水力旋流分离过程数值模拟与分析
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摘要
水力旋流器是利用离心力场实现分离的高效分离设备,具有结构简单、操作方便、分离效率高、生产能力大等优点,广泛应用于选矿、化工、生物等众多工业领域。旋流器结构简单,但内部流场却十分复杂,设计与操作精度要求高。分析旋流器内部多相流流场规律,掌握旋流器参数与流场分布之间的关系,是旋流器设计和应用的关键所在。
本文通过计算流体力学(CFD)方法,对水力旋流器内气液和液固湍流流场进行数值模拟研究。在时均纳维斯托克斯(Navier-Stokes, N-S)方程之上建立旋流器流场的湍流描述,采用雷诺应力湍流(RSM)模型、自由表面多相流动(VOF)模型和斯托克斯拉格朗日(DPM)模型对经典75mm旋流器内气液和液固流场进行了数值计算,并将模拟结果与文献数据进行比较,发现计算结果和文献实验数据吻合良好。同时利用激光粒子测速仪(PIV),测量了旋流器内全流场瞬时的速度,并将实验结果与CFD计算结果进行对比,计算结果和实验结果相吻合,进一步确定CFD计算模型的准确性。
利用所建立的数学模型,考察了旋流器流场形成和发展过程,得到了旋流器内速度场与压力场的分布规律,发现旋流器内不同部位空气柱非定常运动规律各不同：圆柱段与底流口附近的的空气柱,一旦形成后,其直径和形态就不再随时间而变化,属于稳态流场；而圆锥段的空气柱直径和形态随时间变化则十分剧烈。同时考察了入口速度对空气柱稳定性的影响,发现入口速度增加导致旋流器内流体切向速率增加,从而导致中心区域压力下降,空气柱直径增大,但空气柱的非定常流动规律不受入口速度变化的影响。
结构参数是影响旋流器分离性能非常重要的因素,采用所建立的多相流数学模型,对旋流器几何结构参数进行了详细的分析,重点考察了旋流器(直径140mm)结构参数变化对旋流器内流场发展、压力降、分流比和分级效率的影响。结果表明：溢流口直径对流场的影响最大。整体来看,空气柱的直径大小随着溢流口的直径增大而急剧增大,当溢流口直径达到100mm时,整个旋流器内空气柱占据了大部分；随着溢流口直径增加,空气柱趋于稳态运动,当溢流口直径超过65mm时,空气柱在旋流器内一旦形成就不再变化；通过分离效率计算发现溢流口直径为50mm分离效率最高。研究还考察了进料管直径、溢流口直径、溢流口插入深度、底流口直径、柱段长度和锥角这些因素对旋流器性能影响。
通过考察环境压力对旋流器分离性能影响,发现环境压力的变化会对旋流器的流场和性能产生重要影响。通过对旋流器流场的研究,发现环境压力的变化会影响旋流器内空气柱的结构和形态,继而影响空气柱内以及空气柱附近的流场,造成旋流器速度场的变化,从而导致分离效率的改变；同时通过不同大小旋流器研究对比,发现环境压力对大直径旋流器的影响大于小直径旋流器。
基于实验室与模拟计算研究结果,设计了应用于高原低气压环境的旋流器组,旋流器组由两级旋流器构成,并成功应用于青海盐湖钾肥股份有限公司年产10万吨氯化钾生产线。工业运行数据表明,产品中硫酸钙得到有效脱除,精制后产品质量满足工业氯化钾产品要求。
Hydrocyclone is an efficient separation device, in which the multiphase separation can be performed by the centrifugal force field. Because of its high separation efficiency and capacity for the multiphase flow system, hydrocyclone has been applied widely in mineral processing, chemical industry and biological engineering, representing a broad application prospect. In spite of the simple geometry of the hydrocyclone, the dynamics and mechanisms of fluid flow are extremely complicated, and the design and operation for the hydrocyclone separation need to be controlled more precisely. To keep the hydrocyclone running at the best performance, the multiphase flow field in the hydrocyclone should be clarified, and the effects of the parameters on the flow field should be understood very well.
Based on the simulation of computational fluid dynamics (CFD), this paper presents a study for the gas-liquid and liquid-solid turbulent flow field in hydrocyclones. The RANS and the combined Reynolds Stress Model (RSM), the Volume of Fluid (VOF) model and Dispersed phase model (DPM) are used to describe the gas-liquid and liquid-solid flow field in a classic hydrocyclone with75mm diameter. By comparing the simulation results with the experimental data in the reference, the good qualitative agreements between the simulation results and experimental data can be found, that validates the reliability of the developed mathermetical model. The flow field in a hydrocyclone is measured using particle image velocimetry (PIV), good qualitative agreements between the simulated results and PIV data are presented. The developed model is deemed to be an adequate methodology for the investigation of the flow field in a hydrocyclone for the separation flow system.
The formation and development of the flow field in the hydrocyclone are investigated by the simulation using the developed mathematical model, and the pressure distribution within the hydrocyclone is also reprensted. By analyzing the formation mechanism of air core in the hydrocyclone, it is found that the state of the air core is variational:The shape and diameter of air core, mainly on the cylinder section and spigot, are at a steady state, which do not vary with the time; But, at the same time, the high non-steady state is quarried from the part of the conical section, the shape and diameter of air core vary as soon as it forms. This paper also studies the effects of different inlet velocities on the state of air core. The simulated results show that the tangential velocity inside the hydrocyclone increases with the acceleration of inlet velocity, which results in the decrease of pressure at the central area and the increase of air core. But it has no influence on the air core's state.
The dimensions of body construction are also important factors to affect the separartion performance in the hydrocyclone. Based on the simulated results done using the deveopled the multi-phase mathematical model, the analysis of each geometrical dimension is made. This paper focuses on the effects of structural parameters on the flow field inside the hydrocyclone with140mm diameter. The flow features are represented in terms of flow field, pressure drop, split ratio and separation efficiency. The simulated results show that the diameter of vortex finder is the most important factor on the flow field. As a whole, the diameter of air core will increase with the increase of the vortex finder diameter. When the diameter of vortex finder is more than100millimetres, the air core will take up most of the hydrocyclone; the steady state of air core will get better with the increase of the vortex finder diameter. When the diameter of vortex finder is more than65millimetres, the whole air core is at a steady state, which does not vary with the time. The best separation efficiency can be achieved when the diameter of vortex finder is50millimetres. The effects of the diameters of inlet, vortex finder and spigot; the lengths of cylindrical part and vortex finder; cone angle of the hydrocyclone on separation efficiency have also been investigated.
By analyzing the effect of atmospheric pressure on separation performance, it is found that the atmospheric pressure has great influence on the flow field and separation performance of hydrocyclone. It is found that the atmospheric pressure has an impact on the shape of air core formed in hydrocyclone, which results in the change of the flow field inside and near the air core, and the variation of velocity field inside the hydrocyclone leads to the difference of separation efficiency. Comparing three kinds of hydrocyclones with different body size, the atmospheric pressure has greater impact on the hydrocyclones with bigger diameter.
Based on the research achievements of experiment and simulation, the two-stage hydrocyclone unit is designed and optimized for the separation of calcium sulfate (CaSO4) crystal in100,000tons/year KCl production line setup by QingHai Salt Lake Potash limited company. The online experimental data obtained with the optimized operating conditionds, indicate that the content of calcium sulfate in the product is greatly reduced, and industrial potassium chloride can be produced with a higher quality.
本文通过计算流体力学(CFD)方法,对水力旋流器内气液和液固湍流流场进行数值模拟研究。在时均纳维斯托克斯(Navier-Stokes, N-S)方程之上建立旋流器流场的湍流描述,采用雷诺应力湍流(RSM)模型、自由表面多相流动(VOF)模型和斯托克斯拉格朗日(DPM)模型对经典75mm旋流器内气液和液固流场进行了数值计算,并将模拟结果与文献数据进行比较,发现计算结果和文献实验数据吻合良好。同时利用激光粒子测速仪(PIV),测量了旋流器内全流场瞬时的速度,并将实验结果与CFD计算结果进行对比,计算结果和实验结果相吻合,进一步确定CFD计算模型的准确性。
利用所建立的数学模型,考察了旋流器流场形成和发展过程,得到了旋流器内速度场与压力场的分布规律,发现旋流器内不同部位空气柱非定常运动规律各不同：圆柱段与底流口附近的的空气柱,一旦形成后,其直径和形态就不再随时间而变化,属于稳态流场；而圆锥段的空气柱直径和形态随时间变化则十分剧烈。同时考察了入口速度对空气柱稳定性的影响,发现入口速度增加导致旋流器内流体切向速率增加,从而导致中心区域压力下降,空气柱直径增大,但空气柱的非定常流动规律不受入口速度变化的影响。
结构参数是影响旋流器分离性能非常重要的因素,采用所建立的多相流数学模型,对旋流器几何结构参数进行了详细的分析,重点考察了旋流器(直径140mm)结构参数变化对旋流器内流场发展、压力降、分流比和分级效率的影响。结果表明：溢流口直径对流场的影响最大。整体来看,空气柱的直径大小随着溢流口的直径增大而急剧增大,当溢流口直径达到100mm时,整个旋流器内空气柱占据了大部分；随着溢流口直径增加,空气柱趋于稳态运动,当溢流口直径超过65mm时,空气柱在旋流器内一旦形成就不再变化；通过分离效率计算发现溢流口直径为50mm分离效率最高。研究还考察了进料管直径、溢流口直径、溢流口插入深度、底流口直径、柱段长度和锥角这些因素对旋流器性能影响。
通过考察环境压力对旋流器分离性能影响,发现环境压力的变化会对旋流器的流场和性能产生重要影响。通过对旋流器流场的研究,发现环境压力的变化会影响旋流器内空气柱的结构和形态,继而影响空气柱内以及空气柱附近的流场,造成旋流器速度场的变化,从而导致分离效率的改变；同时通过不同大小旋流器研究对比,发现环境压力对大直径旋流器的影响大于小直径旋流器。
基于实验室与模拟计算研究结果,设计了应用于高原低气压环境的旋流器组,旋流器组由两级旋流器构成,并成功应用于青海盐湖钾肥股份有限公司年产10万吨氯化钾生产线。工业运行数据表明,产品中硫酸钙得到有效脱除,精制后产品质量满足工业氯化钾产品要求。
Hydrocyclone is an efficient separation device, in which the multiphase separation can be performed by the centrifugal force field. Because of its high separation efficiency and capacity for the multiphase flow system, hydrocyclone has been applied widely in mineral processing, chemical industry and biological engineering, representing a broad application prospect. In spite of the simple geometry of the hydrocyclone, the dynamics and mechanisms of fluid flow are extremely complicated, and the design and operation for the hydrocyclone separation need to be controlled more precisely. To keep the hydrocyclone running at the best performance, the multiphase flow field in the hydrocyclone should be clarified, and the effects of the parameters on the flow field should be understood very well.
Based on the simulation of computational fluid dynamics (CFD), this paper presents a study for the gas-liquid and liquid-solid turbulent flow field in hydrocyclones. The RANS and the combined Reynolds Stress Model (RSM), the Volume of Fluid (VOF) model and Dispersed phase model (DPM) are used to describe the gas-liquid and liquid-solid flow field in a classic hydrocyclone with75mm diameter. By comparing the simulation results with the experimental data in the reference, the good qualitative agreements between the simulation results and experimental data can be found, that validates the reliability of the developed mathermetical model. The flow field in a hydrocyclone is measured using particle image velocimetry (PIV), good qualitative agreements between the simulated results and PIV data are presented. The developed model is deemed to be an adequate methodology for the investigation of the flow field in a hydrocyclone for the separation flow system.
The formation and development of the flow field in the hydrocyclone are investigated by the simulation using the developed mathematical model, and the pressure distribution within the hydrocyclone is also reprensted. By analyzing the formation mechanism of air core in the hydrocyclone, it is found that the state of the air core is variational:The shape and diameter of air core, mainly on the cylinder section and spigot, are at a steady state, which do not vary with the time; But, at the same time, the high non-steady state is quarried from the part of the conical section, the shape and diameter of air core vary as soon as it forms. This paper also studies the effects of different inlet velocities on the state of air core. The simulated results show that the tangential velocity inside the hydrocyclone increases with the acceleration of inlet velocity, which results in the decrease of pressure at the central area and the increase of air core. But it has no influence on the air core's state.
The dimensions of body construction are also important factors to affect the separartion performance in the hydrocyclone. Based on the simulated results done using the deveopled the multi-phase mathematical model, the analysis of each geometrical dimension is made. This paper focuses on the effects of structural parameters on the flow field inside the hydrocyclone with140mm diameter. The flow features are represented in terms of flow field, pressure drop, split ratio and separation efficiency. The simulated results show that the diameter of vortex finder is the most important factor on the flow field. As a whole, the diameter of air core will increase with the increase of the vortex finder diameter. When the diameter of vortex finder is more than100millimetres, the air core will take up most of the hydrocyclone; the steady state of air core will get better with the increase of the vortex finder diameter. When the diameter of vortex finder is more than65millimetres, the whole air core is at a steady state, which does not vary with the time. The best separation efficiency can be achieved when the diameter of vortex finder is50millimetres. The effects of the diameters of inlet, vortex finder and spigot; the lengths of cylindrical part and vortex finder; cone angle of the hydrocyclone on separation efficiency have also been investigated.
By analyzing the effect of atmospheric pressure on separation performance, it is found that the atmospheric pressure has great influence on the flow field and separation performance of hydrocyclone. It is found that the atmospheric pressure has an impact on the shape of air core formed in hydrocyclone, which results in the change of the flow field inside and near the air core, and the variation of velocity field inside the hydrocyclone leads to the difference of separation efficiency. Comparing three kinds of hydrocyclones with different body size, the atmospheric pressure has greater impact on the hydrocyclones with bigger diameter.
Based on the research achievements of experiment and simulation, the two-stage hydrocyclone unit is designed and optimized for the separation of calcium sulfate (CaSO4) crystal in100,000tons/year KCl production line setup by QingHai Salt Lake Potash limited company. The online experimental data obtained with the optimized operating conditionds, indicate that the content of calcium sulfate in the product is greatly reduced, and industrial potassium chloride can be produced with a higher quality.
引文
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