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Hydrodynamics in a randomly packed bed of cylindrical particles: A comparison between PR-CFD simulations and MRI experiments

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In the article, a model is proposed for a single-phase flow in a random packed bed of arbitrary particles – Raschig rings in particular. The Navier-Stokes flow equations are solved using a projection method on a structured grid and the complex geometry of the bed is captured with the immersed boundary method and direct forcing approach. The model allows for analysis of flows in complex geometries with classical and widely available finite volume or finite difference solvers for Cartesian grids. The generation of unstructured computational grids fitted to the bed particles is not necessary. The realistic bed geometry has been obtained in the simulation of the filling process in which the particles are sequentially introduced into a cylindrical container and move until mechanical equilibrium is attained. The pressure drop in the bed as the function of gas velocity has been found to be in good agreement with empirical formulas for beds of Raschig rings and sample results on detailed flow characteristics are presented.
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One of the major issues for particle-resolved CFD simulations of fixed beds are particle-particle and particle-wall contacts. A fixed bed of cylinders is studied with different local contact modifications, i.e., caps and bridges method for line and area contacts, and caps and united method for overlaps resulting from composite DEM-particles. Effects are analyzed regarding pressure drop, local velocity, and local heat transfer for 191 < Rep < 763. Modeling particle-wall contacts is becoming more important with increasing Rep. Contact modifications inside the bed are becoming less important, since convective heat transfer is dominant. The stable caps method shows promising results in comparison with heat-transfer predictions. However, it overestimates convective heat transfer in the contact regions for high flow rates. The bridges method shows good results for pressure drop and heat-transfer predictions. A difficulty remains the choice of the thermal conductivity of these bridges.
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Cited By (since 1996):8, Export Date: 5 November 2013, Source: Scopus, CODEN: CESCA, doi: 10.1016/j.ces.2012.06.055, Language of Original Document: English, Correspondence Address: Deen, N.G.; Multiphase Reactors Group, Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, PO Box 513, 5600 MB Eindhoven, Netherlands; email: N.G.Deen@TUe.nl, References: Centrella, J., Wilson, J., Planar numerical cosmology. II. The difference equations and numerical tests (1984) Astrophys. J. Suppl. Ser., 54, p. 229;
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In the development of meshes for computational fluid dynamics (CFD) simulations of transport in fixed beds of spheres, particle–particle and wall–particle contact points often present difficulties. We give results for drag coefficient (CD) and heat flow (Q) for flow past sphere–sphere and wall–sphere contact points, focusing on higher flow rates typical of industrial steam reformers (500 < Re < 10,000). Global methods, in which all particles in a bed are either shrunk or enlarged uniformly, change bed voidage giving erroneous results for CD. Local methods, in which bridges are inserted or spherical caps are removed only at the points of contact, give much better results for CD. The bridges approach is preferable for heat transfer, as fluid gaps reduce heat transfer too much, and particle overlaps increase it. A set of graphs is presented to allow estimation of the error introduced by the various methods of dealing with contact points.
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A significant body of current research is aimed at developing methods for numerical simulation of flow and transport in porous media that explicitly resolve complex pore and solid geometries, and at utilizing such models to study the relationships between fundamental pore-scale processes and macroscopic manifestations at larger (i.e., Darcy) scales. A number of different numerical methods for pore-scale simulation have been developed, and have been extensively tested and validated for simplified geometries. However, validation of pore-scale simulations of fluid velocity for complex, three-dimensional (3D) pore geometries that are representative of natural porous media is challenging due to our limited ability to measure pore-scale velocity in such systems. Recent advances in magnetic resonance imaging (MRI) offer the opportunity to measure not only the pore geometry, but also local fluid velocities under steady-state flow conditions in 3D and with high spatial resolution. In this paper, we present a 3D velocity field measured at sub-pore resolution (tens of micrometers) over a centimeter-scale 3D domain using MRI methods. We have utilized the measured pore geometry to perform 3D simulations of Navier-Stokes flow over the same domain using direct numerical simulation techniques. We present a comparison of the numerical simulation results with the measured velocity field. It is shown that the numerical results match the observed velocity patterns well overall except for a variance and small systematic scaling which can be attributed to the known experimental uncertainty in the MRI measurements. The comparisons presented here provide strong validation of the pore-scale simulation methods and new insights for interpretation of uncertainty in MRI measurements of pore-scale velocity. This study also provides a potential benchmark for future comparison of other pore-scale simulation methods.
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In this review paper we introduce currently available methods based on the Navier–Stokes equations for simulation of particulate flows which fully resolve the particles. The methods can be classified under two general categories based on the treatment of the underlying mesh namely fixed mesh methods and body-conformal mesh methods. We first consider body-conformal mesh methods and their properties. We then examine different steps of such algorithms and their application to many particle flow problems and argue why such implementations may not be feasible. Alternatively we discuss fixed mesh methods and categorize them into two subcategories namely immersed boundary methods and fictitious domain methods. A critical review of each method and their variations is provided bearing in mind the application to the particulate flow systems. The algorithms are covered in detail providing suggestions and guidelines for a successful implementation. Fundamental concepts such as discrete delta functions, body forces and calculation of surface integrals in fixed mesh methods are introduced in a simple and coherent way with simple examples and many illustrations. Major variations which are successfully applied to particulate flows are identified and the possibility of addition of heat transfer phenomena to the methods are discussed.
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For liquid flow, superficial velocity profiles inside a packed bed were obtained for monodisperse packings of spheres, deformed spheres, cylinders and Raschig-ring by averaging over several thousand local measurements of the axial flow components within a cross-section. At fully developed flow, the profiles are constant along the packing except for short inlet and outlet zones of about three particles layer length with either a buildup of the profile at the inlet or a degeneration at the exit of the packed bed. Besides velocity profiles, porosity distribution functions were also evaluated experimentally. These were introduced in the extended Brinkman equation which simulates the fluctuating profiles well if the average porosity of the packing is replaced by the radial porosity distribution. The effective viscosity is adjusted to obtain best agreement between measurements and solutions of the Brinkman equation. This effective property, however, influences the flow profile in the very near wall range only, up to approximately a distance of about half the particle diameter. The effective viscosity is found to depend on the porosity data close to the wall, on particle shape, on the Reynolds number, and on the pressure loss relation.
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Three-dimensional structural magnetic resonance imaging (MRI) and MRI velocimetry have been used to fully characterise the structure of the interparticle pore space and the single-phase flow field in a packed bed of alumina catalyst particles. Three orthogonal components of the velocity (Vx, Vy and Vz) are acquired such that the fluid velocity vector is determined at a pore-scale resolution of . The pore space has been analysed by unambiguously partitioning the pore space into individual pores. Characteristics of the individual pores are combined with the MRI velocity data to determine quantitative statistical information concerning flow through these pores. The ability of the lattice-Boltzmann simulation technique to predict the flow field visualised by MRI is also demonstrated by performing the simulation on a lattice derived directly from the MRI experimental three-dimensional image of the structure of the packed bed. A direct comparison of the MRI and lattice-Boltzmann results shows there is good agreement between the two methods. Using the pore analysis in conjunction with the velocity information, the flow field through the pore space is shown to be highly heterogeneous with 40% of the fluid flowing through only 10% of the pores. We also show that the lattice-Boltzmann data may be used to calculate average molecular displacement propagators similar to those acquired experimentally for such systems. The effect of the wall on the fluid velocity and porosity is calculated as a function of distance from the wall. Some difference between the MRI and lattice-Boltzmann results are observed close to the wall because of inertial effects in the high velocity channels which are not simulated by the lattice-Boltzmann method. Finally, we present initial results from the extension of this work to two-phase flow in packed beds. A case study of the visualisation of the extent of wetting of the packing as a function of time following start-up is presented.
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Fixed beds of cylindrical particles are important in chemical engineering applications, but their packing structures are not as well understood or as well characterized as sphere packings. In this work, X-ray microtomography is used to obtain 3D images of 1.8 mm diameter equilateral cylinders in a 23 mm cylindrical container over a range of bulk porosities. A novel algorithm is used to computationally reconstruct the packings, resulting in data sets that give the location and orientation of each cylinder in the imaged packings. Extensive analysis has been performed, including bulk and local porosities, radial distribution functions, and parameters describing local and global ordering. The major factors affecting packing structure are the overall packing density and the proximity to the wall. At the highest overall packing densities, near-wall porosity becomes nearly equal to interior porosity, and significant global ordering occurs near the wall. For a vertical container, global ordering is characterized by the alignment of the particles with an orthogonal coordinate system that has one axis coincident with r (as defined by the container) and the other two axes in the z–θ plane, but rotated 45∘ with the horizontal. The observed structures are relevant in the context of flow maldistribution and heat transfer in fixed beds.
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We present an improved method for computing incompressible viscous flow around suspended rigid particles using a fixed and uniform computational grid. The main idea is to incorporate Peskin’s regularized delta function approach [Acta Numerica 11 (2002) 1] into a direct formulation of the fluid–solid interaction force in order to allow for a smooth transfer between Eulerian and Lagrangian representations while at the same time avoiding strong restrictions of the time step. This technique was implemented in a finite-difference and fractional-step context. A variety of two- and three-dimensional simulations are presented, ranging from the flow around a single cylinder to the sedimentation of 1000 spherical particles. The accuracy and efficiency of the current method are clearly demonstrated.
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CFD is a valuable tool for understanding the flow and pressure drop in packed beds. However, determining the geometry can be complex. One possible method is to use a non-invasive imaging method such as MRI, however, problems occur in processing complex geometries when using traditional commercial meshing software. This work focuses on the use of image based meshing software originally developed for the field of computational biomechanics, to create geometries from 3d MRI scans of packed beds for use with computational dynamics. For this work we focus on disordered packed beds of cylinders at low aspect ratios and Reynolds numbers of Re=1431–5074 (based on particle diameter and superficial velocity). We compare CFD studies with experimental data performed on the actual scanned beds and compare these with the correlation proposed by Eisfeld and Schnitzlein (2001). Computational data is shown to correlate well with experimental and theoretical results.
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The concept of magnetic susceptibility is central to many current research and development activities in magnetic resonance imaging (MRI); for example, the development of MR-guided surgery has created a need for surgical instruments and other devices with susceptibility tailored to the MR environment; susceptibility effects can lead to position errors of up to several millimeters in MR-guided stereotactic surgery; and the variation of magnetic susceptibility on a microscopic scale within tissues contributes to MR contrast and is the basis of functional MRI. The magnetic aspects of MR compatibility are discussed in terms of two levels of acceptability: Materials with the first kind of magnetic field compatibility are such that magnetic forces and torques do not interfere significantly when the materials are used within the magnetic field of the scanner; materials with the second kind of magnetic field compatibility meet the more demanding requirement that they produce only negligible artifacts within the MR image and their effect on the positional accuracy of features within the image is negligible or can readily be corrected. Several materials exhibiting magnetic field compatibility of the second kind have been studied and a group of materials that produce essentially no image distortion, even when located directly within the imaging field of view, is identified. Because of demagnetizing effects, the shape and orientation, as well as the susceptibility, of objects within and adjacent to the imaging region is important in MRI. The quantitative use of susceptibility data is important to MRI, but the use of literature values for the susceptibility of materials is often difficult because of inconsistent traditions in the definitions and units used for magnetic parameters-particularly susceptibility. The uniform use of SI units for magnetic susceptibility and related quantities would help to achieve consistency and avoid confusion in MRI.