Flow and Mixing Optimization of an Existing Biogas Plant through CFD Simulation and Velocity Measurements Prepared

Flow and Mixing Optimization of an Existing Biogas Plant through CFD Simulation and Velocity Measurements Prepared
Author: Obada Yaghi
Publisher: GRIN Verlag
Total Pages: 95
Release: 2019-04-17
Genre: Technology & Engineering
ISBN: 3668925747

Bachelor Thesis from the year 2016 in the subject Engineering - Mechanical Engineering, grade: 94%, German Jordanian University (hosted by Hamburg University of Technology), language: English, abstract: This research project enables further development and improvement of the mixing efficiency in an existing biogas plant, by utilizing CFD simulation as well as a newly developed flow sensor in addition to supportive laboratory tests. The flow was analyzed considering the following variables: The mixing time, the Dry Matter (DM) content, the positioning of the agitators and how it can be related to the amount of velocity dead-zones. The velocity measurements took place at the biogas plant of the company Ardestorfer Bioenergie GmbH in the district of Buxtehude. The current plant capacity is approximately 1.6 MWel using animals manure, energy crops as well as agricultural residuals. In order to be able to perform the CFD simulation, a complete 3D model had to be done of the examined fermenter and the mixing agitators. Moreover, the current setup including fluid properties, boundary and initial conditions had to be taken into consideration. Velocity measurements were used as a validation approach for the simulation results, furthermore to acquire an overview of the flow behavior over the investigated mixing period. Firstly, it was found that at higher DM content the flow seemed to be more stable, and the velocity values get quite higher at the examined points. Moreover, at higher DM content (9.35% compared with 8.8%) the velocity dead-zones seemed to be approximately 70% less. Secondly, another approach was considered to improve the mixing and to minimize the dead-zones by changing the position of the main agitator. The new scenario showed fewer dead-zones by approximately 65% according to the CFD model. Thirdly, at all scenarios and setups, the flow seemed to reach the maximum possible velocity, and rather motion distribution after 150-180 seconds. Showing no remarkable improvement after this period. The mentioned findings were concluded based on comparisons between different velocity measurements as well as CFD simulation results at different operating conditions and setups. Being able to offer proper recommendations for a better energy efficiency in terms of lower energy consumption and better mixing all over the fermenter.

Computational Fluid Dynamics (CFD) Simulation of a Gas-Solid Fluidized Bed. Residence Time Validation Study

Computational Fluid Dynamics (CFD) Simulation of a Gas-Solid Fluidized Bed. Residence Time Validation Study
Author: Baru Debtera
Publisher: GRIN Verlag
Total Pages: 26
Release: 2021-11-29
Genre: Science
ISBN: 3346547728

Academic Paper from the year 2021 in the subject Physics - Mechanics, , language: English, abstract: In this study, numerical simulations of a gas-solid fluidized bed reactor involving a two-fluid Eulerian multiphase model and incorporating the Kinetic Theory of Granular Flow (KTGF) for the solids phase have been performed using a commercial Computational Fluid Dynamics (CFD) software. The fluidized bed setup consists of 1,5 m height and 0,2 m diameter in which a series of experiments were performed using Helium tracer to determine the Residence Time Distribution (RTD) at various normalized velocities i.e., with different degrees of gas-solids mixing. Both 2D and 3D simulations of the fluidized bed reactor are performed. The main purpose of this study is to understand the hydrodynamic behavior of a gas-solid fluidized bed reactor through a framework of Eulerian multiphase model and to analyze hydrodynamic behavior of the gas-solids mixing.

Gas-Liquid Flow Modeling for Renewable Fuels Production

Gas-Liquid Flow Modeling for Renewable Fuels Production
Author:
Publisher:
Total Pages: 0
Release: 2023
Genre:
ISBN:

Aerobic/anaerobic and gas fermentation pathways have emerged as promising new technologies for the generation of renewable fuels/chemicals from biomass derived sugars, and mixtures of greenhouse/energy rich gas streams (CO2/CH4/H2/CO) via microbial action. Example pathways include sugars-to-ethanol conversion, biomethanation (CO2/H2 to CH4), biogas upgrading, CO fermentation and wet-waste conversion. Gas and liquid phase transport, mass-transfer, and mixing physics at large length scales can significantly affect microbial conversion rates, particularly when the microbial reaction requires a narrow set of conditions. These phenomena are difficult to study in small-scale bench-top reactors that are typically well-mixed. Predictive computational fluid dynamics (CFD) based simulations can therefore aid in the scale-up, design and optimization of these reactors. This work presents multiphase Euler-Euler CFD simulations of at-scale (~500 m3) bioreactors. Our mathematical model treats the gas and liquid as interpenetrating phases. This approach reduces the computational complexity of tracking individual gas bubbles that are several orders of magnitude smaller than reactor dimensions. We solve the Reynolds averaged Navier-Stokes (RANS) multiphase equations that account for phase and chemical species transport, interphase mass and momentum transfer and uses a phenomenological model for gas uptake by microbes. We use a customized solver derived from open-source CFD toolbox, OpenFOAM [1], to perform these simulations, which has been validated against small-scale reactors in our previous work [2]. There is currently a knowledge-gap regarding bubble-size distributions when using gas mixtures with vastly different properties, which can have a significant impact overall mass-transfer. For example, hydrogen bubbles are more buoyant compared to other relatively heavier gases (CO2/CH4/CO), resulting in a large distribution of residence times and bubble sizes. This work therefore develops a deeper understanding of bubble dynamics and interphase mass transfer in such heterogenous gas mixtures through well-resolved computational models. We use a population balance model (PBM) for bubble-size-distribution modeling that is validated against small-scale experiments in our solver with an uncertainty quantification study for bubble coalescence and break-up model parameters. Results pertaining to multiple simulations of gas-fermentation reactors are presented where gas mixtures with varying compositions of CO2/CH4/CO/H2 are imposed at the sparger boundaries. The spatio-temporal variations in bubble-size distribution and mass transfer coefficient are analyzed for varying superficial velocities and gas-compositions for varying sizes of bubble-column and airlift reactors. This work will also examine the performance of different reactor designs, viz. bubble column reactor, airlift reactor with an internal draft tube, and a stirred-tank reactor with Rushton impellers. Reactor mass-transfer coefficient, gas hold-up, and dissolved gas distribution are critically analyzed among reactors, and sensitivity studies pertaining to gas flow rates and reactor geometry will be presented. [1] Weller, H., Tabor, G., Jasak, H. and Fureby, C., A tensorial approach to computational continuum mechanics using object-oriented techniques, Computers in physics, 12, 6, 620--631, 1998. [2] Rahimi, M., Sitaraman, H., Humbird, D. and Stickel, J., Computational fluid dynamics study of full-scale aerobic bioreactors: Evaluation of gas-liquid mass transfer, oxygen uptake, and dynamic oxygen distribution, Chemical Engineering Research and Design, 139: 283-295.

Computational Fluid Dynamics (CFD) Simulation of Flow in Mixing Reactor

Computational Fluid Dynamics (CFD) Simulation of Flow in Mixing Reactor
Author: Wain Ket Chong
Publisher:
Total Pages: 34
Release: 2016
Genre: Biochemical engineering
ISBN:

Mixing reactor is a common unit operation in many industrial processes. It is often encountered multiphase flow for mixing process. A computational fluid dynamics (CFD) model based on the mixture formulation for multiphase flow was created to study the mixing hydrodynamics of oil and water in a mixing reactor. This project aimed to develop a reliable CFD model that was able to predict the hydrodynamic properties like velocity or volume fraction. A grid dependency study was conducted to determine the effect of coarse, medium and fine meshes. The simulations were based on an experimental study where the mixing of oil and water occurred in the external loop. It had shown that the medium mesh was seem satisfactory to fulfill the evaluation criterion. The error between prediction of CFD model and experimental data was also within the tolerant range.

CFD Simulations in Mechanically Stirred Tank and Flow Field Analysis

CFD Simulations in Mechanically Stirred Tank and Flow Field Analysis
Author: Hélène Caillet
Publisher:
Total Pages: 0
Release: 2022
Genre: Electronic books
ISBN:

Anaerobic digestion is a widely used process for waste treatment and energy production. This natural process takes place in a controlled environment, anaerobic digesters. Mixing is one of the main operating parameters. The understanding of the flows during the agitation of the medium is crucial for the optimization of the process yield. In fact, the mass and heat transfers are enhanced by the agitation. However, the complex biochemical reactions can be inhibited with overly vigorous agitation. A detailed and in-depth understanding of the phenomena occurring during agitation requires modeling studies. In this chapter, we propose a general approach, based on computational fluid mechanics (CFD), to analyze the mechanical mixing of an anaerobic reactor. We apply this work to the anaerobic digestion of the sugarcane vinasse, which is a liquid waste generated during the production of alcohol. The single-phase Reynolds-averaged Navier-Stokes (RANS) simulations of mechanical agitation of Newtonian fluids for different rotational speeds are presented. The equations system is closed with the standard k-epsilon turbulence model. The flow field is analyzed with the velocity profiles, the Q and Lambda2 fields, the pressure and the vorticity.

Computational Fluid Dynamics for Engineers

Computational Fluid Dynamics for Engineers
Author: Bengt Andersson
Publisher: Cambridge University Press
Total Pages: 203
Release: 2011-12-22
Genre: Technology & Engineering
ISBN: 1139505564

Computational fluid dynamics, CFD, has become an indispensable tool for many engineers. This book gives an introduction to CFD simulations of turbulence, mixing, reaction, combustion and multiphase flows. The emphasis on understanding the physics of these flows helps the engineer to select appropriate models to obtain reliable simulations. Besides presenting the equations involved, the basics and limitations of the models are explained and discussed. The book combined with tutorials, project and power-point lecture notes (all available for download) forms a complete course. The reader is given hands-on experience of drawing, meshing and simulation. The tutorials cover flow and reactions inside a porous catalyst, combustion in turbulent non-premixed flow, and multiphase simulation of evaporation spray respectively. The project deals with design of an industrial-scale selective catalytic reduction process and allows the reader to explore various design improvements and apply best practice guidelines in the CFD simulations.

Modelling Fluid Flow

Modelling Fluid Flow
Author: János Vad
Publisher: Springer Science & Business Media
Total Pages: 424
Release: 2013-04-17
Genre: Technology & Engineering
ISBN: 3662087979

Modelling Fluid Flow presents invited lectures, workshop summaries and a selection of papers from a recent international conference CMFF '03 on fluid technology. The lectures follow the current evolution and the newest challenges of the computational methods and measuring techniques related to fluid flow. The workshop summaries reflect the recent trends, open questions and unsolved problems in the mutually inspiring fields of experimental and computational fluid mechanics. The papers cover a wide range of fluids engineering, including reactive flow, chemical and process engineering, environmental fluid dynamics, turbulence modelling, numerical methods, and fluid machinery.

Bioreactors

Bioreactors
Author: Carl-Fredrik Mandenius
Publisher: John Wiley & Sons
Total Pages: 520
Release: 2016-02-16
Genre: Science
ISBN: 3527683372

In this expert handbook both the topics and contributors are selected so as to provide an authoritative view of possible applications for this new technology. The result is an up-to-date survey of current challenges and opportunities in the design and operation of bioreactors for high-value products in the biomedical and chemical industries. Combining theory and practice, the authors explain such leading-edge technologies as single-use bioreactors, bioreactor simulators, and soft sensor monitoring, and discuss novel applications, such as stem cell production, process development, and multi-product reactors, using case studies from academia as well as from industry. A final section addresses the latest trends, including culture media design and systems biotechnology, which are expected to have an increasing impact on bioreactor design. With its focus on cutting-edge technologies and discussions of future developments, this handbook will remain an invaluable reference for many years to come.

CFD Simulation of Turbulent Non-Newtonian Slurry Flows in Horizontal Pipelines

CFD Simulation of Turbulent Non-Newtonian Slurry Flows in Horizontal Pipelines
Author: Mohsen Sadeghi
Publisher:
Total Pages: 0
Release: 2022
Genre: Computational fluid dynamics
ISBN:

Complex concentrated slurry flows in horizontal pipelines are widely seen in many industries for transportation of solid particles or process wastes. i.e., tailings. Slurry flows can occur in a turbulent regime, and the carrier fluid usually shows a non-Newtonian behavior. Understanding the flow behavior of slurries and the ability to predict the changes in the behavior with respect to variations in the flow conditions are of great importance and help the operators in pipeline design and optimization, and possibly development of separation processes. CFD simulation is a powerful tool to study the multiphase slurry systems, and can be applied to a wide variaty of configurations, flow conditions, and number of phases. In this work, CFD models were developed using ANSYS® FLUENT 2020 R2 commercial package to investigate the flow behavior of slurries in laboratory and industrial scale pipelines. The first part of this thesis investigates a model system in a lab-scale pipeline by studying the transport of monodisperse and bimodal particles in a turbulent non- Newtonian carrier using an Eulerian-Eulerian CFD model coupled with granular kinetic theory. The CFD predictions agreed satisfactorily with experimental data of solids concentration and pressure drop reported in the literature. The effects of the diameter of monodispersed particles (0.5-2 mm), solids concentration (0.1- 0.4), mixture velocity (3-6 m/s), and carrier fluid density (1000-1400 kg/m3) on flow behavior and specific energy consumption were investigated. The mixture velocity has the most significant effect on pressure drop and radial solids distribution. An increase in mixture velocity or solids concentration led to a larger pressure drop, primarily due to the intensified particle-wall and particle-particle interactions. At the maximum velocity of 6 m/s, the solids concentration distribution reversed near the pipe invert with a local maximum in turbulent kinetic energy from a low solids concentration, while turbulence was dampened at the pipe core where the solids concentration is higher. A higher solids concentration and lower mixture velocity led to lower specific energy consumption. In the second part, the work was extended to an industrial-scale pipeline with the study of transport of three-phase oil sands tailings in a horizontal pipeline using the CFD technique via the mixture multiphase model coupled with the kinetic theory of granular flow. The solid particles and bitumen droplets are conveyed via a non-Newtonian carrier fluid in a turbulent regime inside an industrial-scale pipeline with 74 cm diameter and 220m length. Ten sets of field data of velocity distribution and pressure drop were collected and used for the validation of the model. Overall, the CFD results showed exceptional agreement with the field data, with errors of