TY - JOUR
T1 - Analysis of the shear-driven flow in a scale model of a phase separator
T2 - Validation of a coupled CFD approach using experimental data from a physical model
AU - Ortner, Benjamin
AU - Schmidberger, Christian
AU - Prieler, René
AU - Mally, Valentin
AU - Hochenauer, Christoph
N1 - Publisher Copyright:
© 2024 The Author(s)
PY - 2024/7
Y1 - 2024/7
N2 - The effect of shear stress at the interface between a flowing gaseous phase and a liquid-filled cavity, a scenario commonly found in flue gas/slag phase separators, is investigated in this study. This effect is frequently disregarded in computational fluid dynamics (CFD) simulations within metallurgy, primarily due to its limited influence on the motion of liquids (e.g., slag, liquid metal) when compared to other factors such as stirring by natural convection or bubbling. This study was undertaken to investigate shear-driven flow in a 1:4 scale model of a phase separator in which a flue gas stream coming from a furnace is mobilizing the flow of a slag melt. To cover a wide range of operating conditions, silicone oil with varying viscosities (20, 50, and 70 cSt) was considered for mimicking viscous slag. Additionally, different volumetric airflow rates (18, 27, and 36 m3/h) were considered to simulate the flue gas flow. Particle image velocimetry (PIV) measurements were conducted on the model. The experimental results were utilized to validate computationally efficient, coupled steady-state simulations of the system. Notably, the steady-state simulations, requiring approximately one hour of CPU time, demonstrated a computation time decrease of two magnitudes compared to conventional Volume of Fluid (VOF) modeling. A stable, laminar flow pattern of the liquid phase with surface velocities of up to approximately 30 mm/s was observed for the case with the lowest oil viscosity and the highest airflow rate, while a steady, turbulent flow was observed in the gas phase. Conversely, the lowest surface velocities, measuring around 5 mm/s, were recorded and calculated for the scenario with the highest oil viscosity and the lowest airflow rate. It was noted that velocities increased proportionally with the airflow rate but exhibited a disproportionate relationship with oil viscosity. The prediction of velocity magnitudes by the steady-state CFD model was highly accurate, with only minor discrepancies observed between the measured and calculated flow patterns. In summary, valuable insights into the often-overlooked shear stress effects at the phase boundary in gaseous-liquid flow over a cavity are provided by our study.
AB - The effect of shear stress at the interface between a flowing gaseous phase and a liquid-filled cavity, a scenario commonly found in flue gas/slag phase separators, is investigated in this study. This effect is frequently disregarded in computational fluid dynamics (CFD) simulations within metallurgy, primarily due to its limited influence on the motion of liquids (e.g., slag, liquid metal) when compared to other factors such as stirring by natural convection or bubbling. This study was undertaken to investigate shear-driven flow in a 1:4 scale model of a phase separator in which a flue gas stream coming from a furnace is mobilizing the flow of a slag melt. To cover a wide range of operating conditions, silicone oil with varying viscosities (20, 50, and 70 cSt) was considered for mimicking viscous slag. Additionally, different volumetric airflow rates (18, 27, and 36 m3/h) were considered to simulate the flue gas flow. Particle image velocimetry (PIV) measurements were conducted on the model. The experimental results were utilized to validate computationally efficient, coupled steady-state simulations of the system. Notably, the steady-state simulations, requiring approximately one hour of CPU time, demonstrated a computation time decrease of two magnitudes compared to conventional Volume of Fluid (VOF) modeling. A stable, laminar flow pattern of the liquid phase with surface velocities of up to approximately 30 mm/s was observed for the case with the lowest oil viscosity and the highest airflow rate, while a steady, turbulent flow was observed in the gas phase. Conversely, the lowest surface velocities, measuring around 5 mm/s, were recorded and calculated for the scenario with the highest oil viscosity and the lowest airflow rate. It was noted that velocities increased proportionally with the airflow rate but exhibited a disproportionate relationship with oil viscosity. The prediction of velocity magnitudes by the steady-state CFD model was highly accurate, with only minor discrepancies observed between the measured and calculated flow patterns. In summary, valuable insights into the often-overlooked shear stress effects at the phase boundary in gaseous-liquid flow over a cavity are provided by our study.
KW - CFD modeling
KW - Particle image velocimetry
KW - Phase separator
KW - Shear-driven flow
UR - http://www.scopus.com/inward/record.url?scp=85193201322&partnerID=8YFLogxK
U2 - 10.1016/j.ijmultiphaseflow.2024.104852
DO - 10.1016/j.ijmultiphaseflow.2024.104852
M3 - Article
AN - SCOPUS:85193201322
SN - 0301-9322
VL - 177
JO - International Journal of Multiphase Flow
JF - International Journal of Multiphase Flow
M1 - 104852
ER -