Fluid dynamic analysis and modelling of industrial chemical equipment

The research is aimed at contributing to the identification of reliable fully predictive Computational Fluid Dynamics (CFD) methods for the numerical simulation of equipment typically adopted in the chemical and process industries. The apparatuses selected for the investigation, specifically membrane modules, stirred vessels and fluidized beds, were characterized by a different and often complex fluid dynamic behaviour and in some cases the momentum transfer phenomena were coupled with mass transfer or multiphase interactions. Firs of all, a novel modelling approach based on CFD for the prediction of the gas separation process in membrane modules for hydrogen purification is developed. The reliability of the gas velocity field calculated numerically is assessed by comparison of the predictions with experimental velocity data collected by Particle Image Velocimetry, while the applicability of the model to properly predict the separation process under a wide range of operating conditions is assessed through a strict comparison with permeation experimental data. Then, the effect of numerical issues on the RANS-based predictions of single phase stirred tanks is analysed. The homogenisation process of a scalar tracer is also investigated and simulation results are compared to original passive tracer homogenisation curves determined with Planar Laser Induced Fluorescence. The capability of a CFD approach based on the solution of RANS equations is also investigated for describing the fluid dynamic characteristics of the dispersion of organics in water. Finally, an Eulerian-Eulerian fluid-dynamic model is used to simulate mono-disperse suspensions of Geldart A Group particles fluidized by a Newtonian incompressible fluid as well as binary segregating fluidized beds of particles differing in size and density. The results obtained under a number of different operating conditions are compared with literature experimental data and the effect of numerical uncertainties on axial segregation is also discussed.

Application of reactive fluid transport modeling to hydrothermal systems

A one-dimensional multi-component reactive fluid transport algorithm, 1DREACT (Steefel, 1993) was used to investigate different fluid-rock interaction systems. A major short coming of mass transport calculations which include mineral reactions is that solid solutions occurring in many minerals are not treated adequately. Since many thermodynamic models of solid solutions are highly non-linear, this can seriously impact on the stability and efficiency of the solution algorithms used. Phase petrology community saw itself faced with a similar predicament 10 years ago. To improve performance and reliability, phase equilibrium calculations have been using pseudo compounds. The same approach is used here in the first, using the complex plagioclase solid solution as an example. Thermodynamic properties of a varying number of intermediate plagioclase phases were calculated using ideal molecular, Al-avoidance, and non-ideal mixing models. These different mixing models can easily be incorporated into the simulations without modification of the transport code. Simulation results show that as few as nine intermediate compositions are sufficient to characterize the diffusional profile between albite and anorthite. Hence this approach is very efficient, and can be used with little effort. A subsequent chapter reports the results of reactive fluid transport modeling designed to constrain the hydrothermal alteration of Paleoproterozoic sediments of the Southern Lake Superior region. Field observations reveal that quartz-pyrophyllite (or kaolinite) bearing assemblages have been transformed into muscovite-pyrophyllite-diaspore bearing assemblages due to action of fluids migrating along permeable flow channels. Fluid-rock interaction modeling with an initial qtz-prl assemblage and a K-rich fluid simulates the formation of observed mineralogical transformation. The bulk composition of the system evolves from an SiO2-rich one to an Al2O3+K2O-rich one. Simulations show that the fluid flow was up-temperature (e.g. recharge) and that fluid was K-rich. Pseudo compound approach to include solid solutions in reactive transport models was tested in modeling hydrothermal alteration of Icelandic basalts. Solid solutions of chlorites, amphiboles and plagioclase were included as the secondary mineral phases. Saline and fresh water compositions of geothermal fluids were used to investigate the effect of salinity on alteration. Fluid-rock interaction simulations produce the observed mineral transformations. They show that roughly the same alteration minerals are formed due to reactions with both types of fluid which is in agreement with the field observations. A final application is directed towards the remediation of nitrate rich groundwaters. Removal of excess nitrate from groundwater by pyrite oxidation was modeled using the reactive fluid transport algorithm. Model results show that, when a pyrite-bearing, permeable zone is placed in the flow path, nitrate concentration in infiltrating water can be significantly lowered, in agreement with proposals from the literature. This is due to nitrogen reduction. Several simulations investigate the efficiency of systems with different mineral reactive surface areas, reactive barrier zone widths, and flow rates to identify the optimum setup.

New catalysts for the water gas shift reaction at middle-temperature

H2 demand is continuously increasing since its many relevant applications, for example, in the ammonia production, refinery processes or fuel cells. The Water Gas Shift (WGS) reaction (CO + H2O = CO2 + H2 DeltaH = -41.1 kJ.mol-1) is a step in the H2 production, reducing significantly the CO content and increasing the H2 one in the gas mixtures obtained from steam reforming. Industrially, the reaction is carried out in two stages with different temperature: the first stage operates at high temperature (350-450 °C) using Fe-based catalysts, while the second one is performed at lower temperature (190-250 °C) over Cu-based catalysts. However, recently, an increasing interest emerges to develop new catalytic formulations, operating in a single-stage at middle temperature (MTS), while maintaining optimum characteristics of activity and stability. These formulations may be obtained by improving activity and selectivity of Fe-based catalysts or increasing thermal stability of Cu-based catalysts. In the present work, Cu-based catalysts (Cu/ZnO/Al2O3) prepared starting from hydrotalcite-type precursors show good homogeneity and very interesting physical properties, which worsen by increasing the Cu content. Among the catalysts with different Cu contents, the catalyst with 20 wt.% of Cu represents the best compromise to obtain high catalytic activity and stability. On these bases, the catalytic performances seem to depend on both metallic Cu surface area and synergetic interactions between Cu and ZnO. The increase of the Al content enhances the homogeneity of the precursors, leading to a higher Cu dispersion and consequent better catalytic performances. The catalyst with 20 wt.% of Cu and a molar ratio M(II)/M(III) of 2 shows a high activity also at 250 °C and a good stability at middle temperature. Thus, it may be considered an optimum catalyst for the WGS reaction at middle temperature (about 300 °C). Finally, by replacing 50 % (as at. ratio) of Zn by Mg (which is not active in the WGS reaction), better physical properties were observed, although associate with poor catalytic performances. This result confirms the important role of ZnO on the catalytic performances, favoring synergetic interactions with metallic Cu.

The grain-scale distribution and behaviour of melt and fluid in crystalline analogue systems

The production, segregation and migration of melt and aqueous fluids (henceforth called liquid) plays an important role for the transport of mass and energy within the mantle and the crust of the Earth. Many properties of large-scale liquid migration processes such as the permeability of a rock matrix or the initial segregation of newly formed liquid from the host-rock depends on the grain-scale distribution and behaviour of liquid. Although the general mechanisms of liquid distribution at the grain-scale are well understood, the influence of possibly important modifying processes such as static recrystallization, deformation, and chemical disequilibrium on the liquid distribution is not well constrained. For this thesis analogue experiments were used that allowed to investigate the interplay of these different mechanisms in-situ. In high-temperature environments where melts are produced, the grain-scale distribution in “equilibrium” is fully determined by the liquid fraction and the ratio between the solid-solid and the solid-liquid surface energy. The latter is commonly expressed as the dihedral or wetting angle between two grains and the liquid phase (Chapter 2). The interplay of this “equilibrium” liquid distribution with ongoing surface energy driven recrystallization is investigated in Chapter 4 and 5 with experiments using norcamphor plus ethanol liquid. Ethanol in contact with norcamphor forms a wetting angle of about 25°, which is similar to reported angles of rock-forming minerals in contact with silicate melt. The experiments in Chapter 4 show that previously reported disequilibrium features such as trapped liquid lenses, fully-wetted grain boundaries, and large liquid pockets can be explained by the interplay of the liquid with ongoing recrystallization. Closer inspection of dihedral angles in Chapter 5 reveals that the wetting angles are themselves modified by grain coarsening. Ongoing recrystallization constantly moves liquid-filled triple junctions, thereby altering the wetting angles dynamically as a function of the triple junction velocity. A polycrystalline aggregate will therefore always display a range of equilibrium and dynamic wetting angles at raised temperature, rather than a single wetting angle as previously thought. For the deformation experiments partially molten KNO3–LiNO3 experiments were used in addition to norcamphor–ethanol experiments (Chapter 6). Three deformation regimes were observed. At a high bulk liquid fraction >10 vol.% the aggregate deformed by compaction and granular flow. At a “moderate” liquid fraction, the aggregate deformed mainly by grain boundary sliding (GBS) that was localized into conjugate shear zones. At a low liquid fraction, the grains of the aggregate formed a supporting framework that deformed internally by crystal plastic deformation or diffusion creep. Liquid segregation was most efficient during framework deformation, while GBS lead to slow liquid segregation or even liquid dispersion in the deforming areas.

Theoretical studies of fluid membrane mechanics

Biologische Membranen sind Fettmolekül-Doppelschichten, die sich wie zweidimensionale Flüssigkeiten verhalten. Die Energie einer solchen fluiden Oberfläche kann häufig mit Hilfe eines Hamiltonians beschrieben werden, der invariant unter Reparametrisierungen der Oberfläche ist und nur von ihrer Geometrie abhängt. Beiträge innerer Freiheitsgrade und der Umgebung können in den Formalismus mit einbezogen werden. Dieser Ansatz wird in der vorliegenden Arbeit dazu verwendet, die Mechanik fluider Membranen und ähnlicher Oberflächen zu untersuchen. Spannungen und Drehmomente in der Oberfläche lassen sich durch kovariante Tensoren ausdrücken. Diese können dann z. B. dazu verwendet werden, die Gleichgewichtsposition der Kontaktlinie zu bestimmen, an der sich zwei aneinander haftende Oberflächen voneinander trennen. Mit Ausnahme von Kapillarphänomenen ist die Oberflächenenergie nicht nur abhängig von Translationen der Kontaktlinie, sondern auch von Änderungen in der Steigung oder sogar Krümmung. Die sich ergebenden Randbedingungen entsprechen den Gleichgewichtsbedingungen an Kräfte und Drehmomente, falls sich die Kontaktlinie frei bewegen kann. Wenn eine der Oberflächen starr ist, muss die Variation lokal dieser Fläche folgen. Spannungen und Drehmomente tragen dann zu einer einzigen Gleichgewichtsbedingung bei; ihre Beiträge können nicht mehr einzeln identifiziert werden. Um quantitative Aussagen über das Verhalten einer fluiden Oberfläche zu machen, müssen ihre elastischen Eigenschaften bekannt sein. Der "Nanotrommel"-Versuchsaufbau ermöglicht es, Membraneigenschaften lokal zu untersuchen: Er besteht aus einer porenüberspannenden Membran, die während des Experiments durch die Spitze eines Rasterkraftmikroskops in die Pore gedrückt wird. Der lineare Verlauf der resultierenden Kraft-Abstands-Kurven kann mit Hilfe der in dieser Arbeit entwickelten Theorie reproduziert werden, wenn der Einfluss von Adhäsion zwischen Spitze und Membran vernachlässigt wird. Bezieht man diesen Effekt in die Rechnungen mit ein, ändert sich das Resultat erheblich: Kraft-Abstands-Kurven sind nicht länger linear, Hysterese und nichtverschwindende Trennkräfte treten auf. Die Voraussagen der Rechnungen könnten in zukünftigen Experimenten dazu verwendet werden, Parameter wie die Biegesteifigkeit der Membran mit einer Auflösung im Nanometerbereich zu bestimmen. Wenn die Materialeigenschaften bekannt sind, können Probleme der Membranmechanik genauer betrachtet werden. Oberflächenvermittelte Wechselwirkungen sind in diesem Zusammenhang ein interessantes Beispiel. Mit Hilfe des oben erwähnten Spannungstensors können analytische Ausdrücke für die krümmungsvermittelte Kraft zwischen zwei Teilchen, die z. B. Proteine repräsentieren, hergeleitet werden. Zusätzlich wird das Gleichgewicht der Kräfte und Drehmomente genutzt, um mehrere Bedingungen an die Geometrie der Membran abzuleiten. Für den Fall zweier unendlich langer Zylinder auf der Membran werden diese Bedingungen zusammen mit Profilberechnungen kombiniert, um quantitative Aussagen über die Wechselwirkung zu treffen. Theorie und Experiment stoßen an ihre Grenzen, wenn es darum geht, die Relevanz von krümmungsvermittelten Wechselwirkungen in der biologischen Zelle korrekt zu beurteilen. In einem solchen Fall bieten Computersimulationen einen alternativen Ansatz: Die hier präsentierten Simulationen sagen voraus, dass Proteine zusammenfinden und Membranbläschen (Vesikel) bilden können, sobald jedes der Proteine eine Mindestkrümmung in der Membran induziert. Der Radius der Vesikel hängt dabei stark von der lokal aufgeprägten Krümmung ab. Das Resultat der Simulationen wird in dieser Arbeit durch ein approximatives theoretisches Modell qualitativ bestätigt.

Sistemi catalitici per la reazione di water - gas shift a media temperatura

Negli ultimi anni l’interesse nei confronti dell’H2 è cresciuto notevolmente per l’aumento della richiesta energetica mondiale. Uno dei processi più importanti per la produzione di H2 utilizza la reazione di Water-Gas Shift (WGS) per il trattamento delle correnti in uscita dai processi di steam reforming o di ossidazione parziale catalitica. CO + H2O  CO2 + H2 ∆H0298 = -41,2 KJ/mol Sono quindi stati sviluppati sistemi catalitici attivi nella reazione di WGS a media temperatura (circa 300 °C). Partendo da sistemi catalitici a base di Cu/Zn/Al, ottenuti da precursori idrotalcitici e sviluppati in lavori di tesi precedenti, sono state effettuate modifiche nella composizione al fine di aumentarne l’attività e la stabilità. L’aggiunta di piccole quantità di Mg ha un effetto positivo sull’attività dei sistemi catalitici, con effetti più evidenti a 250 °C. Tuttavia, l’aumento del contenuto di Mg, sebbene migliori le proprietà fisiche del catalizzatore (area superficiale e dispersione del Cu) sia del campione calcinato che di quello scaricato dopo reazione, peggiora drasticamente l’attività catalitica. L’aggiunta di piccole quantità di Mg sembra portare alla stabilizzazione della specie attiva Cu+ e promuovere un meccanismo redox superficiale (Cu0 e Cu+). E’ possibile correlare la conversione del CO con il rapporto ZnO/Cu, confermando il ruolo nella reazione di WGS dell’interazione Cu0/ZnO libero. La sostituzione di Mg con Ba comporta un miglioramento delle prestazioni catalitiche, in particolare nelle condizioni MTS (300 °C), suggerendo una più facile dissociazione dell’acqua legata alla stabilizzazione degli ossidrili da parte dei siti basici. È però accompagnato da una diminuzione della stabilità nelle condizioni di reazione. L’aggiunta di piccole quantità di La, Ce o Zr (con un rapporto Al/R = 50 mol/mol) incrementa la stabilità termica, sia in termini di proprietà fisiche che di attività catalitica. A seguito dei cicli termici di invecchiamento accelerato, infatti, non si riscontrano importanti diminuzioni di attività catalitica, evidenziando un’elevata stabilità della fase attiva.

Dynamics, rheology and critical properties of colloidal fluid mixtures

Liquids under the influence of external fields exhibit a wide range of intriguing phenomena that can be markedly different from the behaviour of a quiescent system. This work considers two different systems — a glassforming Yukawa system and a colloid-polymer mixture — by Molecular Dynamics (MD) computer simulations coupled to dissipative particle dynamics. The former consists of a 50-50 binary mixture of differently-sized, like-charged colloids interacting via a screened Coulomb (Yukawa) potential. Near the glass transition the influence of an external shear field is studied. In particular, the transition from elastic response to plastic flow is of interest. At first, this model is characterised in equilibrium. Upon decreasing temperature it exhibits the typical dynamics of glassforming liquids, i.e. the structural relaxation time τα grows strongly in a rather small temperature range. This is discussed with respect to the mode-coupling theory of the glass transition (MCT). For the simulation of bulk systems under shear, Lees-Edwards boundary conditions are applied. At constant shear rates γ˙ ≫ 1/τα the relevant time scale is given by 1/γ˙ and the system shows shear thinning behaviour. In order to understand the pronounced differences between a quiescent system and a system under shear, the response to a suddenly commencing or terminating shear flow is studied. After the switch-on of the shear field the shear stress shows an overshoot, marking the transition from elastic to plastic deformation, which is connected to a super-diffusive increase of the mean squared displacement. Since the average static structure only depends on the value of the shear stress, it does not discriminate between those two regimes. The distribution of local stresses, in contrast, becomes broader as soon as the system starts flowing. After a switch-off of the shear field, these additional fluctuations are responsible for the fast decay of stresses, which occurs on a time scale 1/γ˙ . The stress decay after a switch-off in the elastic regime, on the other hand, happens on the much larger time scale of structural relaxation τα. While stresses decrease to zero after a switch-off for temperatures above the glass transition, they decay to a finite value for lower temperatures. The obtained results are important for advancing new theoretical approaches in the framework of mode-coupling theory. Furthermore, they suggest new experimental investigations on colloidal systems. The colloid-polymer mixture is studied in the context of the behaviour near the critical point of phase separation. For the MD simulations a new effective model with soft interaction potentials is introduced and its phase diagram is presented. Here, mainly the equilibrium properties of this model are characterised. While the self-diffusion constants of colloids and polymers do not change strongly when the critical point is approached, critical slowing down of interdiffusion is observed. The order parameter fluctuations can be determined through the long-wavelength limit of static structure factors. For this strongly asymmetric mixture it is shown how the relevant structure factor can be extracted by a diagonalisation of a matrix that contains the partial static structure factors. By presenting first results of this model under shear it is demonstrated that it is suitable for non-equilibrium simulations as well.

Thermal Casimir effect at fluid interfaces: Fluctuation-induced forces between anisotropic colloids

We study the effective interaction between two ellipsoidal particles at the interface of two fluid phases which are mediated by thermal fluctuations of the interface. Within a coarse-grained picture, the properties of fluid interfaces are very well described by an effective capillary wave Hamiltonian which governs both the equilibrium interface configuration and the thermal fluctuations (capillary waves) around this equilibrium (or mean-field) position. As postulated by the Goldstone theorem the capillary waves are long-range correlated. The interface breaks the continuous translational symmetry of the system, and in the limit of vanishing external fields - like gravity - it has to be accompanied by easily excitable long wavelength (Goldstone) modes – precisely the capillary waves. In this system the restriction of the long-ranged interface fluctuations by particles gives rise to fluctuation-induced forces which are equivalent to interactions of Casimir type and which are anisotropic in the interface plane. Since the position and the orientation of the colloids with respect to the interface normal may also fluctuate, this system is an example for the Casimir effect with fluctuating boundary conditions. In the approach taken here, the Casimir interaction is rewritten as the interaction between fluctuating multipole moments of an auxiliary charge density-like field defined on the area enclosed by the contact lines. These fluctuations are coupled to fluctuations of multipole moments of the contact line position (due to the possible position and orientational fluctuations of the colloids). We obtain explicit expressions for the behavior of the Casimir interaction at large distances for arbitrary ellipsoid aspect ratios. If colloid fluctuations are suppressed, the Casimir interaction at large distances is isotropic, attractive and long ranged (double-logarithmic in the distance). If, however, colloid fluctuations are included, the Casimir interaction at large distances changes to a power law in the inverse distance and becomes anisotropic. The leading power is 4 if only vertical fluctuations of the colloid center are allowed, and it becomes 8 if also orientational fluctuations are included.

Fluid-structure interaction by a coupled lattice Boltzmann-finite element approach

In this thesis, a strategy to model the behavior of fluids and their interaction with deformable bodies is proposed. The fluid domain is modeled by using the lattice Boltzmann method, thus analyzing the fluid dynamics by a mesoscopic point of view. It has been proved that the solution provided by this method is equivalent to solve the Navier-Stokes equations for an incompressible flow with a second-order accuracy. Slender elastic structures idealized through beam finite elements are used. Large displacements are accounted for by using the corotational formulation. Structural dynamics is computed by using the Time Discontinuous Galerkin method. Therefore, two different solution procedures are used, one for the fluid domain and the other for the structural part, respectively. These two solvers need to communicate and to transfer each other several information, i.e. stresses, velocities, displacements. In order to guarantee a continuous, effective, and mutual exchange of information, a coupling strategy, consisting of three different algorithms, has been developed and numerically tested. In particular, the effectiveness of the three algorithms is shown in terms of interface energy artificially produced by the approximate fulfilling of compatibility and equilibrium conditions at the fluid-structure interface. The proposed coupled approach is used in order to solve different fluid-structure interaction problems, i.e. cantilever beams immersed in a viscous fluid, the impact of the hull of the ship on the marine free-surface, blood flow in a deformable vessels, and even flapping wings simulating the take-off of a butterfly. The good results achieved in each application highlight the effectiveness of the proposed methodology and of the C++ developed software to successfully approach several two-dimensional fluid-structure interaction problems.

Multilevel Domain Decomposition Algorithms for Monolithic Fluid-Structure Interaction Problems with Application to Haemodynamics

Finite element techniques for solving the problem of fluid-structure interaction of an elastic solid material in a laminar incompressible viscous flow are described. The mathematical problem consists of the Navier-Stokes equations in the Arbitrary Lagrangian-Eulerian formulation coupled with a non-linear structure model, considering the problem as one continuum. The coupling between the structure and the fluid is enforced inside a monolithic framework which computes simultaneously for the fluid and the structure unknowns within a unique solver. We used the well-known Crouzeix-Raviart finite element pair for discretization in space and the method of lines for discretization in time. A stability result using the Backward-Euler time-stepping scheme for both fluid and solid part and the finite element method for the space discretization has been proved. The resulting linear system has been solved by multilevel domain decomposition techniques. Our strategy is to solve several local subproblems over subdomain patches using the Schur-complement or GMRES smoother within a multigrid iterative solver. For validation and evaluation of the accuracy of the proposed methodology, we present corresponding results for a set of two FSI benchmark configurations which describe the self-induced elastic deformation of a beam attached to a cylinder in a laminar channel flow, allowing stationary as well as periodically oscillating deformations, and for a benchmark proposed by COMSOL multiphysics where a narrow vertical structure attached to the bottom wall of a channel bends under the force due to both viscous drag and pressure. Then, as an example of fluid-structure interaction in biomedical problems, we considered the academic numerical test which consists in simulating the pressure wave propagation through a straight compliant vessel. All the tests show the applicability and the numerical efficiency of our approach to both two-dimensional and three-dimensional problems.