Methods and Models for Accelerating Dynamic Simulation of Fluid Power Circuits

The objective of this dissertation is to improve the dynamic simulation of fluid power circuits. A fluid power circuit is a typical way to implement power transmission in mobile working machines, e.g. cranes, excavators etc. Dynamic simulation is an essential tool in developing controllability and energy-efficient solutions for mobile machines. Efficient dynamic simulation is the basic requirement for the real-time simulation. In the real-time simulation of fluid power circuits there exist numerical problems due to the software and methods used for modelling and integration. A simulation model of a fluid power circuit is typically created using differential and algebraic equations. Efficient numerical methods are required since differential equations must be solved in real time. Unfortunately, simulation software packages offer only a limited selection of numerical solvers. Numerical problems cause noise to the results, which in many cases leads the simulation run to fail. Mathematically the fluid power circuit models are stiff systems of ordinary differential equations. Numerical solution of the stiff systems can be improved by two alternative approaches. The first is to develop numerical solvers suitable for solving stiff systems. The second is to decrease the model stiffness itself by introducing models and algorithms that either decrease the highest eigenvalues or neglect them by introducing steady-state solutions of the stiff parts of the models. The thesis proposes novel methods using the latter approach. The study aims to develop practical methods usable in dynamic simulation of fluid power circuits using explicit fixed-step integration algorithms. In this thesis, twomechanisms whichmake the systemstiff are studied. These are the pressure drop approaching zero in the turbulent orifice model and the volume approaching zero in the equation of pressure build-up. These are the critical areas to which alternative methods for modelling and numerical simulation are proposed. Generally, in hydraulic power transmission systems the orifice flow is clearly in the turbulent area. The flow becomes laminar as the pressure drop over the orifice approaches zero only in rare situations. These are e.g. when a valve is closed, or an actuator is driven against an end stopper, or external force makes actuator to switch its direction during operation. This means that in terms of accuracy, the description of laminar flow is not necessary. But, unfortunately, when a purely turbulent description of the orifice is used, numerical problems occur when the pressure drop comes close to zero since the first derivative of flow with respect to the pressure drop approaches infinity when the pressure drop approaches zero. Furthermore, the second derivative becomes discontinuous, which causes numerical noise and an infinitely small integration step when a variable step integrator is used. A numerically efficient model for the orifice flow is proposed using a cubic spline function to describe the flow in the laminar and transition areas. Parameters for the cubic spline function are selected such that its first derivative is equal to the first derivative of the pure turbulent orifice flow model in the boundary condition. In the dynamic simulation of fluid power circuits, a tradeoff exists between accuracy and calculation speed. This investigation is made for the two-regime flow orifice model. Especially inside of many types of valves, as well as between them, there exist very small volumes. The integration of pressures in small fluid volumes causes numerical problems in fluid power circuit simulation. Particularly in realtime simulation, these numerical problems are a great weakness. The system stiffness approaches infinity as the fluid volume approaches zero. If fixed step explicit algorithms for solving ordinary differential equations (ODE) are used, the system stability would easily be lost when integrating pressures in small volumes. To solve the problem caused by small fluid volumes, a pseudo-dynamic solver is proposed. Instead of integration of the pressure in a small volume, the pressure is solved as a steady-state pressure created in a separate cascade loop by numerical integration. The hydraulic capacitance V/Be of the parts of the circuit whose pressures are solved by the pseudo-dynamic method should be orders of magnitude smaller than that of those partswhose pressures are integrated. The key advantage of this novel method is that the numerical problems caused by the small volumes are completely avoided. Also, the method is freely applicable regardless of the integration routine applied. The superiority of both above-mentioned methods is that they are suited for use together with the semi-empirical modelling method which necessarily does not require any geometrical data of the valves and actuators to be modelled. In this modelling method, most of the needed component information can be taken from the manufacturer’s nominal graphs. This thesis introduces the methods and shows several numerical examples to demonstrate how the proposed methods improve the dynamic simulation of various hydraulic circuits.

Suljetun jäähdytysvesiverkon mallinnus

Työssä selvitettiin Neste Oil Porvoon jalostamon tuotantolinja 2 jäähdytysvesiverkon tilaa. Jäähdytysvesiverkon hydraulinen malli päivitettiin ja verifioitiin painemittauksin. Mallia tarkennettiin säätöventtiilien mallinnuksen sekä virhelähteiden tarkastelun perusteella havaituin muutoksin. Mallin verifioinnissa havaittiin huomattavia eroja mallin ja mitattujen paineiden välillä. Tämä johti mallin tarkempaan tarkasteluun, sekä virhelähteiden ja niiden vaikutusten selvittämiseen. Putkivarusteiden mallinnusmenetelmiä, sekä mallinnusperiaatteita vertailtiin keskenään. Koska jäähdytysveden kokonaiskierto oli riittämätön, tarkasteltiin kolmea vaihtoehtoa riittävän kiertovesimäärän aikaansaamiseksi. Nykyisten kiertovesipumppujen rinnanoperointi, sekä riittävän suureksi skaalatun pumpun käyttö simuloitiin. Kolmantena tapauksena arvioitiin lämmönvaihdinkohtaisen kuristussuunnitelman vaikutus putkiston painehäviöön, sekä putkistolle sopiva kiertovesipumppu. Vaihtoehdoille laskettiin suuntaa-antavat investointi- ja käyttökustannukset. Tarkastelun perusteella riittävän suureksi skaalattu pumppu todettiin kannattavimmaksi pienen hintaeron, sekä luotettavamman jäähdytysvesikierron käyttövarmuuden vuoksi. Työssä onnistuttiin tuottamaan yleispätevää tietoa suljetun jäähdytysvesiverkon hydrauliseen mallinnukseen vaikuttavista tekijöistä, sekä niiden vaikutuksesta mallin tarkkuuteen. Selvityksen perusteella tarkasteltua mallia saatiin tarkemmaksi.

Performance evaluation of hydrocyclone filter for microirrigation

In this study a hydrocyclone filter of 20 cm was selected and its performance was evaluated by studying the variation of discharge, pressure drop, influent concentration, and filtration efficiency with elapsed time of operation. The filter was tested with clean water to determine clean pressure drop and later it was tested with four concentrations of solid suspension, viz. 300; 600; 900 and 1,200 mg L-1. In the concentration of 300 mg L-1, the variation of pressure drop was low. But for the other concentrations of solid suspension, the variation was significant. The maximum pressure drops obtained were 41.19, 45.11, 50.01 and 52.95 kPa at 350, 390, 280 and 190 minutes of elapsed time, respectively. The maximum efficiency of solid suspension was 30.3, 32.96, 43.89 and 52.5% where as the minimum efficiencies were 9.91, 9.93, 9.62 and 9.9%, respectively. The hydrociclone tested presented inefficiency to filter small particles as clay. The initial removal efficiency of higher concentration was bigger than for lower concentration but, the final efficiency are almost the same irrespective of the concentration of solid suspension. The present tested hydrocyclone could be used as a pre-filter microirrigation to prevent emitter clogging.

Vesihöyrypiirin kiertolaskenta kuplapetikattilassa

Työssä selvitetään kiertolaskennan periaatteita kuplapetikattilassa, esitetään lyhyesti kattilan toimintaperiaate ja paneudutaan alan laskentaohjelmistoihin. Luonnonkierto kattilan vesihöyrypiirissä on seurausta hydrostaattisesta paineesta, joka aiheutuu tiheyserosta nousu- ja laskuputkien välillä. Kiertolaskennassa on huomioitava kaksifaasivirtauksen ominaispiirteet. Höyry ja neste virtaavat putkistossa eri nopeuksilla, jolloin esimerkiksi painehäviön määrityksessä käytetään erilaisia korrelaatioita ja käyrästöjä. Kaksifaasivirtauksen laskennassa tarvitaan kolmea eri taseyhtälöä: energiatasetta, massatasetta ja liikemäärätasetta. Luonnonkiertokattiloissa höyrykierron suunnittelussa on kaksi pääasiallista ehtoa. Ensimmäiseksi tulee varmistaa riittävä kiertoveden massavirta, jotta vältetään höyrystinputkien puhki palaminen. Toiseksi tulee välttää höyrystinputken pinnan lämpötilavaihteluita ja värähtelyitä. Alustavassa luonnonkierron mitoituksessa turvaudutaan kokemusperäiseen tietoon. Myöhemmässä tarkemmassa mitoituksessa käytettäviä ohjelmistoja ovat NOWA sekä kaupalliset PPSD ja Apros. Laskenta lähtee liikkeelle siitä, että lasketaan ensin vesihöyrykierron massavirrat erilaisilla lämpökuormilla ja höyryntuotanto määritellään painehäviöiden perusteella. NOWA- ja PPSD- ohjelmistoilla tehtyjen esimerkkilaskelmien perusteella voidaan sanoa, että tulokset riippuvat käytetystä laskentamallista.

Arvometallien liuospuhdistus jatkuvatoimisella ioninvaihdolla

Työn tarkoituksena oli tutkia arvometalleja sisältävän liuoksen puhdistamista jat-kuvatoimisella ioninvaihdolla. Teoriaosassa käsitellään ioninvaihdon periaate, sekä jatkuvatoimisen ioninvaihdon laiteratkaisuja ristivirta- ja vastavirtasysteemeissä. Lopuksi esitellään Simuloidun liikkuvapedin (SMB) virtausnopeuksien laske-miseksi käytettävä kolmiomenetelmä. Kokeellisen osan tarkoituksena on demonstroida laboratorioon rakennetun jatku-vatoimisen ioninvaihtimen, Simuloidun liikkuvapedin, käyttö arvometallia sisäl-tävän liuoksen puhdistamiseksi kahdenarvoisista metalli-ioneista. Kokeissa käy-tettiin hopeaa sisältävää NaCl-liuosta, josta pyrittiin puhdistamaan Mg2+, Ca2+, Pb2+ ja Zn2+-ionit ekstraktina. Laitteistolla suoritettiin kolme ajoa, joista kaksi edusti vastavirtasysteemiä ja yksi ristivirtasysteemiä. Ensimmäisessä vastavirta-ajossa sekä ekstrakti että raffinaattin erottuva hopealiuos tulivat puhtaina. Toisessa vastavirta-ajossa pyrittiin parantamaan tuottavuutta nostamalla syötön virtausnopeutta, jolloin raffinaatin puhtaus kärsi Pb2+ ja Mg2+-ionien kulkeutuessa liuosfaasin mukana raffinaattiin. Ristivirta-ajossa vain yksi kolmesta raffinaatista saavutti 100 % puhtauden. Kokeet osoittivat, että Mg2+, Ca2+, Pb2+ ja Zn2+-ionien erottaminen hopeaionista on mahdollista käyttämällämme SMB-laitteistolla. Tuottavuuden parantaminen syötön virtausnopeutta nostamalla kuitenkin heikentää puhtautta. Cross-flow-systeemin erilleenkytkettyjen kolonnien ansioista painehäviö on pienempi, mikä mahdollistaa korkeammat virtausnopeudet, mikäli ei vaadita 100 % puhtautta.

Horizontal Slug Flow in a Large-Size Pipeline: Experimentation and Modeling

The knowledge of the slug flow characteristics is very important when designing pipelines and process equipment. When the intermittences typical in slug flow occurs, the fluctuations of the flow variables bring additional concern to the designer. Focusing on this subject the present work discloses the experimental data on slug flow characteristics occurring in a large-size, large-scale facility. The results were compared with data provided by mechanistic slug flow models in order to verify their reliability when modelling actual flow conditions. Experiments were done with natural gas and oil or water as the liquid phase. To compute the frequency and velocity of the slug cell and to calculate the length of the elongated bubble and liquid slug one used two pressure transducers measuring the pressure drop across the pipe diameter at different axial locations. A third pressure transducer measured the pressure drop between two axial location 200 m apart. The experimental data were compared with results of Camargo's1 algorithm (1991, 1993), which uses the basics of Dukler & Hubbard's (1975) slug flow model, and those calculated by the transient two-phase flow simulator OLGA.

Flows of Bingham Materials Through Ideal Porous Media: an Experimental and Theoretical Study

The flow of Bingham liquids through porous media has been studied. Experiments have been performed to determine the flow rate / pressure drop relationship for the flow of a grease of Binghamian rheological behavior through an array of rods of circular cross section. The yield stress and plastic viscosity of the grease have been determined with the aid of a controlled stress rotational rheometer. To investigate a wider range of the flow parameters, the mass and momentum conservation equations have been solved numerically, in conjunction with the generalized Newtonian constitutive law and the bi-viscosity model. The finite volume method has been employed to obtain the numerical solution. These numerical results also yielded a flow rate / pressure drop relationship, which is in very good agreement with the experimental results. A capillaric theory has been developed to determine an analytical relationship between the flow rate and pressure drop for flows of Bingham liquids through porous media. It is shown that the predictions of this theory are in good agreement with the experimental and numerical results.

Development of a process for the direct synthesis of hydrogen peroxide in a novel microstructured reactor

Microreactors have proven to be versatile tools for process intensification. Over recent decades, they have increasingly been used for product and process development in chemical industries. Enhanced heat and mass transfer in the reactors due to the extremely high surfacearea- to-volume ratio and interfacial area allow chemical processes to be operated at extreme conditions. Safety is improved by the small holdup volume of the reactors and effective control of pressure and temperature. Hydrogen peroxide is a powerful green oxidant that is used in a wide range of industries. Reduction and auto-oxidation of anthraquinones is currently the main process for hydrogen peroxide production. Direct synthesis is a green alternative and has potential for on-site production. However, there are two limitations: safety concerns because of the explosive gas mixture produced and low selectivity of the process. The aim of this thesis was to develop a process for direct synthesis of hydrogen peroxide utilizing microreactor technology. Experimental and numerical approaches were applied for development of the microreactor. Development of a novel microreactor was commenced by studying the hydrodynamics and mass transfer in prototype microreactor plates. The prototypes were designed and fabricated with the assistance of CFD modeling to optimize the shape and size of the microstructure. Empirical correlations for the mass transfer coefficient were derived. The pressure drop in micro T-mixers was investigated experimentally and numerically. Correlations describing the friction factor for different flow regimes were developed and predicted values were in good agreement with experimental results. Experimental studies were conducted to develop a highly active and selective catalyst with a proper form for the microreactor. Pd catalysts supported on activated carbon cloths were prepared by different treatments during the catalyst preparation. A variety of characterization methods were used for catalyst investigation. The surface chemistry of the support and the oxidation state of the metallic phase in the catalyst play important roles in catalyst activity and selectivity for the direct synthesis. The direct synthesis of hydrogen peroxide was investigated in a bench-scale continuous process using the novel microreactor developed. The microreactor was fabricated based on the hydrodynamic and mass transfer studies and provided a high interfacial area and high mass transfer coefficient. The catalysts were prepared under optimum treatment conditions. The direct synthesis was conducted at various conditions. The thesis represents a step towards a commercially viable direct synthesis. The focus is on the two main challenges: mitigating the safety problem by utilization of microprocess technology and improving the selectivity by catalyst development.

Modeling of Liquid-Solid Flow in Industrial Scale

In the present work, liquid-solid flow in industrial scale is modeled using the commercial software of Computational Fluid Dynamics (CFD) ANSYS Fluent 14.5. In literature, there are few studies on liquid-solid flow in industrial scale, but any information about the particular case with modified geometry cannot be found. The aim of this thesis is to describe the strengths and weaknesses of the multiphase models, when a large-scale application is studied within liquid-solid flow, including the boundary-layer characteristics. The results indicate that the selection of the most appropriate multiphase model depends on the flow regime. Thus, careful estimations of the flow regime are recommended to be done before modeling. The computational tool is developed for this purpose during this thesis. The homogeneous multiphase model is valid only for homogeneous suspension, the discrete phase model (DPM) is recommended for homogeneous and heterogeneous suspension where pipe Froude number is greater than 1.0, while the mixture and Eulerian models are able to predict also flow regimes, where pipe Froude number is smaller than 1.0 and particles tend to settle. With increasing material density ratio and decreasing pipe Froude number, the Eulerian model gives the most accurate results, because it does not include simplifications in Navier-Stokes equations like the other models. In addition, the results indicate that the potential location of erosion in the pipe depends on material density ratio. Possible sedimentation of particles can cause erosion and increase pressure drop as well. In the pipe bend, especially secondary flows, perpendicular to the main flow, affect the location of erosion.

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.

Teollinen öljyn erotus koalesenssisuodatuksella väliaineessa

Koalesenssi on ilmiö, jossa dispergoidun faasin pisarat pyrkivät muodostamaan suurempia pisaroita kunnes erotettava faasi muodostuu. Koalesenssi tapahtuu kolmessa päävaiheessa, jotka ovat lähestyminen, kiinnittyminen ja irrotus. Lähestymiseen vaikuttavat mekanismit ovat muuan muassa sieppaus, diffuusio, törmäysvaikutus, sedimentaatio, sähköiset repul-siovoimat ja van der Waalsin voimat. Kiinnittymisvaiheessa dispergoidun faasin pisarat syrjäyttävät väliaineen nestekalvon samalla kostuttaen väliaineen pinnan. Irrotusvaiheessa pisaran hydrodynaaminen voima voittaa pisaran ja väliaineen välisen adheesiovoiman. Koalesenssin tehokkuuteen vaikuttavat useat eri parametrit kuten virtausnopeus, pedin ominaisuudet, väliaineen ominaisuudet sekä emulsion ominaisuudet. Nämä kaikki asiat tulee ottaa huomioon koalesenssisuodatuksen suunnittelussa. Koalesenssisuodatus lukeutuu syväsuodatusmenetelmiin, jotka on ollut käytössä jo yli 100 vuotta. Koalesenssisuodatusmenetelmä on tehokas menetelmä pienten pisaroiden erottami-seen. Menetelmää käytetään esimerkiksi öljyisten jätevesien puhdistuksessa. Teollisen öljyn syväsuodatuksen etuihin kuuluu muun muassa sen kompakti koko, alhaisemmat käyt-tökustannukset, korkea erotusaste, kyky erotella pienetkin pisarat sekä helppo operointi, automatisointi ja huolto. Suurin haittapuoli on kuitenkin väliaineen tukkeutuminen, joten prosessi vaatii puhdistuksen tai väliaineen uusimisen. Tämän kandidaatintyön tarkoituksena oli koota kirjallisuustyö öljyn koalesenssisuodatuk-sesta. Työssä kartoitettiin koalesenssisuodatuksen lähtökohdat, teoria, tärkeimmät teolli-suuden sovellukset sekä väliaineet.

Modeling a Network of Heat Exchangers

This research work addresses the problem of building a mathematical model for the given system of heat exchangers and to determine the temperatures, pressures and velocities at the intermediate positions. Such model could be used in nding an optimal design for such a superstructure. To limit the size and computing time a reduced network model was used. The method can be generalized to larger network structures. A mathematical model which includes a system of non-linear equations has been built and solved according to the Newton-Raphson algorithm. The results obtained by the proposed mathematical model were compared with the results obtained by the Paterson approximation and Chen's Approximation. Results of this research work in collaboration with a current ongoing research at the department will optimize the valve positions and hence, minimize the pumping cost and maximize the heat transfer of the system of heat exchangers.

Effects of Fin Parameters on Gas-Side Heat Transfer Performance of H-Type Finned Tube Bundle in a Waste Heat Recovery Boiler

Alfa Laval Aalborg Oy designs and manufactures waste heat recovery systems utilizing extended surfaces. The waste heat recovery boiler considered in this thesis is a water-tube boiler where exhaust gas is used as the convective heat transfer medium and water or steam flowing inside the tubes is subject to cross-flow. This thesis aims to contribute to the design of waste heat recovery boiler unit by developing a numerical model of the H-type finned tube bundle currently used by Alfa Laval Aalborg Oy to evaluate the gas-side heat transfer performance. The main objective is to identify weaknesses and potential areas of development in the current H-type finned tube design. In addition, numerical simulations for a total of 15 cases with varying geometric parameters are conducted to investigate the heat transfer and pressure drop performance dependent on H-type fin geometry. The investigated geometric parameters include fin width and height, fin spacing, and fin thickness. Comparison between single and double tube type configuration is also conducted. Based on the simulation results, the local heat transfer and flow behaviour of the H-type finned tube is presented including boundary layer development between the fins, the formation of recirculation zone behind the tubes, and the local variations of flow velocity and temperature within the tube bundle and on the fin surface. Moreover, an evaluation of the effects of various fin parameters on heat transfer and pressure drop performance of H-type finned tube bundle has been provided. It was concluded that from the studied parameters fin spacing and fin width had the most significant effect on tube bundle performance and the effect of fin thickness was the least important. Furthermore, the results suggested that the heat transfer performance would increase due to enhanced turbulence if the current double tube configuration is replaced with single tube configuration, but further investigation and experimental measurements are required in order to validate the results.

Optimizing the Performance of a Heat Exchanger Network

This research is the continuation and a joint work with a master thesis that has been done in this department recently by Hemamali Chathurangani Yashika Jayathunga. The mathematical system of the equations in the designed Heat Exchanger Network synthesis has been extended by adding a number of equipment; such as heat exchangers, mixers and dividers. The solutions of the system is obtained and the optimal setting of the valves (Each divider contains a valve) is calculated by introducing grid-based optimization. Finding the best position of the valves will lead to maximization of the transferred heat in the hot stream and minimization of the pressure drop in the cold stream. The aim of the following thesis will be achieved by practicing the cost optimization to model an optimized network.

Experimentation on Wind Powered Hydraulic Heating System

It is common knowledge of the world’s dependency on fossil fuel for energy, its unsustainability on the long run and the changing trend towards renewable energy as an alternative energy source. This aims to cut down greenhouse gas emission and its impact on the rate of ecological and climatic change. Quite remarkably, wind energy has been one of many focus areas of renewable energy sources and has attracted lots of investment and technological advancement. The objective of this research is to explore wind energy and its application in household heating. This research aims at applying experimental approach in real time to study and verify a virtually simulated wind powered hydraulic house heating system. The hardware components comprise of an integrated hydraulic pump, flow control valve, hydraulic fluid and other hydraulic components. The system design and control applies hardware in-the-loop (HIL) simulation setup. Output signal from the semi-empirical turbine modelling controls the integrated motor to generate flow. Throttling the volume flow creates pressure drop across the valve and subsequently thermal power in the system to be outputted using a heat exchanger. Maximum thermal power is achieved by regulating valve orifice to achieve optimum system parameter. Savonius rotor is preferred for its low inertia, high starting torque and ease of design and maintenance characteristics, but lags in power efficiency. A prototype turbine design is used; with power output in range of practical Savonius turbine. The physical mechanism of the prototype turbine’s augmentation design is not known and will not be a focus in this study.