Particle Flow Research Articles

Online mass-flow-rate measurement of high-intensity gas-conveyed particle flow for dry mineral processing

Measuring the mass flow rate of high-intensity gas-conveyed particle flow (GCPF) in real time is of great importance for enhancing efficiency and productivity in dry mineral processing circuits. It also poses challenges beyond the capability of most existing technologies. In this article, we introduce a novel, cost-effective, online mass flow rate measurement system utilizing a force transducer. A theoretical model of the relationship between the average impact force and the mass flow rate was developed using the Hertz theory of impact. A prototype sensing system was then designed and constructed, followed by a series of experiments to validate the theoretical model. The experimental results corroborated the proposed model and showed the accuracy of the measurement was within 2% for mass flow rates above 1.741 g/s. This demonstrated the system’s capability to measure the mass flow rate of GCPF in real-time using measurements of the average impact force.

Estimation of the effect of rotational speed on flow and mixing quality of particles with different shapes in a rotary drum

Estimation of the effect of rotational speed on flow and mixing quality of particles with different shapes in a rotary drum

Microfluidic device with three-dimensional microtip electrodes for efficient capture and concentration of bacteria-sized microparticles using dielectrophoresis

Microfluidics-based systems have gained considerable attention in the lab-on-chip field owing to their ability to separate, concentrate, and analyze microparticles. Concentrating microparticles is crucial for the high-sensitivity measurement of biomarkers in the analysis of cells or bacteria. This study presents a microfluidic chip using dielectrophoresis (DEP) to capture bacterial microparticles. The chip features a vertically arranged microtip electrode and an indium tin oxide (ITO) electrode, enhancing the electric field concentration effect and enabling optical analysis of the collected particles. The device was designed and fabricated using microfabrication techniques that incorporate a patterned array of microtip electrodes on a polydimethylsiloxane (PDMS) substrate. Experimental studies and numerical simulations were conducted to evaluate the device performance. The fabricated device was applied to the concentration of fluorescent beads with various variables such as particle size, frequency, voltage, and flow rate. The experimental results demonstrated the successful trapping and concentration of microparticles using DEP forces. The recovery rates of the 2.29 µm and 4.42 µm PS beads, when introduced at a flow rate of 1 μL/min and subjected to an applied alternating current (AC) voltage of 200 kHz and 10 Vpp at the microtip electrode, were measured to be 85.50±2.69 % and 91.83±0.63 %, respectively. Additionally, to assess the applicability of the microtip electrode-based DEP device proposed here for bacteria concentration, capture experiments were conducted using Escherichia coli, demonstrating a recovery rate performance of 77.93±7.31 %. These findings highlight the potential of the proposed microfluidic chip for the concentration and measurement of bacteria, such as E. coli.

Controllable generation of engine exhaust similar soot particles using an inverted nitrogen-diluted flame burner for calibration purpose

The calibration of vehicle engine exhaust PN analyzers has been a challenge due to the significant difference in properties between calibration particles and measured particles. In this study, an inverted nitrogen-diluted flame burner was designed to generate engine exhaust similar soot particles and evaluated for calibration use. The burner can produce reference-unimodal soot particles at 61–311 nm and total number concentration up to 108 #/cm3 by adjusting the flow rate of ethylene, nitrogen and air. Excellent stability of 0.91 % enables it to generate a fairly stable calibration particle flow. Mixing nitrogen in ethylene makes burner have a high degree of variability in generating smaller particles. The properties of size distribution, morphology, effective density indicate that the generated soot particles can simulate well with engine exhaust particles. TOA results indicate that the soot have high TC mass concentration of over 559.26 mg/m3 and EC/TC fraction of over 90 %.

Study and derivation of closures in the volume-filtered framework for particle-laden flows

Study and derivation of closures in the volume-filtered framework for particle-laden flows

Continuum modeling of gas–particle flows: an overview

Continuum modeling of gas–particle flows: an overview

Numerical analysis of gas-solid flow erosion in different geometries as alternatives to a standard pipe elbow

This study was conducted with the aim of replacing different geometric fittings instead of the standard 90° elbow and trying to change the flow pattern to reduce erosion damage. Among fittings, the elbows are at a more serious risk. Numerical investigation of the present erosion with the novelty of research on non-spherical particles and changes in the impact angle of particles along with fluid flow using eight new proposed fittings, including two miter fittings, three blinded fittings, one reducer elbow fitting, and two spherical elbows fittings in comparison with the standard 90° elbow was controlled. The numerical simulation of the gas-solid two-phase flow of non-spherical particles was studied using the Euler-Lagrange approach. To carry out the study numerical, first, the gas flow was modeled by the Navier-Stokes equations and the turbulent Reynolds stress model, and then the solid particles were injected using Newton's equation. Finally, the erosion was calculated using Grant and Tabakoff model of the restitution of particles of after hitting the wall and the erosion model of Oka. The amount of erosion caused by changes in the flow pattern was investigated to evaluate the performance of the new proposed fittings. Numerical results for the most critical mode (Vin = 27 m/s and DP = 300 μm) showed that the new proposed fittings increase the erosion resistance by 22.5 % to 39.6 % compared to the standard 90° elbow. Also, in this research, the effect of different parameters including flow velocity, particle diameter size, particle input rate, and particle rotation on erosion were investigated.

Semi-Lagrangian Simulation of Particle Laden Flows using an SPH Framework

Particle–laden flows occur in many natural and industrial systems and simulating them can be particularly challenging. The coupling of smoothed particle hydrodynamics (SPH) with the discrete element method (DEM) can effectively simulate particle-laden multiphase fluid dynamical systems, due to the shared Lagrangian nature of both methods. However, this approach has some inherent shortcomings, including a prohibitively small time step when dealing with small particles. An alternative approach is to use an Eulerian-Eulerian reference frame, usually using finite element or finite volume discretisations. In this approach, momentum and continuity equations are solved for each discrete phase as well as the continuous phase, and particles are modelled by means of concentration and velocity fields. This approach can suffer from strong numerical diffusion in the advection of the concentrations when absolute velocities of the phases are high, whilst their relative velocities are small. This numerical diffusion can obscure important aspects of the behaviour as it can smooth out details, especially in the particle concentration fields. In order to mitigate the shortcomings of these existing techniques, we present a new SPH-based semi-Lagrangian framework for solving the momentum and continuity equations for all phases in particle-laden flows. In this framework, the discrete and continuous phases move relative to a reference frame at a momentum-averaged velocity. By focusing on velocities relative to the reference frame our method substantially reduces numerical diffusion compared to traditional Eulerian-Eulerian approaches, at a lower computational cost compared to Lagrangian-Lagrangian approaches. The simulation approach is validated by means of comparisons to both computational and experimental results for a number of relevant systems including particle-liquid separation in an inclined channel, particle sedimentation in a liquid, and gas-particle fluidised beds. This new method is shown to compare very favourably in terms of both the accuracy of the results and the computational cost required to achieve them.

Migration of a slip-spin solid sphere particle in a micropolar fluid-filled circular cylindrical tube

A combined study analytically and numerically for the axially symmetric creeping flow due to a slip-spin solid sphere surface moving in a microstructure fluid of micropolar type along the centreline of a circular cylindrical tube is introduced. This investigation was presented under low Reynolds number conditions. A general solution is obtained by superposing the essential solutions in both spherical and cylindrical coordinates to solve the Eringen micropolar field equations. The condition of the microrotation, along with couple stress, is used at the surface of the solid particle; while the microrotation is used at the inner cylindrical surface. Boundary conditions are imposed initially on the inner cylindrical surface using Fourier transforms and subsequently on the outer surface of the solid particle using a collocation technique. This paper aims to study the wall interaction problem of a translating slip-spin solid sphere particle in a micropolar fluid along the centreline of a circular cylindrical tube. The study also investigates the effect of the addition of slip conditions for velocity and microrotation on the surface of a solid particle. There is good convergence in the numerical findings obtained for the normalised hydrodynamic drag force (the tube-corrected factor) applying on the surface of the solid particle for several values of the micropolarity coefficient, slip-spin coefficients, and the ratio between the radius of the solid particle and tube. Regarding the flow of a solid sphere particle along the centreline of a cylindrical tube, our drag findings compare favourably to the solutions found in the literature. We found that the normalised drag force acting on the solid particle monotonically increases with the increase of the particle-to-tube radius ratio and reaches infinity in the limitless, with the increase of the micropolarity coefficient, and with the increase of the slip-spin coefficients for a steady ratio of particle-to-tube radius.

Numerical simulation of granular heat transfer within lifter rotating drum using smoothed particle hydrodynamics (SPH)

Abstract The rotating drums are typical industrial thermal processing equipment, which is widely used to heat or cool material particles in the circle fluid bed (CFB) systems. The traditional cylindrical rotating drum cannot significantly promote the heat transfer process of granules in operation, largely limiting further application. In this research, using smoothed particle hydrodynamics (SPH), two different types of lifters are employed to investigate the effects of shape, size, and number of lifters on the coefficient of heat transfer within the rotating drums by combining the flow and mixing characteristics of particles, the stress distribution, the transient velocity and temperature distribution, and the trend of the Peclet number.

Coupled Modeling of Computational Fluid Dynamics and Granular Mechanics of Sand Production in Multiple Fluid Flow

Summary Sand production is a significant issue in oil and gas fields with poorly consolidated formations, often involving the multiphase flow of reservoir fluids and solid particles. The multiscale mechanisms of sand production, particularly fluid flow and particle movement, remain poorly understood. This study investigates these mechanisms using a coupled computational fluid dynamics and discrete element method (CFD-DEM) modeling approach. Single and multiple fluid flows of water and heavy oil were simulated with increasing fluid injection velocities, leading to different sand production patterns. The simulation results were compared with experimental results from a large cylindrical specimen of weak artificial sandstone under similar loading conditions. The multiphase conditions created various localized flow and deformation patterns that influenced both fluid and solid production, resulting in shorter transient sand production periods. Microstructures and phenomena such as fingering and water coning were observed, associated with a critical flow rate below which oil displacement was uniform and no water breakthrough occurred. Higher fluid injection velocities and fluid viscosities resulted in greater drag forces, leading to progressive damage zones and explaining the occurrence of single or multiple staged sand production events. The evolution of the microscopic granular structure was visualized under the effect of transient sand production.

Particle motion and flow contribution in a double-row hydraulic harvesting model for deep-sea mining

The double-row hydraulic sluicing model is widely used in deep-sea mining collecting systems. However, there has been limited research focusing on its flow contributions and the relationship with particle motions. In this paper, a double-row hydraulic sluicing collector with high pickup efficiency is designed. The flow characteristics, the mechanics of the flow field, and the movement of particles in the collector are analyzed in detail through numerical calculations and experiments. The flow contributions and the collecting mechanism are clearly highlighted through aspects such as the frequency of pressure fluctuations and flow-induced vortices. The high-speed jet rolls upward after hitting the ground, forming a high-pressure area on the ground. The upwelling in the collection area is generated by the combination of the high-pressure area and the upward rolling of fluid. Regarding the particles, it is observed that particle motion can be divided into two main stages, rapid acceleration, followed by slow deceleration. Some particles may fall back when rising. Additionally, the analysis of fluid forces on the particles indicates that drag force and pressure gradient force have significant influence on particle motion.

Morphological properties of two-dimensional and three-dimensional bedforms in open channel flow: A flume experiments study

Bedforms are formed by sediment particles under the action of flow, which in turn affect flow and sediment movement. However, the fundamental mechanisms behind the formation and development of bedforms under varying flow conditions, the interconnection between sediment particle movement and bed morphology development, as well as the influence of bedforms on flow and sediment transport, are still not well understood. In the current study, the moveable bed load transport flume experiments under different flow conditions were done, and the development processes of two-dimensional and three-dimensional dunes formed under different flow intensities were simulated. The detailed structure of the bedforms was measured by laser scanning technology, the characteristics of the bedforms were analyzed in detail, and the relations between the formation of the bedforms and the movement of sediment particles are discussed. The results found that the correlation coefficients of the longitudinal profile curve can serve as a quick reference for distinguishing two-dimensional and three-dimensional dunes. When the crestline ratio is used as the criterion for two-dimensional and three-dimensional dunes, the relative amplitude of the dune crestline and the included angle with the flow direction should also be comprehensively considered. The lee side angles of dunes calculated using the triangle generalization method and local section tangent method are compared and show that the values obtained by the former method are only about half of that of the latter. It is also found that the lee side angles of dunes are related to the dune height. The superimposed dunes generally exist in the downstream area of the stoss side of the dunes. The local bed slopes on the stoss side of the dunes show reverse slopes. The superimposed dunes improve the local bed height and further increase the reverse slope degree of the stoss side. A streamwise ridge is an important form located in the upstream area of the dunes stoss side, and they are symmetrically distributed on both sides. Multiple streamwise ridges divide the stoss side of the dunes into relatively independent movement areas, restricting the movement of sediment particles to specific regions. According to the distribution characteristics of bed morphologies, the effects of dunes on sediment particle movement and flow energy consumption are analyzed.

Hydrodynamic force coefficients for spherical triangle shell fragments: Dependence on the aspect ratio and flatness

Euler–Lagrange simulations of particle-laden flow require hydrodynamic models of drag and lift forces for individual particles. Our goal is to develop models that can prescribe these forces for arbitrarily orientated shell objects. Here, we use computational fluid dynamics simulations of steady bottom-boundary layer flow over a series of spherical triangle shell fragments to calculate the hydrodynamic forces. The simulations explicitly resolve the wall boundary layers using grid resolution on the order of y+=1 at the shell fragment surface and use the SST k-omega turbulence closure model. These fragments cover a range of aspect ratio and flatness characteristics. The shell fragments are generated as triangular selections of a spherical shell with azimuthal and longitudinal angles proscribed based on elongation and flatness parameters (varying between 1 to 5, and 0.02 to 0.2 respectively), while characteristic length of the fragment is held constant to define the overall fragment size. Fragment orientations are considered with independently varying pitch, roll, and yaw each ranging from 0 to 180 degrees. The numerical estimates for the forces from all simulations were used to develop robust parameterizations of the drag and lift as a function of aspect ratio and flatness characteristics, as well as orientation of the shell fragments.

Numerical simulation of multiphase flow induced by bottom blowing limestone powder in converter steelmaking

A full-scale three-dimensional model of a 120 t steel converter was established to evaluate the effects of bottom-blown limestone particle injection speed, diameter, and nozzle location on the particle distribution and molten metal flow field using numerical simulations. The results indicated that a particle injection speed of 6 m/s, particle diameter of 0.5 mm, and injection nozzle location at 1/2 of the converter bottom radius provided the longest particle residence time and largest quantity of particles in the molten metal. Furthermore, the use of these parameters produced within the molten metal an obvious particle concentration along the centerline of the converter, the fastest average liquid metal–particle flow velocity, and moderate splashing. These optimal injection parameters created favorable kinetic conditions for the dephosphorization reaction essential to steelmaking. This study provide a theoretical basis for realizing the improved efficiency associated with the use limestone instead of lime in practical steel production.

Shower separation in five dimensions for highly granular calorimeters using machine learning

To achieve state-of-the-art jet energy resolution for Particle Flow, sophisticated energy clustering algorithms must be developed that can fully exploit available information to separate energy deposits from charged and neutral particles. Three published neural network-based shower separation models were applied to simulation and experimental data to measure the performance of the highly granular CALICE Analogue Hadronic Calorimeter (AHCAL) technological prototype in distinguishing the energy deposited by a single charged and single neutral hadron for Particle Flow. The performance of models trained using only standard spatial, energy and charged track position information from an event was compared to models trained using timing information available from AHCAL, which is expected to improve sensitivity to shower development and, therefore, aid in clustering. Both simulation and experimental data were used to train and test the models and their performances were compared. The best-performing neural network achieved significantly superior event reconstruction when timing information was utilised in training for the case where the charged hadron had more energy than the neutral one, motivating temporally sensitive calorimeters. All models under test were observed to tend to allocate energy deposited by the more energetic of the two showers to the less energetic one. Similar shower reconstruction performance was observed for a model trained on simulation and applied to data and a model trained and applied to data.

Stress evolution in rocks around tunnel under uniaxial loading: Insights from PFC3D-GBM modelling and force chain analysis

In underground engineerings, the evolution of the stress state in the surrounding rocks can effectively reveal its fracture mechanism. To precisely describe this microscopic information, the present study utilizes the three-dimensional Grain-based model based on Particle Flow Code (PFC3D-GBM) to construct a square numerical specimen with a pre-existing hole representing a tunnel and subjected it to uniaxial loading. In this model, different types of mineral structures and internal force chain networks are distinguished at a three-dimensional scale. Furthermore, the evolution of force chain networks in the top, bottom, left and right regions around the tunnel is quantitatively characterized. The anti-fracture capability depending on stress state of various structures is calculated and then the fracture mechanism from the point of anti-fracture capability is discussed. The research results indicate that at at the beginning of loading, some red force chains with higher level have appeared on both sides of the tunnel. As the load goes on, red force chain network extending from both sides of the tunnel to the upper and lower ends of the specimen have emerged. The average value and sum value of all force chains show an increasing trend before the peak load and a decreasing trend after the peak load. The average value of force chains within a specific structure can accurately reflect the microscopic mechanical properties of that structure. The average values of force chains on the left and right sides of the tunnel are higher, both in terms of starting points and ascending rates, than those in the upper and lower regions of the tunnel. The orientation distribution of all force chains is relatively uniform, but force chains with higher level are generally align with the loading direction. The fundamental reason for the high degree of fragmentation on the left and right sides of the tunnel is that these regions bear more external load than the upper and lower regions, rather than being inherently more prone to fracture.

Investigating tensile failure mechanisms of layered rocks through physical testing and PFC3D analysis

Rocks generally exhibit less resistance to tension compared to shear or compression forces, and tension cracks often precede shear or compression failures. While the mechanical performance of rock layers under compression has been widely described, their tensile behavior is less known.The current study includes experimental approaches as well as computational testing with the three-dimensional Particle Flow Code (PFC3D) to evaluate the effect of layer thickness and mechanical parameters on the strength and failure patterns of layered rocks-like materials under continuous tension.The Brazilian tensile strength test was conducted on concrete and gypsum specimens. The concrete specimen measured 54 mm in diameter and 27 mm in thickness, resulting in a tensile strength of 1.35 MPa. The gypsum specimen, with the same measurements, had a tensile strength of 0.6 MPa. In addition, uniaxial compressive strength tests were performed on both materials, yielding compressive strengths of 18 MPa for concrete and 6 MPa for gypsum. Our findings indicate that layer thickness and mechanical properties considerably influence failure patterns, tensile strength, and progressive deformation of these materials. The failure modes seen in the layered specimens indicate that the tensile strength ascertained by numerical testing and direct tensile testing is equally accurate. Both the empirical and computational findings are in accordance with the analytical predictions of the failure criterion. In rock engineering, these failure criteria have a high degree of accuracy when it comes to predicting tensile strength and reflecting the failure modes of layered rocks, like layered sandstone, slate, and shale

Flow behavior of polypropylene reactor powder in horizontal stirred bed reactors characterized by X-ray imaging

Horizontal stirred bed reactors (HSBRs) are widely used in the commercial production of polypropylene (PP). Despite their commercial significance, a comprehensive understanding of the flow behavior in HSBRs remains elusive, primarily due to the lack of detailed experimental data. This study investigates the influence of operating parameters on the particle flow behavior of two types of PP reactor powder in a laboratory-scale HSBR using X-ray imaging. Our results indicate that the overall flow behavior and phase holdup in the HSBR are dominated by agitation. Moreover, gas injection through the inlet points at the bottom of the HSBR results in spouting behavior, which can lead to reduced gas-solid contacting and, in extreme cases, complete bypass. Finally, the presence of liquid (in this study, isopropyl alcohol) adversely affects the flow behavior of the PP reactor powder due to liquid bridging at the contact points of particles. Powders that comprise particles with relatively small sizes and dense surface morphology are particularly prone to reduced flow behavior when exposed to liquid.

An Implementation of the Particle Flow Filter in an Atmospheric Model

Abstract The particle flow filter (PFF) shows promise for fully nonlinear data assimilation (DA) in high-dimensional systems. However, its application in atmospheric models has been relatively unexplored. In this study, we develop a new algorithm, PFF-DART, in order to conduct DA for high-dimensional atmospheric models. PFF-DART combines the PFF and the two-step ensemble filtering algorithm in the Data Assimilation Research Testbed (DART), exploiting the highly parallel structure of DART. To evaluate the performance of PFF-DART, we conduct an observing system simulation experiment (OSSE) in a simplified atmospheric general circulation model and compare the performance of PFF-DART with an existing linear and Gaussian DA method. Using the PFF-DART algorithm, we demonstrate, for the first time, the capability of the PFF to yield stable results in a yearlong cycling DA OSSE. Moreover, PFF-DART retains the important ability of the PFF to improve the assimilation of nonlinear and non-Gaussian observations. Finally, we emphasize that PFF-DART is a versatile algorithm that can be integrated with numerous other non-Gaussian DA techniques. This quality makes it a promising method for further investigation within a more sophisticated numerical weather prediction model in the future. Significance Statement Data assimilation is an important tool in weather forecasting. However, fundamental issues arising from linear and Gaussian approximations still exist, which can limit our utilization of observations. The particle flow filter is a promising method that avoids these approximations, but efficient algorithms for this method have yet to be developed. In this study, we develop an algorithm for the particle flow filter that can be implemented in high-dimensional geophysical models. We have demonstrated, for the first time, that the particle flow filter runs efficiently for a yearlong experiment in an atmospheric model. The new algorithm also improves the results over a commonly used data assimilation method. The results in this work demonstrate the potential usage of the particle flow filter in the weather forecasting and other high-dimensional forecasting problems.