EFFECT OF CYCLONE HEIGHT ON HOLDUP MASS AND HEAT TRANSFER RATE IN SOLID CYCLONE HEAT EXCHANGER- CFD APPROACH

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1 EFFECT OF CYCLONE HEIGHT ON HOLDUP MASS AND HEAT TRANSFER RATE IN SOLID CYCLONE HEAT EXCHANGER- CFD APPROACH T. Mothilal 1, V. Velukumar 2, K. Pitchandi 3 and M. Selvin Immanuel 1 1 Department of Mechanical Engineering, T.J.S. Engineering College Peruvoyal, Chennai, India 2 Department of Mechanical Engineering, Muthayammal College of Engineering Rasipuram, Namakkal, India 3 Department of Mechanical Engineering, Sri Venkateshwara College of Engineering Sriperumpudur, Chennai, India haimothi@yahoo.co.in ABSTRACT This work investigates the effect of cyclone height (barrel and cone height) on holdup mass and heat transfer rate in a cyclone heat exchanger using CFD code FLUENT 12. Four barrel height (100, 150, 200 and 250 mm) and four cone height (200, 250, 300 and 350 mm) cyclones were tested in order to find its effect on hold up mass and heat transfer rate from gas to solid particles. Flow field is analyzed using Reynolds averaged Navier stokes equation. RNG k-ɛ turbulence model used to analyze the air flow and discrete phase model (DPM) is adopted to predict the particles tracking in cyclone. Experimental data used for the validation of simulations were obtained from the literature study. Previous works in varying the dimensions of cyclone height does not predict holdup mass and heat transfer rate in cyclone. Result shows that increasing barrel and cone height decreases pressure drop, Maximum tangential velocity and axial velocity increases slightly in cyclone heat exchanger. Holdup mass raises % with change in barrel height ranging from 100 to 250 mm and 2-5 % with change in cone height ranging from 200 to 350 mm. Similarly with increase in barrel and cone height, heat transfer rate raises from % and % respectively. Keywords: cyclone heat exchanger, RNG k-ɛ, DPM, barrel height, cone height, holdup mass, heat transfer rate. INTRODUCTION A heat exchanger is a device built for efficient transfer of heat from one medium to another even if the media is separated by a solid wall which do not mix or in direct contact. Cyclones have been one of the oldest methods for the removal of dispersed particles from their carrying gas. Gaseous stream containing particulates enters tangentially in a body that consists in a cylinder followed by a conical section. The flow phenomena in cyclones are highly swirling and three-dimensional in nature. Performance of cyclone heat exchanger is directly proportionate to the surface area of holdup mass of solid particles inside the cyclone. Holdup mass of solid particles is the total mass of solid particles in cyclone which is involved in the exchange of heat with the hot gas stream. Performance and flow pattern in cyclones is affected by the operating and geometrical parameters. Avici et al. [1] found that surface friction on vortex length and flow regimes play an important role on cyclone performance in addition to flow and geometrical parameters, in small cyclones. Boysan et al. [2] found that standard k-ɛ turbulence model is inadequate to simulate swirl flow, swirling leads to excessive turbulence viscosities and unrealistic tangential velocities. Numerous studies have been performed on cyclone pressure drop by varying operational and geometrical parameters [3, 4, 5, 6]. KhairyElsayed and Chris lacor [7, 8, 9, 10] analyzed different geometrical parameters like inlet height, dust outlet and cone tip diameter of cyclone on its flow patterns and performance. Karagoz et al. [11] studied the structure of vortices and variation of local heat transfer by varying inlet velocity of gas and particles feed rate. A. Jain et al. [12] derived correlation for nusselt number by varying inlet parameters in cyclone heat exchanger. Kyoungwoo park et al. [13] found the effect of vortex finder and cone tip diameter on its performance and observed, particles reentraining degrades the separation efficiency. Bohnet et al. [14] developed a model, in which temperature dependent wall friction coefficient is introduced and re-entrainment of separated particles considered. Marinuc et al. [15] demonstrated theoretically the influence of solid particles dimension and input velocity over collection efficiency. Patterson et al. [16] found, dust load has strong influence on collection efficiency and loading effect stronger at high temperature. Rau et al. [17] reported experimental analysis on air-solid heat transfer reverse flow cyclone with short cylindrical section, compared his test section with conical section and proposed correlation for holdup mass in cyclone heat exchanger. Zhu et al. [18] done experiment on particles collection efficiency of small cyclones by varying cylinder height and exit tube length and operated at high flow rates. Results suggest, flow rate plays significant role in cyclone collection efficiency. Hoekstra et al. [19] experimentally analyzed different geometric swirl numbers by laser-doppler velocimetry. Geometry swirl number has influence on mean flow characteristics and maximum tangential velocity influences vortex size. Shukla et al. [20] evaluated different numerical schemes for dispersed phase in cyclone separator. R.B. Xiang et al. [23] numerically evaluated different cyclone height for flow pattern and separation efficiency. Mothilal.T et al. [24] studied the 1269

2 effect of mass flow rate of inlet air on holdup mass experimentally. Mothilal.T et al. [25, 26] analyzed numerically the geometries such as vortex finder diameter, inlet height and cone tip diameter of cyclone heat exchanger on flow field, Holdup mass and heat transfer rate. These above mentioned studies do not predict the effect of geometrical parameters on holdup mass in cyclone heat exchanger. Present work elaborates the effect of cyclone height on holdup mass and heat transfer rate in cyclone heat exchanger. Numerical Descriptions Governing Equation for Gas Phase Flow in cyclones is assumed to be turbulent swirl flow with incompressible fluid and it can be predicted using RNG k-ɛ turbulence model [11]. Turbulent flow for gas can be described by the Reynolds-Average Navier- Stokes (RANS) equation and equation of continuity for the mean motion. Tensor notation are expressed as follows: u i x i i uiu x x u u 0 ' ' i (1) P u u i 2 u i g i i xi x x xi 3 x i (2) Turbulent Equations for Gas Phase Transport equation for RNG k-ε turbulence model is shown below. t t xi x k x k ku i k eff G k Ym xi x x u i eff C Gk C2 R (3) 2 1 (4) k k In these equations, G k represents the generation of turbulence kinetic energy due to the mean velocity gradients. The constants used in the equations have the following values: C 1ε=1.42, C 2ε=1.68. Model Equation for Particles Phase Following assumptions are made in order to model the particles motion for present analysis. Spherical solid particles gets dispersed and diluted into gas phase, so that the gas-solid interaction and influence of the dispersed particles volume fraction on gas phase are negligibly small. Generally particles loading in a cyclone is small (3-5%), therefore presence of particles does not affected by flow field (i.e., one-way coupling) [5], [20]. Interaction among the particles is neglected due to dilute flow. Discrete phase model (DPM) is used to define the initial position, velocity, size of individual particles in order to simulate the particles motion in the cyclone [5, 20]. Traectories of particles are obtained by integrating the force balance on the particles. Equation of motion of small particles, which is added in the effects of nonlinear drag and gravitational force, in terms of the Eulerian-Lagrangian approach is given by [20]. du p FD u u p dt g x p p F x F xis an additional acceleration (force/unit particles mass) term, F D is the drag force per unit particles mass and F D (5) 18 c D R e 2 (6) 24 p d p Here, u is the fluid phase velocity, u p is the particles velocity, μ is the molecular viscosity of the fluid, ρ is the fluid density, ρ p is the density of the particles, and d p is the particles diameter. Re is the relative Reynolds number, which is defined as follows: d p u p Re u Geometrical Descriptions Development of different cyclones is based on stairmand high efficiency cyclone. Stairmand high efficiency cyclone collects more particles compared to conventional and high throughput cyclones [3], [5], [6]. Therefore evaluation of numerical study was performed on stairmand high efficiency model. Cyclone heights of different cyclones are shown in the Table-1 and the 2D description is shown in Figure-1. 3D modeling was done by using Solid works modeling software shown in Figure- 2. (7) 1270

3 Table-1. Dimension description of different cyclones. Cyclone description Length (mm) Length/D Cyclone diameter (D) Inlet height (H) Inlet width (W) Vortex finder diameter (Dv) Vortex finder length (s) Cone tip diameter (Dc) Barrel Height B B B B Cone height C C C C *Where B2 and C2 are same Figure-1. 2D model of different cyclone heat exchanger. 1271

4 B1 B2 B3 B4 C1 C2 C3 C4 Figure-2. 3D model of cyclone heat exchanger with different cyclone height. Discretization of Cyclone and Boundary Conditions Non uniform Hybrid mesh [11] generated for all seven cyclones by using ANSYS ICEM CFD software [21]. Every mesh consists of around elements, nodes are used in the simulation. Mesh generated cyclone is shown in the Figure-3. Velocity inlet boundary condition was applied at gas inlet and solid inlet, outflow boundary condition applied at gas outlet. Density of the air is kg/m 3 [22] and the turbulent intensity (I) is 5% [5], [20] and hydraulic diameter (D H) is m. Maximum number of steps used for particles tracking is and the step length factor is 5 [22]. Grid refinement test was performed to confirm solutions are grid independent. Figure-3. Mesh generated cyclone. Solver Settings SIMPLE algorithm used for Pressure-velocity coupling and higher upwind interpolation scheme used in all numerical experiments. Fluid flow is steady, three dimensional and Eulerian-lagrangian approach used to 1272

5 simulate model. In this study, steady and incompressible fluid flow transport equations of continuous phase are solved using Eulerian reference frame. Simulation of dispersed phase is performed by tracking a large number of spherical dispersed particles through converged flow field of continuous flow field in a Lagrangian reference frame by using one way coupling method via discrete phase model (DPM) [5], [20]. Collisions between the dispersed particles and cyclone walls are taken into account by using coefficient of restitution of 0.8 [20]. Simulation of the cyclone heat exchanger is initiated by running the steady state solver. Solution gets converged with pre-set scaled residuals of , as convergence criterion for all equations. RESULT AND DISCUSSIONS Present study evaluates the effect of different cyclone heights (Barrel and cone height) on holdup mass and heat transafer rate. Inlet air is fed at different inlet air velocity ranging from 5 to 20 m/s, air temperature of 473 K and particles are fed at constant particles diameter (300 micron) and feed rate of (0.5 g/s). Effect of Cyclone Height on Flow Field Time-averaged static pressure of different cyclone heights decreases radially from the wall to center and it is shown in Figure-4. Two vortical motions exist, one moves down (outer vortex) and the other moving up (inner vortex). A negative pressure zone appears in forced vortex region due to high swirling velocity. It was observed from figure (4) static pressure decreases more for cone height compared to barrel height. Flow velocity can classify into three components viz., tangential, axial and radial velocity [7]. Maximum tangential velocity decreases, axial velocity slightly increases with increase in cyclone height and negligible variation in radial velocity. Similar result observed from khairy Elsayed et al. [7]. Validation In order to validate the present simulation, heat transfer rate is compared with the experimental heat transfer rate stated by A.ain et al. [12]. The result shows that heat transfer rate increases with increase in inlet air flow rate. Heat transfer rate predicted from the simulation (standard stairmand dimension) have similar trend of A. ain et al. [12] shown in Figure-5. Effect of cyclone height (barrel and cone height) on holdup mass is presented in Figure-6. It indicates holdup mass rises 1.6 to 3.6 % with increase in barrel height (100 to 250 mm) and 2 to 5% with increase in cone height (200 to 350 mm) at constant particles diameter (300 micron) and air velocity ranging from (5 m/s) and similar result was observed at all inlet air velocities. Increase in cyclone height, increases swirling rotation of gas and solid which increases centrifugal force of the gas-solid phase mixture inside the cyclone, thus the holdup mass increases with increase in both barrel and cone dimensions. Effect of Cyclone Height on Heat Transfer Rate Heat transfer rate of particles related with mass flow rate, specific heat capacity and temperature difference between inlet and outlet temperature of particles [12]. q = m scp s (Ts out Ts in) (9) The effect of cyclone height on heat transfer rate is shown in Figure-7. Increase in both barrel and cone height in cyclone increases heat transfer rate. Increasing barrel height from (100 to 250 mm) increases heat transfer rate % and for cone height (200 to 350mm) % rise is observed at constant particle diameter (300 micron) and air velocity (5 m/s). Similar result was observed at all inlet air velocities. As cyclone volume, swirling rotation and holdup mass increases, with increase in cyclone height contact time for particles with hot gas get increased which maximize the outlet particles temperature in the bin. Thus heat transfer rate increases with increase in cyclone height. 100 Static Pressure (Pa) 50 Barrel height Radial distance (mm) 100 mm 150 mm Effect of Cyclone Height on Holdup Mass Holdup mass is the total mass of solid particles present inside the cyclone at any instant of time and it depends upon residence time (T R) and mass flow rate of solid particles. M h= m s X T R (8) Residence time (T R) of particles defined as the time taken by particles to travel from inlet to outlet (bin). 1273

6 85 Static pressure (Pa) Radial mmdistance (mm) 250 mm Figure-4. Static pressure of barrel height and cone height on radial distance. Heat transfer rate (w) Holdup mass (g) Inlet air velocity (m/s) Present CFD A.Jain Experiment [12] Figure-5. Comparison between simulation and experimental heat transfer rate Cone height Cyclone barrel height (mm) 5 m/s 10 m/s 15 m/s 20 m/s Holdup mass (g) Heat transfer rate (w) Heat transfer rate (w) Cyclone cone height (mm) 5 m/s 10 m/s 15 m/s 20 m/s Figure-6. Effect of cyclone height on holdup mass Cyclone barrel height (mm) 5 m/s 10 m/s 15 m/s 20 m/s Cyclone cone height (mm) 5 m/s 10 m/s 15 m/s 20 m/s Figure-7. Effect of cyclone height on heat transfer rate. 1274

7 CONCLUSIONS RNG k-ɛ turbulence model has been used to study the effect of cyclone height on holdup mass and heat transfer rate. Seven cyclones with different barrel height and cone height have been investigated. The following conclusion has been obtained. 1. Cyclone height has a significant effect on the flow pattern. Pressure drop, maximum tangential velocity decreases with increase in both barrel and cone height and axial velocity increases slightly with increase in cyclone height. Negligible variation in radial velocity was observed with increase in cyclone height. 2. Holdup mass of cyclone rises with increase in cyclone height (both barrel and cone height). Holdup mass raises more with effect of change in cone height than barrel height and cone height has impact of 0.5 to 2 % higher than barrel height in holdup mass. 3. Heat transfer rate increases with increase in cyclone height (both barrel and cone height) dimensions. Heat transfer rate increases 0.4 to 0.8 % more with change in cone height than Barrel height. 4. This work can be extended to optimize the dimensions of the cyclone heat exchanger to obtain higher efficiency. NOMENCLATURE Cp s Specific heat capacity of solid particles in J/kg K F D Drag force in N g Gravitational acceleration in m/s 2 J Diffusion flux in moles/cm 2 s k Turbulent kinetic energy in m 2 /s 2 K eff Effective conductivity in W/m-K M h Holdup mass in g m s Mass flow rate of the solid particles in the cyclone in kg/sec P Mean pressure in bar q Effective heat transfer rate in W T sin Inlet solid temperature in K T sout Exit solid temperature in K u Gas velocity in m/s Y m Fluctuating dilatation in compressible turbulence Residence time of particles in seconds T R Greek Letters Ɛ turbulent dissipation rate in m 2 /s 3 µ Molecular viscosity of fluid in kg/m/s ρ p Particles density in Kg/m 3 ρ Gas density in Kg/m 3 ƞ Efficiency Drag coefficient defined as per the equation α k Inverse effective Prandtl number for k Inverse effective Prandtl number for Ɛ α ᶓ REFERENCES [1] Avci, I. Karagoz, Effects of Flow and Geometrical Parameters on the Collection Efficiency in Cyclone Separators. Journal of Aero science: (2003) vol. 34 (7) pp: [2] Boysan, W.H. Fayer, J. Swithtenbank A Fundamental Mathematical Modeling Approach to Cyclone Design. Trans. Inst. Chem. Eng: (1982) vol.60 (4), pp [3] J. Gimbun, T.G. Chuah, A. Fakhru I-Razi, S.Y. Choong, The influence of temperature and inlet velocity on cyclone pressure drop: a CFD study. Chemical Engineering and Processing: (2005) vol. 44 (1), pp [4] FeritFicici, Vedat Ari, Murat Kapsiz, The effects of Vortex finder on the pressure drop in Cyclone separators : International Journal of the Physical Sciences: (2010) vol. 5(6), pp [5] KhairyElsayed, Chris lacor, Optimization of the cyclone separator geometry for minimum pressure drop using mathematical models and CFD simulations. Chemical Engineering science: (2010) [6] Jianyi Chen, Mingxian Shi, A universal model to calculate cyclone pressure drop. Power technology: (2007) 171 pp [7] KhairyElsayed, Chris Lacor, The effect of cyclone inlet dimensions on the flow pattern and performance. Applied Mathematical Modelling: (1968) [8] KhairyElsayed, Chris Lacor, The effect of the dust outlet geometry on the performance and hydrodynamics of gas cyclones. Computers & Fluids (2012) 68 pp [9] KhairyElsayed, Chris Lacor, Numerical modeling of the flow field and performance in cyclones of different cone-tip diameters. Computers & Fluids (2011) 51, pp [10] KhairyElsayed, Chris Lacor, The effect of cyclone vortex finder dimensions on the flow pattern and performance using LES. Computers & Fluids (2013) 71, pp

8 [11] I Karagoz, F. Kaya, CFD investigation of the flow and heat transfer characteristics in a tangential inlet cyclone. International Communications in Heat and Mass Transfer, (2007) vol.34, pp [12] A. Jain, B. Mohanty, B. Pitchumani, K.S. Raan, Studies on Gas-Solid Heat Transfer in Cyclone Heat Exchanger. Journal of Heat Transfer. ASME: (2006) vol. 128(8), pp [13] Kyoungwoo Park, Chol-HoHong,Ji-Won Han, Byeong-Sam Kim,Cha-Sik Park, Oh Kyung Kwon, The Effect of Cyclone Shape and Dust Collector on Gas-Solid Flow and Performance. World Academy of Science, Engineering and Technology: (2012) vol. 6, pp [14] M. Bohnet, Influence of the gas temperature on the separation efficiency of aerocyclones. Chemical Engineering and Processing: Process Intensification: (1995) vol.34 (3), pp [15] M. Marinuc, F. Rus, The effect of particles size and input velocity on cyclone separation process. Bulletin of the Transilvania, University of Braşov, (2011) vol. 4 (53), pp [22] Ansys ICEM CFD, ICEM CFD theory guide, Ansysinc. [23] R.B. Xiang and K.W. Lee, Numerical study of flow field in cyclones of different height. Chemical Engineering and Processing: (2005), 44, pp [24] T. Mothilal, K. Pitchandi, Effect of mass flow rate of inlet gas on holdup mass of solid cyclone heat exchanger, Applied Mechanics and Materials. Vols (2014) pp [25] T. Mothilal, K. Pitchandi, V. Velukumar, M. Selvin Immanuel, Influence of Vortex finder Diameter and Cone tip diameter on Holdup mass and Heat transfer rate in cyclone-cfd Approach, International Journal of Applied Engineering Research. Vol. 10 No. 33 (2015). [26] T. Mothilal, K. Pitchandi, V. Velukumar, M. Selvin Immanuel, The effect of Vortex finder diameter and inlet height on holdup mass and heat transfer characteristics in cyclone heat exchanger-cfd Approach, International Journal of Applied Engineering Research. Vol. 10 No. 77 (2015). [16] P.A. Patterson, R.J. Munz, Cyclone efficiencies at very high temperatures. Can. J. Chemical Engineering: (1989) vol. 67, pp [17] A.V. Rau, R. Sita, J.P. Subrahamanyam, T.R. Rao, B. Pitchumani, Gas- Solid Heat Transfer in Cyclone Heat Exchanger. Indian Chem. Eng., Sect. A: (1994) vol. 36 (1-2), pp [18] Y. Zhu, K.W. Lee, Experimental Study on Small Cyclones Operating at High Flow rates. Journal of Aerosol Science: (1999) vol. 30, pp [19] A.J. Hoekstra, J.J. Derksen, H.E.A. Van Den Akker, An experimental and numerical study of turbulent swirling flow in gas cyclone. Chemical Engineering Science: (1999) vol. 54, pp [20] Sueetkumarshukla, Prashantshukla and Pradyumna Gosh, Evaluation of Numerical schemes for dispersed phase modeling of cyclone seperators. Engineering applications of Computational Fluid Mechanics: (2011) Vol. 5, No-2, pp [21] Ansys Fluent, Fluent 12. Theory guide, Ansysinc. 1276

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