Abstract: To overcome the some shortcomings associated with traditional flotation machines and columns in collophanite flotation, a flotation device was designed and fabricated in the laboratory. A multi-impeller pump with same function as a mechanical cell was used instead of the injection sparger and circulation pump in column flotation unit. The influence of main operational parameters of the device like feed flow rate, air flow rate and impellers’ speed on collophanite flotation was analyzed. Experiment results indicate that the influence of the operational parameters were significant on flotation recovery and grade of phosphate concentrate. The best operating conditions of the device were: feed flow rate 0.62 L/min, air flow rate 6.67 L/min and impellers speed 900 rpm. At these conditions, a phosphate concentrate assaying about 30.5% P2O5 and 1% MgO with a P2O5 recovery of about 81% was obtained from a Yuan'an phosphate ore sample containing about 22.30% P2O5 and 3.2% MgO.
Abstract: Conducting crystallization in an agitated vessel requires a proper selection of mixing parameters that would result in a production of crystals of specific properties. In dual impeller systems, which are characterized by a more complex hydrodynamics due to the possible fluid flow interactions, revealing a clear link between mixing parameters and crystallization kinetics is still an open issue. The aim of this work is to establish this connection by investigating how fluid flow patterns, generated by two impellers mounted on the same shaft, reflect on metastable zone width of borax decahydrate, one of the most important parameters of the crystallization process. Investigation was carried out in a 15-dm3 bench scale batch cooling crystallizer with an aspect ratio (H/T) equal to 1.3. For this reason, two radial straight blade turbines (4-SBT) were used for agitation. Experiments were conducted at different impeller spacings at the state of complete suspension. During the process of an unseeded batch cooling crystallization, solution temperature and supersaturation were continuously monitored what enabled a determination of the metastable zone width. Hydrodynamic conditions in the vessel achieved at different impeller spacings investigated were analyzed in detail. This was done firstly by measuring the mixing time required to attain the desired level of homogeneity. Secondly, fluid flow patterns generated in a described dual impeller system were both photographed and simulated by VisiMix Turbulent software. Also, a comparison of these two visualization methods was performed. Experimentally obtained results showed that metastable zone width is definitely affected by the hydrodynamics in the crystallizer. This means that this crystallization parameter can be controlled not only by adjusting the saturation temperature or cooling rate, as is usually done, but also by choosing a suitable impeller spacing that will result in a formation of crystals of wanted size distribution.
Abstract: A Computational Fluid Dynamics (CFD) technique has been applied to simulate the gas-liquid phase in double stirred tank of Rushton impeller. Eulerian-Eulerian model was adopted to simulate the multiphase with standard correlation of Schiller and Naumann for drag co-efficient. The turbulence was modeled by using standard k-ε turbulence model. The present CFD model predicts flow pattern, local gas hold-up, and local specific area. It also predicts local kLa (mass transfer rate) for single impeller. The predicted results were compared with experimental and CFD results of published literature. The predicted results are slightly over predicted with the experimental results; however, it is in reasonable agreement with other simulated results of published literature.
Abstract: A loading factor performance is necessary for the modeling of centrifugal compressor gas dynamic performance curve. Measured loading factors are linear function of a flow coefficient at an impeller exit. The performance does not depend on the compressibility criterion. To simulate loading factor performances, the authors present two parameters: a loading factor at zero flow rate and an angle between an ordinate and performance line. The calculated loading factor performances of non-viscous are linear too and close to experimental performances. Loading factor performances of several dozens of impellers with different blade exit angles, blade thickness and number, ratio of blade exit/inlet height, and two different type of blade mean line configuration. There are some trends of influence, which are evident – comparatively small blade thickness influence, and influence of geometry parameters is more for impellers with bigger blade exit angles, etc. Approximating equations for both parameters are suggested. The next phase of work will be simulating of experimental performances with the suggested approximation equations as a base.
Abstract: The effect of the shape of the vessel bottom and the length of baffles on the velocity distributions in a turbulent and in a transitional flow has been simulated. The turbulent flow was simulated using standard k-ε model and simulation was verified using LES whereas transitional flow was simulated using only LES. It has been found that both the shape of tank bottom and the baffles’ length has significant effect on the flow pattern and velocity distribution below the impeller. In the dished bottom tank with baffles reaching the edge of the dish, the large rotating volume of liquid was formed below the impeller. Liquid in this rotating region was not fully mixing. A dead zone was formed here. The size and the intensity of circulation within this zone calculated by k-ε model and LES were practically identical what reinforces the accuracy of the numerical simulations. Both types of simulations also show that employing full-length baffles can reduce the size of dead zone formed below the impeller. The LES was also used to simulate the velocity distribution below the impeller in transitional flow and it has been found that secondary circulation loops were formed near the tank bottom in all investigated geometries. However, in this case the length of baffles has smaller effect on the volume of rotating liquid than in the turbulent flow.
Abstract: Nowadays, to decrease the number of downtimes in the industries such as metal mining, petroleum and chemical industries, predictive maintenance is crucial. In order to have efficient predictive maintenance, knowing the performance of critical equipment of production line such as pumps and hydro-cyclones under variable operating parameters, selecting best indicators of this equipment health situations, best locations for instrumentation, and also measuring of these indicators are very important. In this paper, computer aided engineering (CAE) tools are implemented to study some important elements of copper process line, namely slurry pumps and cyclone to predict the performance of these components under different working conditions. These modeling and simulations can be used in predicting, for example, the damage tolerance of the main shaft of the slurry pump or wear rate and location of cyclone wall or pump case and impeller. Also, the simulations can suggest best-measuring parameters, measuring intervals, and their locations.
Abstract: At present, vibrations of rotors of gas transmittal unit evade sustainable forecasting. This paper describes elastic oscillation modes in resilient supports and rotor impellers modeled during computational experiments with regard to interference in the system of gas-dynamic flow and compressor rotor. Verification of aeroelastic approach was done on model problem of interaction between supersonic jet in shock tube with deformed plate. ANSYS 15.0 engineering analysis system was used as a modeling tool of numerical simulation in this paper. Finite volume method for gas dynamics and finite elements method for assessment of the strain stress state (SSS) components were used as research methods. Rotation speed and material’s elasticity modulus varied during calculations, and SSS components and gas-dynamic parameters in the dynamic system of gas-dynamic flow and compressor rotor were evaluated. The analysis of time dependence demonstrated that gas-dynamic parameters near the rotor blades oscillate at 200 Hz, and SSS parameters at the upper blade edge oscillate four times higher, i.e. with blade frequency. It has been detected that vibration amplitudes correction in the test points at magnetic bearings by aeroelasticity may correspond up to 50%, and about -π/4 for phases.
Abstract: Interaction between mixing and crystallization is often
ignored despite the fact that it affects almost every aspect of the
operation including nucleation, growth, and maintenance of the
crystal slurry. This is especially pronounced in multiple impeller
systems where flow complexity is increased. By choosing proper
mixing parameters, what closely depends on the knowledge of the
hydrodynamics in a mixing vessel, the process of batch cooling
crystallization may considerably be improved. The values that render
useful information when making this choice are mixing time and
power consumption. The predominant motivation for this work was
to investigate the extent to which radial dual impeller configuration
influences mixing time, power consumption and consequently the
values of metastable zone width and nucleation rate. In this research,
crystallization of borax was conducted in a 15 dm3 baffled batch
cooling crystallizer with an aspect ratio (H/T) of 1.3. Mixing was
performed using two straight blade turbines (4-SBT) mounted on the
same shaft that generated radial fluid flow. Experiments were
conducted at different values of N/NJS ratio (impeller speed/
minimum impeller speed for complete suspension), D/T ratio
(impeller diameter/crystallizer diameter), c/D ratio (lower impeller
off-bottom clearance/impeller diameter), and s/D ratio (spacing
between impellers/impeller diameter). Mother liquor was saturated at
30°C and was cooled at the rate of 6°C/h. Its concentration was
monitored in line by Na-ion selective electrode. From the values of
supersaturation that was monitored continuously over process time, it
was possible to determine the metastable zone width and
subsequently the nucleation rate using the Mersmann’s nucleation
criterion. For all applied dual impeller configurations, the mixing
time was determined by potentiometric method using a pulse
technique, while the power consumption was determined using a
torque meter produced by Himmelstein & Co. Results obtained in
this investigation show that dual impeller configuration significantly
influences the values of mixing time, power consumption as well as
the metastable zone width and nucleation rate. A special attention
should be addressed to the impeller spacing considering the flow
interaction that could be more or less pronounced depending on the
spacing value.
Abstract: Excessive vibration means increased wear, increased
repair efforts, bad product selection & quality and high energy
consumption. This may be sometimes experienced by cavitation or
suction/discharge recirculation which could occur only when net
positive suction head available NPSHA drops below the net positive
suction head required NPSHR. Cavitation can cause axial surging, if it
is excessive, will damage mechanical seals, bearings, possibly other
pump components frequently, and shorten the life of the impeller.
Efforts have been made to explain Suction Energy (SE), Specific
Speed (Ns), Suction Specific Speed (Nss), NPSHA, NPSHR & their
significance, possible reasons of cavitation /internal recirculation, its
diagnostics and remedial measures to arrest and prevent cavitation in
this paper. A case study is presented by the author highlighting that
the root cause of unwanted noise and vibration is due to cavitation,
caused by high specific speeds or inadequate net- positive suction
head available which results in damages to material surfaces of
impeller & suction bells and degradation of machine performance, its
capacity and efficiency too. Author strongly recommends revisiting
the technical specifications of CW pumps to provide sufficient NPSH
margin ratios >1.5, for future projects and Nss be limited to 8500 -
9000 for cavitation free operation.
Abstract: The 6th version of Universal modeling method for
centrifugal compressor stage calculation is described. Identification
of the new mathematical model was made. As a result of
identification the uniform set of empirical coefficients is received.
The efficiency definition error is 0,86 % at a design point. The
efficiency definition error at five flow rate points (except a point of
the maximum flow rate) is 1,22 %. Several variants of the stage with
3D impellers designed by 6th version program and quasi threedimensional
calculation programs were compared by their gas
dynamic performances CFD (NUMECA FINE TURBO).
Performance comparison demonstrated general principles of design
validity and leads to some design recommendations.
Abstract: Universal modeling method well proven for industrial
compressors was applied for design of the high flow rate supersonic
stage. Results were checked by ANSYS CFX and NUMECA Fine
Turbo calculations. The impeller appeared to be very effective at
transonic flow velocities. Stator elements efficiency is acceptable at
design Mach numbers too. Their loss coefficient versus inlet flow
angle performances correlates well with Universal modeling
prediction. The impeller demonstrates ability of satisfactory operation
at design flow rate. Supersonic flow behavior in the impeller inducer
at the shroud blade to blade surface Φ des deserves additional study.
Abstract: There is an evident trend to elevate pressure ratio of a
single stage of a turbo compressors - axial compressors in particular.
Whilst there was an opinion recently that a pressure ratio 1,9 was a
reasonable limit, later appeared information on successful modeling
tested of stages with pressure ratio up to 2,8. The authors recon that
lack of information on high pressure stages makes actual a study of
rational choice of design parameters before high supersonic flow
problems solving. The computer program of an engineering type was
developed. Below is presented a sample of its application to study
possible parameters of the impeller of the stage with pressure ratio
3,0. Influence of two main design parameters on expected efficiency,
periphery blade speed and flow structure is demonstrated. The results
had lead to choose a variant for further analysis and improvement by
CFD methods.
Abstract: The computational fluid dynamics (CFD) study of
stirred tank with the air-water interface are carried out in the presence
of different types of the impeller and with or without baffles. A
multiple reference frame (MRF) approach with the volume of fluid
(VOF) method is used to capture the air-water interface. The RANS
(Reynolds Averaged Navier-Stokes) equations with k-ε turbulence
model are solved to predict the flow behavior of water and air phase
which are treated as a different phases. The predicted results have
shown that the VOF method is able to capture the interface in the
unbaffled tank. While, the VOF method is showing an unfeasible
results in the baffled tank with high rotational impeller speed. For
continuous stirred tank, the air-water interface is disturbed by the
inflow and the level of water is also increased with time.
Abstract: A computational fluid dynamics simulation is done for
non-Newtonian fluid in a baffled stirred tank. The CMC solution is
taken as non-Newtonian shear thinning fluid for simulation. The
Reynolds Average Navier Stocks equation with steady state multi
reference frame approach is used to simulate flow in the stirred tank.
The turbulent flow field is modelled using realizable k-ε turbulence
model. The simulated velocity profiles of Rushton turbine is
validated with literature data. Then, the simulated flow field of CD-6
impeller is compared with the Rushton turbine. The flow field
generated by CD-6 impeller is less in magnitude than the Rushton
turbine. The impeller global parameter, power number and flow
number, and entropy generation due to viscous dissipation rate is also
reported.
Abstract: Cavitation is one of the most well-known process faults that may occur in different industrial equipment especially centrifugal pumps. Cavitation also may happen in water pumps and turbines. Sometimes cavitation has been severe enough to wear holes in the impeller and damage the vanes to such a degree that the impeller becomes very ineffective. More commonly, the pump efficiency will decrease significantly during cavitation and continue to decrease as damage to the impeller increases. Typically, when cavitation occurs, an audible sound similar to ‘marbles’ or ‘crackling’ is reported to be emitted from the pump. In this paper, the most effective monitoring items and techniques in detecting cavitation discussed in details. Besides, some successful solutions for solving this problem for sea water vertical Centrifugal lift Pump discussed through a case history related to Iran oil industry. Furthermore, balance line modification, strainer choking and random resonance in sea water pumps discussed. In addition, a new Method for diagnosing mechanical conditions of sea water vertical Centrifugal lift Pumps introduced. This method involves disaggregating bus current by device into disaggregated currents having correspondences with operating currents in response to measured bus current. Moreover, some new patents and innovations in mechanical sea water pumping and cooling systems discussed in this paper.
Abstract: The speed profiles, gas holdup (eG) and global oxygen transfer coefficient (kLa) from a stirred airlift bioreactor using water as the fluid model, was investigated by computational fluid dynamics modeling. The parameters predicted by the computer model were validated with the experimental dates. The CFD results were very close to those obtained experimentally. During the simulation it was verified a prevalent impeller effect at low speeds, propelling a large volume of fluid against the walls of the vessel, which without recirculation, results in low values of eG and kLa; however, by increasing air velocity, the impeller effect is smaller with the air flow being greater, in the region of the riser, causing fluid recirculation, which explains the increase in eG and kLa.
Abstract: Different approaches for heating\cooling of stirred tanks, coils and jackets, are investigated using computational fluid dynamics (CFD).A time-dependant sliding mesh approach is applied to simulate the flow in both conditions. The investigations are carried out under the turbulent flow conditions for a Rushton impeller and heating elements are considered isothermal. The flow behavior and temperature distribution are studied for each case and heat transfer coefficient is calculated. Results show different velocity profiles for each case. Unsteady temperature distribution is not similar for different cases .In the case of the coiled stirred vessel more uniform temperature and higher heat transfer coefficient is resulted.
Abstract: The impeller and the casing are the key components of
a centrifugal pump. Although there have been many studies on the
impeller and the volute casing of centrifugal pump, further study of the
volute casing to improve the performance of centrifugal pumps is
needed. In this paper, the effect of cross-sectional area on the
performance of volute casing was investigated using a commercial
CFD code. The performance characteristics, not only at the off-design
point but also for a full type model are required these days. So we
conducted numerical analysis for all operating points by using
complete geometry through transient analysis. Transient analysis on
the complete geometry of a real product has the advantage of
simulating realistic flow. The results of this study show the variation of
a performance curve by modifying the above-mentioned design
parameter.
Abstract: Composite laminates are relatively weak in out of
plane loading, inter-laminar stress, stress concentration near the edge
and stress singularities. This paper develops a new analytical
formulation for laminated composite rotating disc fabricated from
symmetric sequential quasi isotropic layers to predict three
dimensional stress and deformation. This analysis is necessary to
evaluate mechanical integrity of fiber reinforced multi-layer
laminates used for high speed rotating applications such as high
speed impellers. Three dimensional governing equations are written
for rotating composite disc. Explicit solution is obtained with
"Frobenius" expansion series. Based on analytical results, there are
two separate zones of three dimensional stress fields in centre and
edge of rotating disc. For thin discs, out of plane deformations and
stresses are small in comparison with plane ones. For relatively thick
discs deformation and stress fields are three dimensional.
Abstract: In this paper, three dimensional flow characteristic was
presented by a revision of an impeller of an axial turbo fan for
improving the airflow rate and the static pressure. TO consider an
incompressible steady three-dimensional flow, the RANS equations
are used as the governing equations, and the standard k-ε turbulence
model is chosen. The pitch angles of 44°, 54°, 59°, and 64° are
implemented for the numerical model. The numerical results show that
airflow rates of each pitch angle are 1,175 CMH, 1,270 CMH, 1,340
CMH, and 800 CMH, respectively. The difference of the static
pressure at impeller inlet and outlet are 120 Pa, 214 Pa, 242 Pa, and 60
Pa according to respective pitch angles. It means that the 59° of the
impeller pitch angle is optimal to improve the airflow rate and the
static pressure.