基于颗粒脉动参数CFD模拟的气固流化床流场性质与流动结构研究
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摘要
气固流化床因其传热传质效率高、处理量大的优点而在工业领域得到了极其广泛的应用。从催化剂的开发、反应器流体力学性质的表征到工业装置的建立和改造,气固流化床一直是国内外学者研究的热点对象。作为一种典型的多相流反应器,气固流化床中存在着气泡搅动、颗粒运动及气固两相作用,是一个非线性瞬态系统,而这些复杂作用引发的各种流动参数随时间脉动是流化床最显著的特点。因此,相比于时均参数,流化床的脉动参数包含了关于流动结构和两相传递行为更加丰富的信息。对于流化床这样具有显著多尺度结构特点的化工对象,其囊括的流动结构形态多样、各具特征,常见的如气泡、涡流和颗粒聚团等,这些流动结构的行为本质和演化规律是揭示多相流动性质、解决过程强化和优化设计的瓶颈。因此,研究流化床中颗粒与气泡、局部与整体产生的脉动信号,进而对流场性质和流动结构进行刻画,对于多相流动过程流体力学性质的深刻认识以及反应器的精确设计具有重要意义。
针对现有气固流化床中脉动信号测量技术和流动结构表征方法的不足,本研究以计算流体力学(CFD)软件Fluent为研究手段,基于湍流脉动与流化床脉动的相似性,建立了多相流场性质与流动结构的表征方法,据此开展了一系列针对流化床流体力学特性的研究。在理论研究的基础上,开发了聚乙烯多温区冷凝态工艺并进行工业试验,成效显著。本论文的主要研究成果如下：
1.基于湍流脉动与流化床脉动的共性,提出借鉴单相湍流理论分析流化床脉动信号、揭示多相流场性质与流动结构特征的方法,包括颗粒脉动能谱分析、流场间歇性分析、相干结构表征与提取、颗粒涡多尺度演化分析以及颗粒温度分析,以实现“在信号中提取规律,向无序中寻求有序”的目标。
2.将CFD模拟结果与实验及文献数据相比较,分别验证了单、双分散颗粒流化床的计算模型的准确性。利用CFD模拟方法采集颗粒脉动速度信号并进行频谱分析和小波分解,分别考察了单分散和双分散颗粒流化床的能谱性质和流场间歇性。颗粒脉动能谱可以划分为含能区、惯性子区和耗散区,且惯性子区符合Levy-Kolmogorov定律。采用小波平坦因子考察了流场间歇性随频率(尺度)的分布,低频段大尺度脉动的间歇性较弱,高频段小尺度脉动的间歇性较强。对于双分散颗粒流化床,两种颗粒的小波平坦因子分布趋势相同,但在高于10Hz处开始出现差别。通过空隙率脉动频谱考察了流化床中气泡的流体力学行为,且主频的模拟值与经验公式计算值吻合较好,说明CFD模拟能较为准确地反映气泡的运动特性。
3.建立了颗粒脉动速度小波系数概率密度函数(PDF)与流化床中相干结构的关系,并对相干结构进行表征、提取,对提取前后的小波系数分别应用ESS标度律,考察了相干结构对流场性质的作用,证明了本文所采用的相干结构提取方法的有效性。采用自相关分析,研究了颗粒涡的时间尺度、多尺度形态及演化规律,发现颗粒涡的时间尺度与小波尺度呈普适关系,某些尺度的颗粒涡随时间呈规律性运动,相邻尺度的颗粒涡还会出现合并或分裂的现象。将颗粒涡的演化过程与流态化转变过程相关联。
4.利用CFD模拟及声发射检测技术,提出颗粒温度分布表征流动模式的判据。考察了双分散颗粒流化床的层流颗粒温度和湍流颗粒温度随径向位置、轴向位置和表观气速的变化,发现在分布板附近,湍流颗粒温度突然降低的位置对应于颗粒运动的“滞留区”,且位于轻、重颗粒的分层之间的边界,随着表观气速的增大,“滞留区”的高度降低。颗粒时均速度和颗粒雷诺应力分布亦可用于分析颗粒流动模式与相间作用。
5.以气相法聚乙烯冷凝态工艺为背景,分别建立了鼓泡流化床和中心射流床的计算模型,利用CFD模拟,考察了侧壁气流对床层流体力学性质的影响。结果表明,侧壁气流能够促进颗粒水平方向的运动,增强壁面附近的颗粒脉动活跃性,有利于减少粘壁现象的发生。侧壁气流具有稳定颗粒流型的作用,有利于流化床的平稳操作,并对颗粒涡的演化起到调制作用。研究结果为冷凝液蒸发破坏涡流热点的工艺路线提供了理论指导。
6.在工艺理论分析的基础上,提出多温区聚乙烯冷凝态工艺的设想,并得到工业装置试验的初步证实。首先从理论研究的角度探讨了多温区聚乙烯冷凝态技术的可行性。开发了具有高分离效率、低压降的气液分离器和冷凝液喷射装置；探讨了多温区聚乙烯冷凝态技术所具有的聚合温度差异化、聚合单体浓度差异化和催化剂温度敏感性差异化的特征及其对产品性能的影响。分析表明反应器下部有利于形成支链较多的、低密度高分子量的聚乙烯,而反应器上部有利于形成支链较少、高密度低分子量的聚乙烯。该技术在天津石化12万吨／年气相法聚乙烯装置上进行工业预试验,产量提高8%以上,且成功生产出性能优良、富有特色的树脂产品。本技术被命名为“气液法流化床聚乙烯工艺成套技术”,并于2012年入选中国石化“十条龙攻关”项目。
The gas-solid fluidized beds are extremely widely applied in the industrial fields due to their high efficiency of heat and mass transfer and large handling capacity. From the development of catalyst to the description of reactor hydrodynamic characteristics and establishment of industrial plant, gas-solid fluidized beds are always the research hotspot at home and abroad. As a typical multi-phase flow reactor, there exists bubble agitation, particle motion and phase interaction in a gas-solid fluidized bed. It is a non-linear transient system, and the most significant feature of fluidized bed is the fluctuation of various flow parameters generated by the above complex phenomenon. Hence, compared to the time-averaged flow parameters, the fluctuating parameters contain much more abundant information about flow structures and phase transfer. The flow structures in a fluidized bed include bubbles, vortex and particle clusters, whose behaviors and evolution are the bottleneck of revealing multi-phase flow features and achieving process intensification and optimal design. Therefore, it is of great significance to study the local and overall fluctuating signals generated by bubbles and particles in the fluidized bed, based on which the different flow structures are described and analyzed. By this way, the multi-phase flow field characteristics can be comprehended deeply and the reactor can be designed accurately.
In order to overcome the shortages of current fluctuating signal measuring and flow structure characterizing methods, our work employed the computational fluid dynamics (CFD) software Fluent to simulate the fluidized bed and obtain the fluctuating parameters. Based on the similarity of single-phase turbulent fluctuation and fluidized bed fluctuation, we established the characterizing method of multi-phase flow filed and flow structures. The hydrodynamic characteristics of fluidized bed were studied by this method. Besides, we developed the multiple-temperature-zone ethylene polymerization process with condensing mode and implemented the industrial test, achieving remarkable effects. The main research achievements of this paper are as follows.
1. Based on the similarity of single-phase turbulent fluctuation and fluidized bed fluctuation, we established the analytical methods of fluidized bed fluctuating signals and the characterizing methods of multi-phase flow filed and flow structures, including the analysis of particle fluctuating energy spectrum, flow field intermittency, multi-scale evolution of particle vortex, granular temperature, and the characterization and extraction of coherent structures. The aim was to extract regularities in random signals, and to discover order in disorder.
2. By comparing the simulated results with experimental or literature data, the CFD models of mono-dispersed and bi-dispersed fluidized bed were validated. The particle fluctuating velocity signals were monitored by CFD simulation, and analyzed by power spectrum and wavelet decomposition. According to that, the particle fluctuating energy spectrum and flow field intermittency in mono-dispersed and bi-dispersed fluidized bed was studied. The particle fluctuating energy spectrum can be divided into energy-containing region, inertial region and dissipation region. The Levy-Kolmogorov scaling law was obeyed in the inertial region. The flow field intermittency distribution with frequency was investigated by the wavelet flatness factor. The intermittency was weak in low frequency and large scale fluctuation, while it was strong in high frequency and small scale fluctuation. For bi-dispersed system, the wavelet flatness factors of the two kinds of particles showed similar distribution trend, however the differences appeared in frequency higher than10Hz. The bubble dynamics was also investigated by the voidage fluctuation spectrum. The dominant frequency agreed well with the empirical formula calculated value. That meant CFD simulation can provide accurate information of bubble motion.
3. The relationship between probability density function (PDF) of wavelet coefficients and coherent structures was established. The coherent structure signals were extracted and the Extended Self Similarity (ESS) scaling law was applied before and after the extraction. The effects of coherent structures on the flow field property were investigated and the extracting method was validated. The time scale and multi-scale evolution of particle vortex was studied by autocorrelation analysis. The universal relation of particle vortex time scales and wavelet scales was established. The vortex at some scales moved regularly as time passed. Particle vortexes at adjacent scales merged with or separated from others. The variation of particle vortex evolution was related to the fluidization transition.
4. The relation of CFD simulated granular temperature and experimental acoustic emission (AE) energy generated by particle impacting wall was established. The granular temperature was proved to be able to indicate the flow pattern. The radial and axial distribution of granular temperature in bi-dispersed fluidized bed was studied. Above the distributor, when turbulent granular temperature dropped suddenly, particles moved into the "stagnant" zone and lost their vitality, corresponding to the boundary of flotsam and jetsam layer. As the superficial gas velocity increased, the height of "stagnant" zone decreased. The distribution of particle time-averaged velocity and Reynolds stress was also applied to indicate the flow pattern and phase interaction.
5. In order to study the gas phase ethylene polymerization process with condensing mode, the calculating model of bubbling fluidized bed and central jetting fluidized bed were established. The CFD simulation was used to investigate the effects of gas ejection from wall on hydrodynamic characteristics. The gas ejection promoted horizontal motion of particle phase and strengthened the particle fluctuating activity near wall, which can reduce particle agglomeration on the wall. Besides, the gas ejection can stabilize the particle flow pattern and modulate the evolution of particle vortex. The work provided a theoretical guide of condensing liquid evaporation destroying the particle vortex hotspots.
6. Based on the theoretical analysis, the scheme of multiple-temperature-zone ethylene polymerization process was proposed and was verified preliminarily in the industrial plants. The feasibility of this technique was discussed firstly. The gas-liquid separator and liquid ejecting equipment was developed. The characteristics of this technique and their effects on resin performance were analyzed, including the differences of polymerizing temperature, monomer concentration and temperature sensitivity of catalyst between the two reaction zones. The polyethylene of low density, high molecular weight and more branched chains can be produced in the lower reaction zone, while the polyethylene of high density, low molecular weight and less branched chains can be produced in the above reaction zone. The new process was tested in the120000ton/year ethylene polymerization plants of Sinopec Tianjin Company. The output was increased by8%and the resin with excellent performance and distinct characteristics was produced successfully. This process was named as "Packaged technology of gas-liquid fluidized bed ethylene polymerization" and selected as "Sinopec Ten Dragons" project in2012.
针对现有气固流化床中脉动信号测量技术和流动结构表征方法的不足,本研究以计算流体力学(CFD)软件Fluent为研究手段,基于湍流脉动与流化床脉动的相似性,建立了多相流场性质与流动结构的表征方法,据此开展了一系列针对流化床流体力学特性的研究。在理论研究的基础上,开发了聚乙烯多温区冷凝态工艺并进行工业试验,成效显著。本论文的主要研究成果如下：
1.基于湍流脉动与流化床脉动的共性,提出借鉴单相湍流理论分析流化床脉动信号、揭示多相流场性质与流动结构特征的方法,包括颗粒脉动能谱分析、流场间歇性分析、相干结构表征与提取、颗粒涡多尺度演化分析以及颗粒温度分析,以实现“在信号中提取规律,向无序中寻求有序”的目标。
2.将CFD模拟结果与实验及文献数据相比较,分别验证了单、双分散颗粒流化床的计算模型的准确性。利用CFD模拟方法采集颗粒脉动速度信号并进行频谱分析和小波分解,分别考察了单分散和双分散颗粒流化床的能谱性质和流场间歇性。颗粒脉动能谱可以划分为含能区、惯性子区和耗散区,且惯性子区符合Levy-Kolmogorov定律。采用小波平坦因子考察了流场间歇性随频率(尺度)的分布,低频段大尺度脉动的间歇性较弱,高频段小尺度脉动的间歇性较强。对于双分散颗粒流化床,两种颗粒的小波平坦因子分布趋势相同,但在高于10Hz处开始出现差别。通过空隙率脉动频谱考察了流化床中气泡的流体力学行为,且主频的模拟值与经验公式计算值吻合较好,说明CFD模拟能较为准确地反映气泡的运动特性。
3.建立了颗粒脉动速度小波系数概率密度函数(PDF)与流化床中相干结构的关系,并对相干结构进行表征、提取,对提取前后的小波系数分别应用ESS标度律,考察了相干结构对流场性质的作用,证明了本文所采用的相干结构提取方法的有效性。采用自相关分析,研究了颗粒涡的时间尺度、多尺度形态及演化规律,发现颗粒涡的时间尺度与小波尺度呈普适关系,某些尺度的颗粒涡随时间呈规律性运动,相邻尺度的颗粒涡还会出现合并或分裂的现象。将颗粒涡的演化过程与流态化转变过程相关联。
4.利用CFD模拟及声发射检测技术,提出颗粒温度分布表征流动模式的判据。考察了双分散颗粒流化床的层流颗粒温度和湍流颗粒温度随径向位置、轴向位置和表观气速的变化,发现在分布板附近,湍流颗粒温度突然降低的位置对应于颗粒运动的“滞留区”,且位于轻、重颗粒的分层之间的边界,随着表观气速的增大,“滞留区”的高度降低。颗粒时均速度和颗粒雷诺应力分布亦可用于分析颗粒流动模式与相间作用。
5.以气相法聚乙烯冷凝态工艺为背景,分别建立了鼓泡流化床和中心射流床的计算模型,利用CFD模拟,考察了侧壁气流对床层流体力学性质的影响。结果表明,侧壁气流能够促进颗粒水平方向的运动,增强壁面附近的颗粒脉动活跃性,有利于减少粘壁现象的发生。侧壁气流具有稳定颗粒流型的作用,有利于流化床的平稳操作,并对颗粒涡的演化起到调制作用。研究结果为冷凝液蒸发破坏涡流热点的工艺路线提供了理论指导。
6.在工艺理论分析的基础上,提出多温区聚乙烯冷凝态工艺的设想,并得到工业装置试验的初步证实。首先从理论研究的角度探讨了多温区聚乙烯冷凝态技术的可行性。开发了具有高分离效率、低压降的气液分离器和冷凝液喷射装置；探讨了多温区聚乙烯冷凝态技术所具有的聚合温度差异化、聚合单体浓度差异化和催化剂温度敏感性差异化的特征及其对产品性能的影响。分析表明反应器下部有利于形成支链较多的、低密度高分子量的聚乙烯,而反应器上部有利于形成支链较少、高密度低分子量的聚乙烯。该技术在天津石化12万吨／年气相法聚乙烯装置上进行工业预试验,产量提高8%以上,且成功生产出性能优良、富有特色的树脂产品。本技术被命名为“气液法流化床聚乙烯工艺成套技术”,并于2012年入选中国石化“十条龙攻关”项目。
The gas-solid fluidized beds are extremely widely applied in the industrial fields due to their high efficiency of heat and mass transfer and large handling capacity. From the development of catalyst to the description of reactor hydrodynamic characteristics and establishment of industrial plant, gas-solid fluidized beds are always the research hotspot at home and abroad. As a typical multi-phase flow reactor, there exists bubble agitation, particle motion and phase interaction in a gas-solid fluidized bed. It is a non-linear transient system, and the most significant feature of fluidized bed is the fluctuation of various flow parameters generated by the above complex phenomenon. Hence, compared to the time-averaged flow parameters, the fluctuating parameters contain much more abundant information about flow structures and phase transfer. The flow structures in a fluidized bed include bubbles, vortex and particle clusters, whose behaviors and evolution are the bottleneck of revealing multi-phase flow features and achieving process intensification and optimal design. Therefore, it is of great significance to study the local and overall fluctuating signals generated by bubbles and particles in the fluidized bed, based on which the different flow structures are described and analyzed. By this way, the multi-phase flow field characteristics can be comprehended deeply and the reactor can be designed accurately.
In order to overcome the shortages of current fluctuating signal measuring and flow structure characterizing methods, our work employed the computational fluid dynamics (CFD) software Fluent to simulate the fluidized bed and obtain the fluctuating parameters. Based on the similarity of single-phase turbulent fluctuation and fluidized bed fluctuation, we established the characterizing method of multi-phase flow filed and flow structures. The hydrodynamic characteristics of fluidized bed were studied by this method. Besides, we developed the multiple-temperature-zone ethylene polymerization process with condensing mode and implemented the industrial test, achieving remarkable effects. The main research achievements of this paper are as follows.
1. Based on the similarity of single-phase turbulent fluctuation and fluidized bed fluctuation, we established the analytical methods of fluidized bed fluctuating signals and the characterizing methods of multi-phase flow filed and flow structures, including the analysis of particle fluctuating energy spectrum, flow field intermittency, multi-scale evolution of particle vortex, granular temperature, and the characterization and extraction of coherent structures. The aim was to extract regularities in random signals, and to discover order in disorder.
2. By comparing the simulated results with experimental or literature data, the CFD models of mono-dispersed and bi-dispersed fluidized bed were validated. The particle fluctuating velocity signals were monitored by CFD simulation, and analyzed by power spectrum and wavelet decomposition. According to that, the particle fluctuating energy spectrum and flow field intermittency in mono-dispersed and bi-dispersed fluidized bed was studied. The particle fluctuating energy spectrum can be divided into energy-containing region, inertial region and dissipation region. The Levy-Kolmogorov scaling law was obeyed in the inertial region. The flow field intermittency distribution with frequency was investigated by the wavelet flatness factor. The intermittency was weak in low frequency and large scale fluctuation, while it was strong in high frequency and small scale fluctuation. For bi-dispersed system, the wavelet flatness factors of the two kinds of particles showed similar distribution trend, however the differences appeared in frequency higher than10Hz. The bubble dynamics was also investigated by the voidage fluctuation spectrum. The dominant frequency agreed well with the empirical formula calculated value. That meant CFD simulation can provide accurate information of bubble motion.
3. The relationship between probability density function (PDF) of wavelet coefficients and coherent structures was established. The coherent structure signals were extracted and the Extended Self Similarity (ESS) scaling law was applied before and after the extraction. The effects of coherent structures on the flow field property were investigated and the extracting method was validated. The time scale and multi-scale evolution of particle vortex was studied by autocorrelation analysis. The universal relation of particle vortex time scales and wavelet scales was established. The vortex at some scales moved regularly as time passed. Particle vortexes at adjacent scales merged with or separated from others. The variation of particle vortex evolution was related to the fluidization transition.
4. The relation of CFD simulated granular temperature and experimental acoustic emission (AE) energy generated by particle impacting wall was established. The granular temperature was proved to be able to indicate the flow pattern. The radial and axial distribution of granular temperature in bi-dispersed fluidized bed was studied. Above the distributor, when turbulent granular temperature dropped suddenly, particles moved into the "stagnant" zone and lost their vitality, corresponding to the boundary of flotsam and jetsam layer. As the superficial gas velocity increased, the height of "stagnant" zone decreased. The distribution of particle time-averaged velocity and Reynolds stress was also applied to indicate the flow pattern and phase interaction.
5. In order to study the gas phase ethylene polymerization process with condensing mode, the calculating model of bubbling fluidized bed and central jetting fluidized bed were established. The CFD simulation was used to investigate the effects of gas ejection from wall on hydrodynamic characteristics. The gas ejection promoted horizontal motion of particle phase and strengthened the particle fluctuating activity near wall, which can reduce particle agglomeration on the wall. Besides, the gas ejection can stabilize the particle flow pattern and modulate the evolution of particle vortex. The work provided a theoretical guide of condensing liquid evaporation destroying the particle vortex hotspots.
6. Based on the theoretical analysis, the scheme of multiple-temperature-zone ethylene polymerization process was proposed and was verified preliminarily in the industrial plants. The feasibility of this technique was discussed firstly. The gas-liquid separator and liquid ejecting equipment was developed. The characteristics of this technique and their effects on resin performance were analyzed, including the differences of polymerizing temperature, monomer concentration and temperature sensitivity of catalyst between the two reaction zones. The polyethylene of low density, high molecular weight and more branched chains can be produced in the lower reaction zone, while the polyethylene of high density, low molecular weight and less branched chains can be produced in the above reaction zone. The new process was tested in the120000ton/year ethylene polymerization plants of Sinopec Tianjin Company. The output was increased by8%and the resin with excellent performance and distinct characteristics was produced successfully. This process was named as "Packaged technology of gas-liquid fluidized bed ethylene polymerization" and selected as "Sinopec Ten Dragons" project in2012.
引文
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