Effect of Bottom Bubbling Conditions on Surface Reaction Rate in Oxygen-Water System

In secondary steelmaking, the enhancement of the reaction rate in the low carbon period during the decarburization of steel is considered the most effective method to produce ultralow carbon steel. In a previous study, it was revealed that the surface reaction is dominant during the final stage of the actual refining process. In order to improve the surface reaction rate, it is necessary to enlarge the reaction region, which is usually achieved by increasing the plume eye area. In this study, water model experiments were carried out to estimate the influence of bottom stirring conditions on the gas-liquid reaction rate; for this purpose, the deoxidation rate during the bottom bubbling process was measured. Five types of nozzle configurations were used to study the effect of the plume eye area on the reaction rate at various gas flow rates. The results reveal that the surface reaction rate is influenced by the gas flow rate and the plume eye area. An empirical correlation was developed for the reaction rate and the plume eye area. This correlation was applied to estimate the gas-liquid reaction rate mat the bath surface.

Smoldering combustion of "incense" sticks - Experiments and modeling

This paper is concerned with the experimental and modeling studies on the smoldering rates of incense sticks as a function of ambient oxygen fraction in air, the flow velocity and size. The experimental results are obtained both for forward and reverse smolder conditions. The results are explained on the basis of surface combustion due to diffusion of oxygen to the surface by both free and forced convection supporting the heat transfer into the solid by conduction, into the stream by convection and the radiant heat transfer from the surface. The heat release at the surface is controlled by the convective transport of the oxidizer to the surface. To obtain the diffusion rates particularly for the reverse smolder, CFD calculations of fluid flow with along with a passive scalar are needed; these calculations have been made both for forward and reverse smolder. The interesting aspect of the CFD calculations is that while the Nusselt umber for forward smolder shows a clear root( Re-u) dependence ( Re-u = Flow Reynolds Number), the result for reverse smolder shows a peak in the variation with Reynolds number with the values lower than for forward smolder and unsteadiness in the flow beyond a certain flow rate. The results of flow behavior and Nusselt number are used in a simple model for the heat transfer at the smoldering surface to obtain the dependence of the smoldering rate on the diameter of the incense stick, the flow rate of air and the oxygen fraction. The results are presented in terms of a correlation for the non-dimensional smoldering rate with radiant flux from the surface and heat generation rate at the surface. The correlations appear reasonable for both forward and reverse smolder cases.

Studies on pneumatic atomization

A study of atomization has been made with an external mixing-type pneumatic atomizer. The drops were sampled on Vaseline-coated cells using a shutter arrangement and their sizes were measured under a microscope. The effects of liquid viscosity, liquid surface tension, liquid flow rate, air velocity, and nozzle angle on drop size have been studied. A model, which explains adequately the influence of various factors, has been proposed. This model predicts the values of average drop sizes over a wide range of operating conditions. The model also explains the data of other investigators who have used other kinds of pneumatic atomizers.

Studies on helium flow in experimental loops with different impedances operated with fountain effect pumps

An experimental flow loop with He II flow driven by fountain effect pumps (FEPs) is studied with respect to operation at different flow impedances and with thermal loads applied at different positions. The measured values of temperature, flow rate and pressure drop are compared with calculations resulting from a simplified model which assumes ideal performance of the porous plug and of the heat exchangers and which does not take into account Gorter-Mellink (GM) conduction. The main features of the loop are shown to be well described by this model. Refined calculations with a more complex model, including GM conduction of the He II, are only required for predicting the temperature distribution in some discrete regions of the loop.

Electro-magnetically Actuated Minute Polymer Pump Fabricated using Packaging Technology

Design, fabrication and preliminary testing of a flat pump with millimetre thickness are described in this paper. The pump is entirely made of polymer materials barring the magnet and copper coils used for electromagnetic actuation. The fabrication is carried out using widely available microelectronic packaging machinery and techniques. Therefore, the fabrication of the pump is straightforward and inexpensive. Two types of prototypes are designed and built. One consists of copper coils that are etched on an epoxy plate and the other has wound insulated wire of 90 mu m diameter to serve as a coil. The overall size of the first pump is 25 mm x 25 mm x 3.6 mm including the 3.1 mm-thick NdFeB magnet of diameter 12 mm. It consists of a pump chamber of 20 mm x 20 mm x 0.8 mm with copper coils etched from a copper-clad epoxy plate using dry-film lithography and milled using a CNC milling machine, two passive valves and the pump-diaphragm made of Kapton film of 0.089 mm thickness. The second pump has an overall size of 35 mm x 35 mm x 4.4 mm including the magnet and the windings. A breadboard circuit and DC power supply are used to test the pump by applying an alternating square-wave voltage pulse. A water slug in a tube attached to the inlet is used to observe and measure the air-flow induced by the pump against atmospheric pressure. The maximum flow rate was found to be 15 ml/min for a voltage of 2.5 V and a current of 19 mA at 68 Hz.

Work fluctuations in an elastic dumbbell model of polymers in planar elongational flow

We use a path-integral approach to calculate the distribution P(w, t) of the fluctuations in the work W at time t of a polymer molecule (modeled as an elastic dumbbell in a viscous solvent) that is acted on by an elongational flow field having a flow rate (gamma) over dot. We find that P(w, t) is non-Gaussian and that, at long times, the ratio P(w, t)/ P (-w, t) is equal to expw/(k(B)T)], independent of (gamma) over dot. On the basis of this finding, we suggest that polymers in elongational flows satisfy a fluctuation theorem.

Flow of liquid/liquid dispersions in a Hele-Shaw cell

Flow of liquid/liquid dispersions have been investigated in a Hele-Shaw cell which contained a thin disk held between two parallel plates. This device offers a well defined flow field and also permits visual observation of the dispersed drop movement. The dispersed drops coalesce with the disk for the systems where the dispersed phase wets the disk surface. The dispersed phase accumulate at the downstream end of the disk and they detach from there as blobs. Through an accurate measurement of accumulated dispersed phase volume, the coalescence rate was determined. The coalescence efficiency in the Hele Shaw cell is determined by dividing the coalescence hate by the undisturbed flow rate of the dispersed phase through an area equal to the projected area of the disk on a plane normal to the flow direction. The coalescence efficiency first increases and then decreases with the flow rate of dispersion. The coalescence rate/disk dimensions increases with the decrease in the disk dimensions. The rate of coalescence increases with the increase in the dispersed drop diameter and it decreases with the increase in the continuous phase viscosity. The presence of surfactants reduces the coalescence rate. All these results are quantitatively explained through a model, which takes into account several important features like various mechanism of drainage, the roles of dispersion and continuous phase viscosities, and the drop deformation.

Flow from T-spout ladles

The ladle constitutes a crucial element in the pouring system for developing process consistency and quality in the manufacture of castings. Flow of molten metal from T-spout ladles, with the spout projecting at an angle from the shell of the ladle, was investigated by simulation, modeling and analysis. This was followed by experimental validation for water flow in translucent models, and verification in a cast iron foundry. Key parameters in the design of a ladle (for its geometry) have been identified as the ladle size, spout diameter and its angle. Velocity and flow rate from a T-spout ladle are governed by and increase with increase in angle of tilt apart from the aforementioned design parameters. Cross section and profile of the issuing jet displaying a stable twisting pattern, during its free-fall of model fluid water and molten metal iron, are notable aspects in the design of the ladle, particularly the spout exit.

Effect of natural convection on oscillating flow in a pipe with cryogenic temperature difference across the ends

The effect of natural convection on the oscillatory flow in an open-ended pipe driven by a timewise sinusoidally varying pressure at one end and subjected to an ambient-to-cryogenic temperature difference across the ends, is numerically studied. Conjugate effects arising out of the interaction of oscillatory flow with heat conduction in the pipe wall are taken into account by considering a finite thickness wall with an insulated exterior surface. Two cases, namely, one with natural convection acting downwards and the other, with natural convection acting upwards, are considered. The full set of compressible flow equations with axissymmetry are solved using a pressure correction algorithm. Parametric studies are conducted with frequencies in the range 5-15 Hz for an end-to-end temperature difference of 200 and 50 K. Results are obtained for the variation of velocity, temperature. Nusselt number and the phase relationship between mass flow rate and temperature. It is found that the Rayleigh number has a minimal effect on the time averaged Nusselt number and phase angle. However, it does influence the local variation of velocity and Nusselt number over one cycle. The natural convection and pressure amplitude have influence on the energy flow through the gas and solid. (C) 2011 Elsevier Ltd. All rights reserved.

Mass Distribution Studies in Effervescent Sprays

An experimental study on liquid mass distribution in effervescent sprays using water and air as working fluids is presented in this paper. Optical patternation and techniques of image processing are employed for analyzing the spray. The flow regime inside the effervescent atomizer largely dictates the mass distribution patterns. The patterns are seen to vary from concentrated, poorly atomized liquid lumps to uniformly distributed, fine droplets as the flow regime changes from bubbly flow to annular flow. A large variety of instantaneous spray patterns are observed in bubbly flow regime indicating a highly unsteady atomization process. However, relatively better consistency in spray patterns is observed at higher gas flow rates. Thus, the degree of unsteadiness gradually diminishes as gas flow rate is increased. The axial evolution of the spray in annular mode shows good mixing of liquid and gas across the interface.

Study of Fluid Flow and Mixing Behaviour of a Vacuum Degasser

In recent times the demand of ultra-low carbon steel (ULCS) with improved mechanical properties such as good ductility and good workability has been increased as it is used to produce cold-rolled steel sheets for automobiles. For producing ULCS efficiently, it is necessary to improve the productivity of the vacuum degassers such as RH, DH and tank degasser. Recently, it has been claimed that using a new process, called REDA (revolutionary degassing activator), one can achieve the carbon content below 10 ppm in less time. As such, REDA process has not been studied thoroughly in terms of fluid flow and mass transfer which is a necessary precursor to understand and design this process. Therefore, momentum and mass transfer of the process has been studied by solving momentum and species balance equations along with k-epsilon turbulent model in two-dimension (2D) for REDA process. Similarly, computational fluid dynamic studies have been made in 2D for tank and RH degassers to compare them with REDA process. Computational results have been validated with published experimental and theoretical data. It is found that REDA process is the most efficient among all these processes in terms of mixing efficiency. Fluid flow phenomena have been studied in details for REDA process by varying gas flow rate, depth of immersed snorkel in the steel, diameter of the snorkel and change in vacuum pressure. It is found that design of snorkel affects the melt circulation in the bath significantly.

Influence of Bottom Bubbling Rate on Formation of Metal Emulsion in Al-Cu Alloy and Molten Salt System

In steel refining process, an increase of interfacial area between the metal and slag through the metal droplets emulsified into the slag, so-called ``metal emulsion'', is one prevailing view for improving the reaction rate. The formation of metal emulsion was experimentally evaluated using Al-Cu alloy as metal phase and chloride salt as slag phase under the bottom bubbling condition. Samples were collected from the center of the salt phase in the container. Large number of metal droplets were separated from the salt by dissolving it into water. The number, surface area, and weight of the droplets increased with the gas flow rate and have local maximum values. The formation and sedimentation rates of metal droplets were estimated using a mathematical model. The formation rate increased with the gas flow rate and has a local maximum value as a function of gas flow rate, while the sedimentation rate is independent of the gas flow rate under the bottom bubbling condition. Three types of formation mode of metal emulsion, which occurred by the rupture of metal film around the bubble, were observed using high speed camera. During the process, an elongated column covered with metal film was observed with the increasing gas flow rate. This elongated column sometimes reached to the top surface of the salt phase. In this case, it is considered that fine droplets were not formed and in consequence, the weight of metal emulsion decreased at higher gas flow rate.

A novel gas flow sensing application using piezoelectric ZnO thin films deposited on Phynox alloy

We report on the novel flow sensing application of piezoelectric ZnO thin film deposited on Phynox alloy sensing element. Characterization of piezoelectric ZnO films deposited on Phynox (Elgiloy) substrate at different RF powers is discussed. ZnO films deposited at RF power of 100W were found to have fine c-axis orientation, possesses excellent surface morphology with lower rms surface roughness of 1.87 nm and maximum d(31) coefficient value 4.7 pm V-1. The thin cantilever strip of Phynox alloy with ZnO film as a sensing layer for flow sensing has been tested for flow rates ranging from 2 to 18 L min(-1). A detailed theoretical analysis of the experimental set-up showing the relationship between output voltage and force at a particular flow rate has been discussed. The sensitivity of now sensing element is similar to 18 mV/(L min(-1)) and typical response time is of the order of 20 m s. The sensing element is calibrated using in-house developed testing set-up. (C) 2012 Elsevier B.V. All rights reserved.

Sustainability of apparent slip in micro-channel flows

In the present work, we experimentally study the flow of water over textured hydrophobic surfaces in a micro-channel. Shear stress measurements are done along with direct visualization of trapped air pockets on the hydrophobic surface. The trapped air pockets on such surfaces are known to be responsible for apparent slip at these surfaces and hence in significant drag reduction. In typical circumstances, the apparent slip reduces over time as seen, for example, from our shear stress measurements. This implies that the drag reduction will not be sustained. We have performed extensive visualizations of the trapped air pockets while varying flow parameters like the flow rate and the pressure. We present here direct visualizations that show that under some conditions, the air pockets can grow with time. The variation of the air pocket size with time is found to change qualitatively and quantitatively as the flow rate is varied. These measured changes in the air pocket size with time have a direct bearing on the sustainability of apparent slip in micro-channel flows.

A Finite Element Method Based Approach for Evaluating the Sensitivity of Faraday-Type Electromagnetic Flow Meter for Liquid Sodium Flow

Faraday-type electromagnetic flow meters are employed for measuring the flow rate of liquid sodium in fast breeder reactors. The calibration of such flow meters, owing to the required elaborative arrangements is rather difficult. On the other hand, theoretical approach requires solution of two coupled electromagnetic partial differential equation with profile of the flow and applied magnetic field as the inputs. This is also quite involved due to the 3D nature of the problem. Alternatively, Galerkin finite element method based numerical solution is suggested in the literature as an attractive option for the required calibration. Based on the same, a computer code in Matlab platform has been developed in this work with both 20 and 27 node brick elements. The boundary conditions are correctly defined and several intermediate validation exercises are carried out. Finally it is shown that the sensitivities predicted by the code for flow meters of four different dimensions agrees well with the results given by analytical expression, thereby providing strong validation. Sensitivity for higher flow rates, for which analytical approach does not exist, is shown to decrease with increase in flow velocity.