Multiphase Computational Fluid Dynamics Model Research Articles

Modeling and simulation of novel bio-emulated flow field with improved branch channels on PEMFC performance

The channel geometry of the bipolar plate in the proton exchange membrane fuel cell (PEMFC) significantly influences its performance. In this study, a bio-emulated flow field (BEFF) pattern in the bipolar plate was used based on the external carotid artery design with its branches. A comprehensive investigation was conducted using a three-dimensional (3-D) multiphase computational fluid dynamics (CFD) model on bio-emulated flow fields with branch channels of zero (BE-0), six (BE-6), and ten (BE-10). The results obtained were compared with traditional parallel flow fields (TPFF) and traditional serpentine flow fields (TSFF). The BE-10 results showed reduced pressure drop, uniform distribution of reactants, and higher power output compared with other configurations. The peak power density of BE-10 surpassed that of TPFF by approximately 45.07% and exceeded BE-0 by 10.39%. The novel BEFF structure with an increase in branch channels showed that the reactants, temperature, and static pressure distribution are more uniform with better water management.

High current density operation of proton exchange membrane fuel cells at a constant relative humidity

To further reduce the size and cost of proton exchange membrane fuel cells, it is desired to operate at high current densities exceeding 2 A/cm2, and consequently achieve power densities above 1 W/cm2. In a prior one-dimensional modeling study that employed the Engineering Equation Solver (EES), it was suggested that proton exchange membrane fuel cells might operate at current densities as high as 10 A/cm2 and even more when appropriate operating and channel dimensions are chosen, and perforated metal plates are used as porous transport layers instead of carbon fiber papers. The current study verifies the general findings of the previous 1-D model by a 3-D multiphase computational fluid dynamics model in Ansys CFX to obtain additional insights. Operating a proton exchange membrane fuel cell at a constant humidity (100%, 80%, 60%) from the inlet to the outlet at the cathode side appears feasible, and results for a current density above 6 A/cm2 were obtained. This mode of operation is promising also for automotive applications.

High current density operation of proton exchange membrane fuel cells at a constant relative humidity

To further reduce the size and cost of proton exchange membrane fuel cells, it is desired to operate at high current densities exceeding 2 A/cm2, and consequently achieve power densities above 1 W/cm2. In a prior one-dimensional modeling study that employed the Engineering Equation Solver (EES), it was suggested that proton exchange membrane fuel cells might operate at current densities as high as 10 A/cm2 and even more when appropriate operating and channel dimensions are chosen, and perforated metal plates are used as porous transport layers instead of carbon fiber papers. The current study verifies the general findings of the previous 1-D model by a 3-D multiphase computational fluid dynamics model in Ansys CFX to obtain additional insights. Operating a proton exchange membrane fuel cell at a constant humidity (100%, 80%, 60%) from the inlet to the outlet at the cathode side appears feasible, and results for a current density above 6 A/cm2 were obtained. This mode of operation is promising also for automotive applications.

Influence and optimization of dual-orifice jet nozzles on oil capture performance of under-race lubrication with a radial oil scoop for high-speed bearings in aero-engine

The objective of this research is to determine the influence of dual-orifice jet nozzles on the oil–air flow dynamics and oil capture performance in the under-race lubrication for high-speed bearings and to identify the optimal design parameter combinations for optimizing the oil capture performance. An experimental setup for under-race lubrication is specifically designed, complemented by a multiphase computational fluid dynamics model to elucidate the oil–air flow behavior. The response surface methodology is combined with a multi-objective particle swarm optimization algorithm to perform multi-objective optimization of the oil capture performance. The findings indicate that oil capture efficiency initially rises to a peak and subsequently declines with increasing orifice spacing, identifying an optimal orifice spacing that maximizes efficiency. While the oil flow rate from dual-orifice jet nozzles is lower than twice that of single-orifice jet nozzles, appropriate parameter matching allowed for an increase in both captured lubricant oil and efficiency. Optimized configurations achieved substantial enhancements in oil capture efficiency, with the greatest improvement exceeding 16%, all while maintaining precise oil supply to the high-speed bearings.

High Current Density Operation of a Proton Exchange Membrane Fuel Cell with Varying Inlet Relative Humidity—A Modeling Study

This paper focuses on proton exchange membrane fuel cell (PEMFC) operation at current densities in the order of 6 A/cm2. Such high current densities are conceivable when the traditional carbon fiber papers are replaced with perforated metal plates as the gas diffusion layer to enhance waste heat removal, and at the same time the relative humidity inside the fuel cell is kept below 100% by applying appropriate operating conditions as was found in previous one-dimensional modeling work. In the current paper, we applied a three-dimensional, multi-phase computational fluid dynamics model based on Ansys-CFX to obtain additional insight into the underlying physics. The calculated pressure drops are in very good agreement with previous one-dimensional modeling work, and the current densities in all case studies are in the order of 5–6 A/cm2, but different from the previous one-dimensional study, the results suggest that the relative humidity is very close to 100% throughout the entire channel length when the inlet relative humidity is 100%, ensuring best hydration cell conditions and hence best performance. Importantly, the model results suggest that fuel cell performance at a high current density in conjunction with relatively low stoichiometric flow ratios around 1.5–2 is possible.

Column flotation hydrodynamics operating in the heterogeneous regime estimated by electrical resistance tomography and multi-phase CFD model

ABSTRACT This paper investigates the two-phase flow hydrodynamics of a column flotation operated from a homogeneous to a heterogeneous flow regimes using experimental and computational fluid dynamics (CFD) techniques. Experiments were conducted in a lab scale column flotation of 0.1 m internal diameter and 2.5 m length at various superficial gas velocities using a dual plane electrical resistance tomography (ERT). The mean gas holdup increased from 2 to 18% with the increase in superficial gas velocity from 0.6 to 7.2 cm/s. The gas holdup-based bubble swarm velocity method identified four distinct flow regimes, i.e. homogeneous bubbling regime, narrow discrete bubbling regime, a sustained helical flow regime and churn turbulent flow regime in the column. Further, transient simulations were conducted using a two-fluid model coupled with a population balance model to assess the flow behavior inside the column. Virtual mass, lift and drag forces were incorporated into the model to account for the interphase forces. Numerical simulations predicted mean gas holdup was matching with the experimental data at low gas velocities (<2.4 cm/s), and a marginal deviation was noted at higher gas velocities (>2.4 cm/s). The predicted radial gas holdup profiles were found to change from flatter to parabolic with the increase in gas velocities, i.e. similar to the experiments. The effect of particle size on the rate constant and recovery was estimated with Luttrell and Yoon’s performance model using the particle floatability input data and the two-phase experimental data. The developed CFD model can be useful to optimize the operating and design parameters for efficient operation of the column flotation process.

Nomograph derivation for underwater sour gas releases in shallow waters based on computational fluid dynamics simulations

Ruptured underwater pipelines releasing sour gas (i.e., natural gas with high concentrations of H2S) pose significant threats to environmental safety due to their toxic and contaminative properties. This study suggests a transient Eulerian-Eulerian multiphase computational fluid dynamics (CFD) model for assessing the environmental impact of sour gas releases in shallow, ecologically sensitive waters. Employing the Realizable k-ε turbulence model and additional bubble plume mechanisms, the model was rigorously validated against well-documented experimental data, showing high levels of agreement across multiple metrics. Key environmental safety parameters—such as rise time and H2S surface gas concentration, indicative of toxic exposure risk to aquatic life and human health—were extracted for multiple release scenarios. To present generalized and easily accessible data, these parameters were nondimensionalized and incorporated into a nomograph, enabling environmental risk assessments to be conducted four orders of magnitude faster than with high-fidelity simulations. The study emphasizes the nomograph's utility in rapid, environmentally relevant risk assessment and emergency planning for mitigating the impact of sour gas spills. An error and sensitivity analysis revealed uncertainties of ±7 % for rise time and ±58 % for surface gas concentration, pinpointing avenues for future research.

Enhancing CO2 capture efficiency: Computational fluid dynamics investigation of gas-liquid vortex reactor configurations for process intensification

This study employs non-thermal Computational Fluid Dynamics (CFD) simulations to explore the efficacy of a gas–liquid vortex reactor (GLVR) for intensifying CO2 capture. The investigation concentrates on the multiphase flow and mass transfer behavior in diverse GLVR experimental units. Employing a multiphase Euler-Euler CFD model integrated with a Population Balance Model (CFD-PBM), a mass transfer model, and reaction kinetics, allows us to accurately simulate the reactive absorption of CO2 into aqueous Monoethanolamine (MEA). Experiments are conducted using a 30 wt% MEA solution for CO2 absorption, serving the purpose of model validation. This comprehensive approach enables a simulation of complex dynamics within the GLVR, emphasizing bubble breakage, coalescence, and reactive mass transfer processes. Examining bubble size distribution, pressure drop, CO2 absorption efficiency, and energy input systematically across various reactor geometries and operational conditions, our findings demonstrate that an optimized GLVR configuration significantly enhances CO2 absorption compared to the original design. Furthermore, the optimized GLVR outperforms state-of-the-art process intensification equipment in terms of CO2 absorption rate per unit reactor volume and energy efficiency.

Numerical Simulation of Pipeline Scour and Sedimentation around Submerged Pipelines with an Open-Source Multiphase-CFD Model

This paper presents a comprehensive study on pipeline scour and sedimentation phenomena using an open-source multiphase Computational Fluid Dynamics (CFD) model. The research focuses on understanding the complex interactions between fluid flow, sediment transport, and scour formation around submerged pipelines. The proposed analysis aims to enhance the understanding of scour development and sedimentation deposition, which is crucial for the design, operation, and maintenance of various engineering structures, including offshore pipelines and underwater infrastructure. The results show that the model exhibits the ability to compute sediment transport without depending on traditional assumptions related to bed-load and suspended-load layers. The simulation results affirm the model's proficiency in replicating the underlying mechanisms accountable for the onset of these processes, notably seepage flow and piping. Furthermore, this model can successfully depict the vortex phenomenon, which promotes the accumulation of sediment around the pipe. This phenomenon arises from the contrast in pressure between the centre of the vortex and the pressure exerted on the sediment beneath it.

Comparative Study of Droplet Diameter Distribution: Insights from Experimental Imaging and Computational Fluid Dynamics Simulations

The interfacial area between two phases plays a crucial role in the mass transfer rate of gas–liquid processes such as absorption. In this context, the droplet size distribution within the flow field of a droplet-based absorber significantly affects the surface area, thereby influencing the absorption efficiency. This study focuses on developing a computational fluid dynamics (CFD) model to predict the size and distribution of water droplets free-falling in a transparent square tube. This model serves as a digital twin of our experimental setup, enabling a comparative analysis of experimental and computational results. For the accurate measurement of droplet size and distribution, specialized experimental equipment was developed, and a high-speed camera along with Fiji software was used for the capturing and processing of droplet images. At the point of injection and at two different heights, the sizes and distributions of falling droplets were measured using this setup. The interaction between the liquid water droplets and the gas phase within the square tube was modeled using the Eulerian–Lagrangian (E-L) framework in the STAR-CCM+ software. The E-L multiphase CFD model yielded approximations with errors ranging from 11 to 27% for various average mean diameters, including d10, d20, d30, and d32, of the liquid droplets at two distinct heights (200 mm and 400 mm) for both nozzle plates. This comprehensive approach provides valuable insights into the dynamics of droplet-based absorption processes.

Enhancing Efficiency in Alkaline Electrolysis Cells: Optimizing Flow Channels through Multiphase Computational Fluid Dynamics Modeling

The efficient operation of alkaline water electrolysis cells hinges upon understanding and optimizing gas–liquid flow dynamics. Achieving uniform flow patterns is crucial to minimize stagnant regions, prevent gas bubble accumulation, and establish optimal conditions for electrochemical reactions. This study employed a comprehensive, three-dimensional computational fluid dynamics Euler–Euler multiphase model, based on a geometric representation of an alkaline electrolytic cell. The electrochemical model, responsible for producing hydrogen and oxygen at the cathode and anode during water electrolysis, is integrated into the flow model by introducing mass source terms within the user-defined function. The membrane positioned between the flow channels employs a porous medium model to selectively permit specific components to pass through while restricting others. To validate the accuracy of the model, comparisons were made with measured data available in the literature. We obtained an optimization design method for the channel structure; the three-inlet model demonstrated improved speed and temperature uniformity, with a 22% reduction in the hydrogen concentration at the outlet compared to the single-inlet model. This resulted in the optimization of gas emission efficiency. As the radius of the spherical convex structure increased, the influence of the spherical convex structure on the electrolyte intensified, resulting in enhanced flow uniformity within the flow field. This study may help provide recommendations for designing and optimizing flow channels to enhance the efficiency of alkaline water electrolysis cells.

Effect of static magnetic field on the molten pool dynamics during laser powder bed fusion of Inconel 718 superalloy

Recent researches show that a static magnetic field (SMF) has an impact on the molten pool dynamics and microstructure of laser powder bed fusion (L-PBF). This work is intended to the multiple effect of SMF on the molten pool dynamics during L-PBF of Inconel 718 superalloy. A three-dimensional (3D) multiphase computational fluid dynamics (CFD) model at the powder-bed scale was established by coupling the electromagnetic braking and Seebeck effect in a static vertically-distributed magnetic field. Results show that the magnetic damping force (MDF) of the order of 104 N/m3∼105 N/m3 within the whole molten pool suppresses the Marangoni convection. The thermoelectric magnetic force (TEMF) of the order of 106 N/m3∼107 N/m3 rotates in the mushy zone and further enhances the melt flow of the whole molten pool. The SMF will not transform the flow pattern and temperature distribution in the molten pool. SMFs of 0.1 T and 0.3 T will suppress the melt flow, while that of 0.5 T will enhance the melt flow. The width of molten pool first decreases and then increases when the magnetic flux density (MFD) increases from 0 T to 0.5 T. In addition, applying a SMF of 0.3 T can effectively inhibit pore defect and spatters. This work can provide insight into the control of molten pool by introducing a SMF during L-PBF.

Thermo-fluid dynamics and morphology evolution of nickel-based superalloy in a multilayer laser directed energy deposition process

The complex thermo-fluid dynamics of the molten pool determine the dimension accuracy and mechanical properties of laser directed energy deposition (L-DED) components. In this work, a three-dimensional (3D) multiphase computational fluid dynamics (CFD) model based on the Volume of Fluid (VOF) method was proposed to establish the relationship between the thermo-fluid dynamics and the molten pool morphology evolution of René N5 nickel-based superalloy in L-DED. The single-track and ten-layer deposition processes under unidirectional and bidirectional scanning strategies were studied. Results show that the predicted deposition morphology and dimensions are in good agreement with the experimental samples. The heat accumulation in the multilayer deposition process increases the size of the molten pool, thereby increasing the width of the deposit. Different from the single-layer deposition driven by the Marangoni force, gravity is the key factor in the multilayer deposition process without the side support. The hump structure at the starting position under unidirectional scanning is attributed to the backward flow of the melt of the molten pool, while the decline structure at the end position is enhanced by the forward flow of the melt. At the starting position of each layer under bidirectional scanning, the expansion of the molten pool resulted from the heat accumulation and mass addition increases the width of the two ends and compensates for the deposition height. This work can provide a theoretical basis for understanding the uneven morphology characteristics and the dimensional accuracy control in L-DED.

Influence of impeller clearance, impeller size and baffles on copper sorption on zeolite NaX: Do the size and position really matter?

Even though optimal mixing parameters may significantly influence the sorption process and its costs, the influence of hydrodynamics on sorption in a batch reactor hasn't yet been adequately studied. In this study, the hydrodynamic conditions produced by pitched blade turbine (PBT) impellers of various diameters and positions in baffled and unbaffled reactors were investigated. The objective was to investigate their influence on the just suspended impeller speed (NJS), power consumption per zeolite mass and the sorption process at the same temperature, initial copper solution concentration, and zeolite particle size in all the experiments conducted. The results show that NJS generally decreases as impeller diameter increases and is lower in the reactor without baffles. A transient multiphase computational fluid dynamics model was developed to provide valuable insight into the complex flow kinetics and it was found that the further the impeller is from the bottom of the baffled reactor the wider is the secondary suspension flow and the intensity of the flow below the impeller decreases. For this reason, complete suspension of the NaX zeolite particles in the solution was achieved at a higher PBT impeller speed. Due to the swirling motion of the suspension, this phenomenon is not observed in the unbaffled reactor for all the impellers used besides the smallest one. The power consumption per zeolite mass, at the state of complete zeolite suspension, increases in baffled reactor and decreases in unbaffled reactor with increasing impeller diameter having significantly lower values in the unbaffled reactor. The significantly lower power consumption per zeolite mass in an unbaffled system could be attributed to, not only the generally lower NJS values, but also to the resistance force which baffles make to the tangential fluid flow. The Ritchie model and Mixed surface reaction and diffusion controlled adsorption kinetic model were used for the kinetic analysis of the experimental kinetic data. The kinetic results indicate that the process is faster when the impeller is at the standard of bottom clearance, regardless of the presence of the baffles.

Assessing low Reynolds number airfoil performance in microburst environments for micro/unmanned aerial vehicles: A numerical study

This study aims to investigate the impact of microbursts, which are a common meteorological phenomenon, on aircraft performance. A multiphase computational fluid dynamics model has been developed to simulate the microburst-generated downdraft environment over an airfoil. The simulations were conducted at a 12° angle of attack for takeoff conditions with a Reynolds number of 2×105. The lift and drag coefficients were compared to experimental results and exhibited a strong correlation. Additionally, this study examined the volume of fluid and the coefficient of pressure distribution. It also examined the boundary-layer velocity profiles at five different chord positions, the location of rivulet formation on the upper surface of the airfoil, and water film height. The results revealed a maximum variation of 72.18% and 16.53% in lift and drag coefficients, respectively, between the numerical and experimental results. These findings provide valuable insight into the effects of microbursts on aircraft performance and have implications for the aviation industry.

Analysis of cavitation and shear in bellows pump: transient CFD modelling and high-speed visualization

Pneumatic drive bellows pumps (PDBPs) are a crucial fluid control component in the semiconductor industry. However, when dealing with specific chemical mechanical polishing (CMP) slurries, agglomeration of particles can occur, leading to scratches, particle residues, pits, and other defects on the wafer surface. The leading cause of agglomeration has been proposed to be cavitation and excessive shear in PDBPs. A high-fidelity multiphase computational fluid dynamics (CFD) model, which fully resolves the response of check valves under hydrodynamic and other external loads, was established to evaluate cavitation behaviour and shear distribution in PDBPs. Moreover, a test rig was built to visualize cavitating flow patterns in PDBPs and verify the accuracy of the CFD model. Among different cavitation regions captured by high-speed visualization, the region near the inner leading edge of the end-ring of the inlet valve is dominant, with high intensity, long duration, and complex morphology evolution. Detailed initiation and development process of cavities in the dominant region are analysed numerically. The shear rate in different domains of PDBPs is estimated, and the inlet valve domain stands out from the other. The strongest shear rate is observed near the leading edge of the end-ring. Furthermore, an analysis of the relationship between cavitation and shear indicates that the high-intensity vortices generated owing to strong shear account for the inception of cavitation. This study contributes to understanding inner flow details in PDBPs and provides a guideline for further optimization of similar pumps.

Flow-Through Short-Crested Trapezoidal Weirs: Effect of Downstream Slope

Trapezoidal profiled weirs and barrages are employed extensively in agrarian countries like India and Pakistan for diverting river water for canal-fed irrigation. The downstream slope of a weir is designed as 1V∶3H, although in some older structures, slopes as mild as 1V∶5H are noticed. Downstream slopes of 1V∶5H also exist for the barrages on the Nile in Egypt and in the standard Crump weir used in the UK and some European countries. This study explores the effect of the downstream slope of a short-crested trapezoidal weir on its flow hydraulics and conveyance properties. Irrigation barrages and weirs, apart from diverting water to a canal, also help in measuring the discharge of a river, which is a function of the up- and downstream water levels. For large discharges during floods, the gates of a barrage are withdrawn to ensure an uncontrolled flow that may either be free or submerged, depending on the downstream water level. Although past studies on uncontrolled flows have recognized the effect of the upstream slope of a weir on the coefficient of discharge, Cd, this study establishes that it is also influenced by a weir’s downstream slope. An equation of Cd for free flows and a flow reduction factor for submerged flows are proposed considering both weir-face angles. For free flows, Cd is seen to increase with the steepness of a weir’s downstream slope; for submerged flows, the discharge reduction factor is observed to improve as the slope becomes milder, leading to a greater conveyance. Data from our own laboratory experiments, past publications, and results derived from a 2D RANS-VOF multiphase computational fluid dynamics model are used in arriving at the conclusions reported in the study.

Numerical Simulation of Electric Arc Heating Process in the Refining Ladle

This article presents a comprehensive multiphase computational fluid dynamics model to simulate the arc heating process in the ladle. The results on temperature distribution, slag eye size, flow characteristics, and wall shear stress under three flow rate conditions are discussed. Validation of the results is carried out by comparing them with industrial measurements. The study highlights that when the flow rate increases by 100%, the temperature difference in the ladle decreases by 17.37%, while the slag eye‐opening and wall shear stress increase by 116.38% and 49.86%, respectively. The study emphasizes the details of model development and utilization of models to optimize the process.

Investigation of the hydrogen bubble effect on the overpotential in an alkaline water electrolyzer

The efficiency of alkaline water electrolysis (AWE) technology is highly influenced by the electrogenerated bubbles. Most of the efficiency improvement methods based on the enhancement of the flow field have been evaluated on the overall bubble effect. In this work, we distinguish the different bubble effects and investigate their effects on the overpotential, respectively. An experimental investigation was carried out in a vertical plane electrode electrolyzer with forced convection. The correction factor for the outlet gas flow rate on the surface of the cathodic electrode was obtained by comparing experimental and theoretical results, whose value was around 1.6 under the conditions of this study. Meanwhile, according to the experimental results, the two-way coupling Euler-Lagrange multiphase computational fluid dynamics (CFD) model was modified. Experimental and numerical results indicate that the electrolyte inlet velocity at a higher current density has a stronger influence on the hydrogen bubble curtain than that at a lower current density. More importantly, the bubbles covering on the electrode have a stronger influence on the overpotential than that dispersing in the electrolyte, and it is about 100 times difference.

Numerical study on the effects of bund on liquid pool spreading and vapor dispersion after a catastrophic LNG tank failure

Liquefied natural gas (LNG) storage tanks are usually equipped with bunds to provide an additional layer of protection. However, the catastrophic failure of an LNG storage tank usually results in a bund overtopping. The overtopped LNG will evaporate rapidly at ground surface to form the flammable gas cloud. Previous studies have developed computational fluid dynamics (CFD) models to investigate the ability of bunds to retain liquids; However, the models were developed based on ambient liquid, ignoring the evaporation phenomena and vapor dispersion of LNG. In this work, a multiphase CFD model which integrated with the evaporation model was proposed to simulate the complete overtopping process (including LNG overtopping, LNG spread, LNG evaporation and vapor dispersion). The data from two field experiments were used to validate the model. In addition, this paper studied a case of catastrophic failure that derived from an industrial LNG Tank. The effect of the bund configurations on the wind flow field, the overtopping fraction, the spread of LNG and the dispersion of LNG vapor cloud was analyzed. The present work can help relevant personnel to better assess the engineering risks associated with catastrophic failure of storage tanks for decision making in the process safety framework.