侧进式搅拌反应器内均相及多相流体动力学的数值研究
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摘要
侧进式三相搅拌反应器是脱硫吸收过程的核心设备,在烟气脱硫过程(FGD)中得到广泛应用。反应器内存在复杂的流体办学行为,包括浆液、固体颗粒和氧化空气的三相流动,直接影响传质和化学反应,决定了整个吸收塔的脱硫效率。但是,由于设备尺寸较大(直径达20m)和大量固体颗粒(脱硫产品晶体)、气泡(氧化空气)的存在,其流体力学的实验研究颇为困难,其设计和优化主要通过工程经验来实现,致使反应器的性能难以达到设计要求。近年来,计算流体力学(CFD)技术已经成为工业设备设计中通用的流体力学研究手段,但对侧进式三相搅拌釜,目前还鲜有报导。本文针对大型侧进式搅拌釜,以CFD技术为主要研究手段,对釜内均相和多相流场开展深入研究,以望为脱硫塔三相氧化釜的设计及优化提供理论依据。
论文主要开展了以下几方面的研究工作。
首先,采用雷诺平均N-S控制方程组和标准k-e湍流模型相结合,以一个直径和高度均为13m的大型侧进式搅拌釜为研究对象,对其内部均相宏观流场进行数值计算。结果表明,将计算域划分为大约90万网格时计算得到的搅拌功率曲线和流体速度分布与实验数据吻合较好；考察不同操作参数和搅拌桨安装情况对釜内低速死区分布的影响发现,增大搅拌转速很难彻底有效地消除水平面上的死区；搅拌桨垂直向下5.71°或水平偏转11°安装能明显改善流体运动。三桨和四桨搅拌体系对釜上部流场的优化要好于两桨体系；但在相同转速下,双桨、三桨和四桨搅拌釜的搅拌功率不同程度地高于单桨搅拌釜。综合考虑,三桨体系搅拌效率较高。
其次,对三种轴流桨：宽叶推进式轴流桨(WBH)、旋流式轴流桨(MTP)和窄叶推进式轴流桨(NBH)进行了比较研究。在低粘度流体搅拌中,WBH和MTP的搅拌功率较高,但由于泵排量也较大,因此泵送效率明显高于桨叶较窄的NBH。三种桨叶背后均形成一个单一的尾流漩涡,但是WBH和MTP的尾涡结构使得釜内整体循环流动更理想,即排出流类似于水平射流,且速度分布梯度较大,形成了一个较大的循环流动；而NBH的排出流一定程度地偏向桨径向方向,导致其泵轴向排量明显小于WBH和MTP。此外,MTP的流线型桨叶使得其尾涡里的湍流动能较小,能有效地预防搅拌桨周围气穴的形成,因此将其应用到一个冷模气液侧进式搅拌釜中,气液分散效果较好。
第三,检验了不同气液界面边界条件和相间作用力模型对气液两相流模拟的影响。采用的气-液界面边界条件包括：速度进口、压力出口、仅考虑质量守恒的脱气边界和同时考虑相间反作用力的脱气边界；而相间作用力模型包括：标准S-N曳力模型、修正S-N曳力模型、Tsuchiya曳力模型和升力作用模型。结果显示,在采用速度进口作为气-液边界面条件、修正S-N模型或Tsuchiya模型作为曳力模型时,总体气含率和气体分布的预测结果与实验数据吻合较好,且升力作用对预测结果影响不大。气体的加入会对液相流场产生影响,特别是在釜上部区域内；增大转速能增强釜上部的液相轴向运动和釜下部的液相径向运动；大通气量和高转速下,釜中心到壁面间的通气区域内局部气含率梯度较大,导致流体密度差增大,从而使得整体流动更为剧烈。
第四,采用考虑气泡聚并和破碎的气泡界面浓度模型(BIACM)(?)和气泡群平衡模型(BPBM)两种气泡尺寸预测模型对气-液侧进式搅拌釜内气泡尺寸分布进行了研究,实现了BIACM-CFD和BPBM-CFD耦合计算。在BPBM-CFD耦合计算中,将Luo&Svendsen破碎模型分别与Luo聚并模型和Prince聚并模型组合。结果表明,在较高湍动能耗散率区域内,这两个聚并模型存在较大差异,但是预测气泡尺寸均集中在3-5mm之间,这与实验结果相一致。最后,采用欧拉-颗粒多相流模型对固-液两相流进行模拟,考察了RSM和标准k-εmixture两种湍流模型的影响。结果表明,欧拉-颗粒多相(EGM)方程和标准k-εmixture湍流方程相结合的CFD模型的预测较为准确；临界悬浮转速和颗粒粒径及固体装载量之间、无量纲颗粒悬浮高度与搅拌转速之间均成线性关系；大颗粒由于自由沉积速度增加,增加搅拌转速对固体悬浮的改善不明显；高固含量下,受阻沉降和悬浮粘度增加的共同作用使得颗粒悬浮均匀度增加。
A side-entering multiphase stirred reactor is one of the key equipment in the desulfurization and absorption process, and widely applied in Fuel Gas Desulfurization (FGD) process. The complicated flow dynamics of solids suspension and oxidation gas dispersion in the reactor could directly affect mass transfer and chemical reaction, and determine the desulfurization efficiency. The large size of the reactor (diameter equal to20m) and the exiting of the plentiful solid particles (desulfurization product) and gas bubbles (oxidation air) make the experimental research of fluid dynamical extremely difficult. The traditional device design and operation optimization conducted by using the engineering experiences easily leads to the poor performance of the reactor. Recently, the numerical simulation has been employed to undertake the design work of various industrial equipments. However, the reported CFD researcheson side-entering multiphase stirred tanks are extremely limited. The major emphasis of this dissertation is the application of CFD technique to investigate single-and multi-phase flow behaviors in the large-size side-entering stirred tank for guiding the equipment design and optimizationtheoretically.
Firstly, the Reynolds-averaged Navier-Stokes governing equations combined with standard k-ε turbulence model were employed to simulation the single-phase turbulent flow field in an industrial-scale stirred tank with diameter and height of13m and equipped with a side-entering impeller. The calculated power curve and velocity profiles were in good agreement with the available experimental results for the finer-mesh cases in which about900,000mesh cells were included in the calculation domain. The effect of operation parameters and impeller layout on mixing effect was studied in detail. The results indicate that the increasing of impeller speed cannot effectively eliminate the mixing dead zone, and the flow pattern can be obviously improved when the impeller was inserted into the tank with a vertical angle of5.71°or a horizontal angle of11°. Comparing with two-impeller stirred system, the three-and four-impeller systems can more obviously decrease the area of low-velocity dead zone, especially in the top part of the tank. But the total power consumption of two-, three-and four-impeller stirred tank was obviously higher than that of the single-impeller stirred tank. In general, the three-impeller stirred system has the expected mixing performance with lower power consumption.
Secondly, mixing behavior of wide-blade hydrofoil (WBH) impeller, marine-type propeller (MTP) and narrow-blade hydrofoil (NBH) impeller was respectively investigated in order to design a high-efficiency mixing system for the side-entering stirred tank. The simulated results indicate that WBH and MTP with the wider blades consumed more energy that NBH, but also have higher pumping efficiency due to their higher pumping capacity in turbulent flow regime of low-viscosity fluid. A single trailing vortex formed behind the blades of all the three impellers, but trailing vortex structure of WBH and MTP resulted in a better bulk flow pattern, and the discharged flows were similar to a horizontal jet flow with the sharply velocity gradient. But the discharged flow produced by NBH deviated to the impeller radial direction that made the pumping capacity lower. Moreover, there is a reduction in the turbulence kinetic energy of trailing vortices as the larger curvature of MTP blades, and that is very beneficial to prevent the impeller from erosion and invalidation. Hence MTP has been proposed for an existing gas-liquid side-entering tank and achieved a significant improvement in the performance of gas dispersion.
Thirdly, the dissertation has conducted the first detailed numerical simulations to study the effects of boundary conditions of gas-liquid surface and-interphase force models under the assumption of uniform bubbles. The gas-liquid boundary conditions involved in the work include velocity-inlet, pressure-outlet, degassing boundary; and the interphase force models include standard S-N drag force model, revised S-N drag force model, Tsuchiya drag force model and lift force model. The modeling results clearly indicate that the predicted total gas hold-up and gas distribution calculated by the model in which the gas-liquid surface was set as a'velocity inlet' and the interphase force model was the revised S-N model or Tsuchiya model, were in good agreement with the experimental measurements. And the life force in the modeling can be ignored. Further, the effect of operating parameters on gas-liquid two-phase flow has been investigated. It can be known that the profiles of liquid-phase velocity vectors with and without gas phase were obviously different; the increasing impeller speed can improve the fluid axial movement in the top part of the tank and the radial movement in the bottom part of the tank; and the gradient of local gas hold-up was sharp in the domain between the tank center and wall on the cases of high gas capacity, that resulted in the difference of fluid density and improved the bulk fluid flow.
Fourthly, the bubble interfacial area concentration model (BIACM) and the bubble population balance model (BPBM) were respectively incorporated into the fluid dynamical models through UDF subroutines to predict the bubble size distribution in a gas-liquid side-entering stirred tank. The effect of bubble coalescence and break-up was taken into consideration. In the simulations of BPBM-CFD coupled model, Luo-Svendsen bubble break-up model was respectively combined with Luo's bubble coalescence model and Prince's model to describe the bubble calescence and break-up process. The simulations show that the difference between the predicted results of bubble coalescence rate calculated by these models was found in the domain of higher turbulence dissipation, resulting in the different simulating results of the bubble size distribution. But the predicted bubble size in the tank for all the cases ranged from3to5mm, well agreeing with the experimental results.
Lastly, it is the first to study solids suspension quality in a stirred tank equipped with three side-entering impellers by using computational fluid dynamics (CFD) technique. Using an Eulerian-Granular Multiphase (EGM) model respectively coupling with standard k-ε mixture turbulence model and Reynolds stress model performed simulations of solid-liquid flow. CFD predictions have been verified by comparing the predicted results with the experimental just suspended impeller speed and solid sediment pattern at the tank bottom. The effects of impeller agitation speed, particle size and solid volume loading on just suspended impeller speed Njs, cloud height h and suspension homogeneity have been investigated to assess the solid suspension quality under the different operation conditions. The computational model and results discussed in this study would be useful for understand the solid-liquid dispersion process in side-entering stirred tanks and extend the application of CFD models for equipment design and process optimization.
论文主要开展了以下几方面的研究工作。
首先,采用雷诺平均N-S控制方程组和标准k-e湍流模型相结合,以一个直径和高度均为13m的大型侧进式搅拌釜为研究对象,对其内部均相宏观流场进行数值计算。结果表明,将计算域划分为大约90万网格时计算得到的搅拌功率曲线和流体速度分布与实验数据吻合较好；考察不同操作参数和搅拌桨安装情况对釜内低速死区分布的影响发现,增大搅拌转速很难彻底有效地消除水平面上的死区；搅拌桨垂直向下5.71°或水平偏转11°安装能明显改善流体运动。三桨和四桨搅拌体系对釜上部流场的优化要好于两桨体系；但在相同转速下,双桨、三桨和四桨搅拌釜的搅拌功率不同程度地高于单桨搅拌釜。综合考虑,三桨体系搅拌效率较高。
其次,对三种轴流桨：宽叶推进式轴流桨(WBH)、旋流式轴流桨(MTP)和窄叶推进式轴流桨(NBH)进行了比较研究。在低粘度流体搅拌中,WBH和MTP的搅拌功率较高,但由于泵排量也较大,因此泵送效率明显高于桨叶较窄的NBH。三种桨叶背后均形成一个单一的尾流漩涡,但是WBH和MTP的尾涡结构使得釜内整体循环流动更理想,即排出流类似于水平射流,且速度分布梯度较大,形成了一个较大的循环流动；而NBH的排出流一定程度地偏向桨径向方向,导致其泵轴向排量明显小于WBH和MTP。此外,MTP的流线型桨叶使得其尾涡里的湍流动能较小,能有效地预防搅拌桨周围气穴的形成,因此将其应用到一个冷模气液侧进式搅拌釜中,气液分散效果较好。
第三,检验了不同气液界面边界条件和相间作用力模型对气液两相流模拟的影响。采用的气-液界面边界条件包括：速度进口、压力出口、仅考虑质量守恒的脱气边界和同时考虑相间反作用力的脱气边界；而相间作用力模型包括：标准S-N曳力模型、修正S-N曳力模型、Tsuchiya曳力模型和升力作用模型。结果显示,在采用速度进口作为气-液边界面条件、修正S-N模型或Tsuchiya模型作为曳力模型时,总体气含率和气体分布的预测结果与实验数据吻合较好,且升力作用对预测结果影响不大。气体的加入会对液相流场产生影响,特别是在釜上部区域内；增大转速能增强釜上部的液相轴向运动和釜下部的液相径向运动；大通气量和高转速下,釜中心到壁面间的通气区域内局部气含率梯度较大,导致流体密度差增大,从而使得整体流动更为剧烈。
第四,采用考虑气泡聚并和破碎的气泡界面浓度模型(BIACM)(?)和气泡群平衡模型(BPBM)两种气泡尺寸预测模型对气-液侧进式搅拌釜内气泡尺寸分布进行了研究,实现了BIACM-CFD和BPBM-CFD耦合计算。在BPBM-CFD耦合计算中,将Luo&Svendsen破碎模型分别与Luo聚并模型和Prince聚并模型组合。结果表明,在较高湍动能耗散率区域内,这两个聚并模型存在较大差异,但是预测气泡尺寸均集中在3-5mm之间,这与实验结果相一致。最后,采用欧拉-颗粒多相流模型对固-液两相流进行模拟,考察了RSM和标准k-εmixture两种湍流模型的影响。结果表明,欧拉-颗粒多相(EGM)方程和标准k-εmixture湍流方程相结合的CFD模型的预测较为准确；临界悬浮转速和颗粒粒径及固体装载量之间、无量纲颗粒悬浮高度与搅拌转速之间均成线性关系；大颗粒由于自由沉积速度增加,增加搅拌转速对固体悬浮的改善不明显；高固含量下,受阻沉降和悬浮粘度增加的共同作用使得颗粒悬浮均匀度增加。
A side-entering multiphase stirred reactor is one of the key equipment in the desulfurization and absorption process, and widely applied in Fuel Gas Desulfurization (FGD) process. The complicated flow dynamics of solids suspension and oxidation gas dispersion in the reactor could directly affect mass transfer and chemical reaction, and determine the desulfurization efficiency. The large size of the reactor (diameter equal to20m) and the exiting of the plentiful solid particles (desulfurization product) and gas bubbles (oxidation air) make the experimental research of fluid dynamical extremely difficult. The traditional device design and operation optimization conducted by using the engineering experiences easily leads to the poor performance of the reactor. Recently, the numerical simulation has been employed to undertake the design work of various industrial equipments. However, the reported CFD researcheson side-entering multiphase stirred tanks are extremely limited. The major emphasis of this dissertation is the application of CFD technique to investigate single-and multi-phase flow behaviors in the large-size side-entering stirred tank for guiding the equipment design and optimizationtheoretically.
Firstly, the Reynolds-averaged Navier-Stokes governing equations combined with standard k-ε turbulence model were employed to simulation the single-phase turbulent flow field in an industrial-scale stirred tank with diameter and height of13m and equipped with a side-entering impeller. The calculated power curve and velocity profiles were in good agreement with the available experimental results for the finer-mesh cases in which about900,000mesh cells were included in the calculation domain. The effect of operation parameters and impeller layout on mixing effect was studied in detail. The results indicate that the increasing of impeller speed cannot effectively eliminate the mixing dead zone, and the flow pattern can be obviously improved when the impeller was inserted into the tank with a vertical angle of5.71°or a horizontal angle of11°. Comparing with two-impeller stirred system, the three-and four-impeller systems can more obviously decrease the area of low-velocity dead zone, especially in the top part of the tank. But the total power consumption of two-, three-and four-impeller stirred tank was obviously higher than that of the single-impeller stirred tank. In general, the three-impeller stirred system has the expected mixing performance with lower power consumption.
Secondly, mixing behavior of wide-blade hydrofoil (WBH) impeller, marine-type propeller (MTP) and narrow-blade hydrofoil (NBH) impeller was respectively investigated in order to design a high-efficiency mixing system for the side-entering stirred tank. The simulated results indicate that WBH and MTP with the wider blades consumed more energy that NBH, but also have higher pumping efficiency due to their higher pumping capacity in turbulent flow regime of low-viscosity fluid. A single trailing vortex formed behind the blades of all the three impellers, but trailing vortex structure of WBH and MTP resulted in a better bulk flow pattern, and the discharged flows were similar to a horizontal jet flow with the sharply velocity gradient. But the discharged flow produced by NBH deviated to the impeller radial direction that made the pumping capacity lower. Moreover, there is a reduction in the turbulence kinetic energy of trailing vortices as the larger curvature of MTP blades, and that is very beneficial to prevent the impeller from erosion and invalidation. Hence MTP has been proposed for an existing gas-liquid side-entering tank and achieved a significant improvement in the performance of gas dispersion.
Thirdly, the dissertation has conducted the first detailed numerical simulations to study the effects of boundary conditions of gas-liquid surface and-interphase force models under the assumption of uniform bubbles. The gas-liquid boundary conditions involved in the work include velocity-inlet, pressure-outlet, degassing boundary; and the interphase force models include standard S-N drag force model, revised S-N drag force model, Tsuchiya drag force model and lift force model. The modeling results clearly indicate that the predicted total gas hold-up and gas distribution calculated by the model in which the gas-liquid surface was set as a'velocity inlet' and the interphase force model was the revised S-N model or Tsuchiya model, were in good agreement with the experimental measurements. And the life force in the modeling can be ignored. Further, the effect of operating parameters on gas-liquid two-phase flow has been investigated. It can be known that the profiles of liquid-phase velocity vectors with and without gas phase were obviously different; the increasing impeller speed can improve the fluid axial movement in the top part of the tank and the radial movement in the bottom part of the tank; and the gradient of local gas hold-up was sharp in the domain between the tank center and wall on the cases of high gas capacity, that resulted in the difference of fluid density and improved the bulk fluid flow.
Fourthly, the bubble interfacial area concentration model (BIACM) and the bubble population balance model (BPBM) were respectively incorporated into the fluid dynamical models through UDF subroutines to predict the bubble size distribution in a gas-liquid side-entering stirred tank. The effect of bubble coalescence and break-up was taken into consideration. In the simulations of BPBM-CFD coupled model, Luo-Svendsen bubble break-up model was respectively combined with Luo's bubble coalescence model and Prince's model to describe the bubble calescence and break-up process. The simulations show that the difference between the predicted results of bubble coalescence rate calculated by these models was found in the domain of higher turbulence dissipation, resulting in the different simulating results of the bubble size distribution. But the predicted bubble size in the tank for all the cases ranged from3to5mm, well agreeing with the experimental results.
Lastly, it is the first to study solids suspension quality in a stirred tank equipped with three side-entering impellers by using computational fluid dynamics (CFD) technique. Using an Eulerian-Granular Multiphase (EGM) model respectively coupling with standard k-ε mixture turbulence model and Reynolds stress model performed simulations of solid-liquid flow. CFD predictions have been verified by comparing the predicted results with the experimental just suspended impeller speed and solid sediment pattern at the tank bottom. The effects of impeller agitation speed, particle size and solid volume loading on just suspended impeller speed Njs, cloud height h and suspension homogeneity have been investigated to assess the solid suspension quality under the different operation conditions. The computational model and results discussed in this study would be useful for understand the solid-liquid dispersion process in side-entering stirred tanks and extend the application of CFD models for equipment design and process optimization.
引文
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