FFT – Fast Multipole Tree Steady and Unsteady Potential Flow Solver

In this paper a precorrected FFT-Fast Multipole Tree (pFFT-FMT) method for solving the potential flow around arbitrary three dimensional bodies is presented. The method takes advantage of the efficiency of the pFFT and FMT algorithms to facilitate more demanding computations such as automatic wake generation and hands-off steady and unsteady aerodynamic simulations. The velocity potential on the body surfaces and in the domain is determined using a pFFT Boundary Element Method (BEM) approach based on the Green’s Theorem Boundary Integral Equation. The vorticity trailing all lifting surfaces in the domain is represented using a Fast Multipole Tree, time advected, vortex participle method. Some simple steady state flow solutions are performed to demonstrate the basic capabilities of the solver. Although this paper focuses primarily on steady state solutions, it should be noted that this approach is designed to be a robust and efficient unsteady potential flow simulation tool, useful for rapid computational prototyping.

Análisis del modelo de Internacionalización de e-Tech Simulation según la teoría de redes

La teoría de redes de Johanson y Mattson (1988) explica como las pequeñas empresas, también conocidas como PyMes, utilizan las redes de negocio para desarrollar sus procesos de internacionalización. Es así que a través de las redes pueden superar sus limitaciones de tamaño para encontrar cierto tipo de fluidez y dinamismo en su gestión, con el fin de aprovechar los beneficios de la internacionalización. A partir del desarrollo y fortalecimiento de las relaciones dentro de la red la organización puede posicionarse en una instancia competitiva cada vez más fuerte (Jarillo, 1988). Según Forsgren y Johanson (1992), para los gerentes es importante coordinar la interacción entre los diferentes actores de la red, ya que a través de estas su posición dentro de la red mejora y así mismo el flujo de recursos será mayor. El propósito de este trabajo es analizar el modelo de internacionalización según la teoría de redes, desde una perspectiva cultural, de e-Tech Simulation una PyME “Born to be global” norteamericana. Esta empresa ha minimizado su riesgo de internacionalización, a través del desarrollo de acuerdos entre los diferentes actores. Al mejorar su posición dentro de la red, es decir al fortalecer aún más los lazos existentes y crear nuevas relaciones, la empresa ha obtenido mayores beneficios de la misma y ha logrado ser aún más flexible con sus clientes. Es por esto que a partir de este análisis se planteó una serie de recomendaciones para mejorar los procesos de negociación dentro de la red, bajo un contexto cultural. De igual forma se evidencio la importancia del papel del emprendimiento del gerente en los procesos de internacionalización, así como su habilidad para mezclar los recursos obtenidos de diferentes mercados internacionales para satisfacer las necesidades de los clientes.