Flow patterns mass flows

Typical Flow Problems and Flow Patterns An assessment of common flow problems (e.g., no flow due to arching and ratholing, etc.) and the two primary flow patterns (mass flow vs. funnel flow). 

For each of these different design concerns, we will review the key equipment parameters and flow properties. Note that these common flow concerns (arching, ratholing, adverse two-phase flow effects) and flow patterns (mass flow vs. funnel flow)... 

The best known and the most applied method to design silos for flow is the method developed by Jenike [1]. He distinguishes two flow patterns, mass flow and funnel flow, the border tines of which depend on the inclination of the hopper, the angle [Pg.18]

FLOW PATTERNS MASS FLOW / FUNNEL FLOW... 

In Chapter 2, the design of the so-called ideal reactors was discussed. The reactor ideahty was based on defined hydrodynamic behavior. We had assumedtwo flow patterns plug flow (piston type) where axial dispersion is excluded and completely mixed flow achieved in ideal stirred tank reactors. These flow patterns are often used for reactor design because the mass and heat balances are relatively simple to treat. But real equipment often deviates from that of the ideal flow pattern. In tubular reactors radial velocity and concentration profiles may develop in laminar flow. In turbulent flow, velocity fluctuations can lead to an axial dispersion. In catalytic packed bed reactors, irregular flow with the formation of channels may occur while stagnant fluid zones (dead zones) may develop in other parts of the reactor. Incompletely mixed zones and thus inhomogeneity can also be observed in CSTR, especially in the cases of viscous media. 

The diversity in correlations reported in the literatme can therefore be attributed to differences in the flow patterns, mean flow strengths and direction, turbulence intensity variations, etc. Table 7A.2 lists some important literature studies and the resulting correlations for the volumetric gas-liquid mass transfer coefficient in stirred vessels. 

A third flow pattern, expanded flow, is a combination of funnel flow and mass flow (see Figure 2.6). Usually this is achieved by placing a small mass flow hopper below a funnel flow hopper. The mass flow hopper section expands the flow channel from the outlet up to the top cross section of the mass flow hopper. It is important to ensure that this cross-sectional area is sufficiently large so as to avoid ratholing in the funnel flow hopper section. Expanded flow designs are generally considered only when the cylinder diameter exceeds 6 m or so. 

Because mass flow bins have stable flow patterns that mimic the shape of the bin, permeabihty values can be used to calculate critical, steady-state discharge rates from mass flow hoppers. Permeabihty values can also be used to calculate the time required for fine powders to settle in bins and silos. In general, permeabihty is affected by particle size and shape, ie, permeabihty decreases as particle size decreases and the better the fit between individual particles, the lower the permeabihty moisture content, ie, as moisture content increases, many materials tend to agglomerate which increases permeabihty and temperature, ie, because the permeabihty factor, K, is inversely proportional to the viscosity of the air or gas in the void spaces, heating causes the gas to become more viscous, making the sohd less permeable. 

Most flow problems can be overcome by using a mass flow design if the mass flow pattern developed by the bin is not disturbed. Thus a properly designed feeder or discharger must be employed. A feeder is used whenever there is a requirement to transfer soflds at a controlled rate from the bin to a process or a tmck. A discharger is used when there is a need to discharge soflds, not control the rate of discharge. 

To be consistent with a mass flow pattern in the bin above it, a feeder must be designed to maintain uniform flow across the entire cross-sectional area of the hopper outlet. In addition, the loads appHed to a feeder by the bulk soHd must be minimised. Accuracy and control over discharge rate ate critical as well. Knowledge of the bulk soHd s flow properties is essential. 

Many appHcations use screws with constant pitch to feed material from a slotted opening. The configuration shown in Figure 9a shows a constant pitch and constant diameter causing a preferential flow channel to form at the back (over the first flight) of the screw. This type of flow destroys the mass flow pattern and potentially allows some or all of the problems discussed about fiinnel flow. 

A combination of tapered shaft diameter and increasing pitch is shown in Figure 10a. This allows a length-to-diameter ratio of about 6 1 instead of 3 1. A half pitch screw is used over the tapered diameter. This approach results in an exceUent mass flow pattern provided that the hopper to which it attaches is also designed for mass flow. 

A potential problem for rotary valve usage is that they tend to pull material preferentially from the upside of the valve, which can affect the mass flow pattern. Another problem is that once soHd drops from the vane, the air or gas that replaces it is often pumped back up into the bin. In addition, air can leak around the valve rotor. Such air flows can decrease the soflds flow rates and/or cause flooding problems. A vertical section shown in Figure 13 can alleviate the preferential flow problem because the flow channel expands in this area, usually opening up to the full outlet. To rectify the countercurrent air flow problem, a vent line helps to take the air away to a dust collector or at least back into the top of the bin. 

An alternative to traditional mass flow bin design is to use a patented BINSERT, which consists of a hopper-within-a-hopper below which is a single-hopper section (Fig. 15). The velocity pattern in such a unit is controded by the position of the bottom hopper. A completely uniform velocity profile can be achieved which results in an absolute minimum level of segregation. Alternatively, by changing the geometry at the bottom of the hopper, a velocity profile can be developed in which the center section moves faster than the outside, thus providing in-bin blending of the materials (7). 

The key to solving these problems is to design the vessel for a mass flow pattern. This involves consideration of both the hopper angle and surface finish, the effect of inserts used to introduce gas and control the soHds flow pattern, and sizing the outlet valve to avoid arching and discharge rate limitations. In addition, the gas or Hquid must be injected such that the soHd particles ate uniformly exposed to it, and flow instabiHties such as fluidization in localized regions are avoided. 

Flow Regimes in Multiphase Reactors. Reactant contacting, product separations, rates of mass and heat transport, and ultimately reaction conversion and product yields are strong functions of the gas and Hquid flow patterns within the reactors. The nomenclature of commonly observed flow patterns or flow regimes reflects observed flow characteristics, ie, armular, bubbly, plug, slug, spray, stratified, and wavy. 

The Optimum Velocity Profile. The optimum velocity profile (41), that is the velocity profile that yields the maximum value for the flow pattern efficiency, is one in which the mass velocitypv is constant over the radius of the centrifuge except for a discontinuity at the wall of the centrifuge (r = rP). This optimum velocity profile is shown in Figure 14a. For this case the following values for the separation parameters of the centrifuge are obtained... 

Experimental values of Hqg -nd Hql for a number of distillation systems of commercial interest are also readily available. Extrapolation of the data or the correlations to conditions that differ significantly from those used for the original experiments is risky. For example, pressure has a major effect on vapor density and thus can affect the hydrodynamics significantly. Changes in flow patterns affeci both mass-transfer coefficients and interfacial area. 

Solid-Liquid Mass Transfer There is potentially a major effect of both shear rate and circulation time in these processes. The sohds can either be fragile or rugged. We are looking at the slip velocity of the particle and also whether we can break up agglomerates of particles which may enhance the mass transfer. When the particles become small enough, they tend to follow the flow pattern, so the slip velocity necessary to affect the mass transfer becomes less and less available. 

VFO works well in gas turbines. In a nine-month test program, the combustion properties of VFO were studied in a combustion test module. A gas turbine was also operated on VFO. The tests were conducted to study the combustion characteristics of VFO, the erosive and corrosive effects of VFO, and the operation of a gas turbine on VFO. The combustion tests were conducted on a combustion test module built from a GE Frame 5 combustion can and liner. The gas turbine tests were conducted on a Ford model 707 industrial gas turbine. Both the combustion module and gas turbine were used in the erosion and corrosion evaluation. The combustion tests showed the VFO to match natural gas in flame patterns, temperature profile, and flame color. The operation of the gas turbine revealed that the gas turbine not only operated well on VFO, but its performance was improved. The turbine inlet temperature was lower at a given output with VFO than with either natural gas or diesel fuel. This phenomenon is due to the increase in exhaust mass flow provided by the addition of steam in the diesel for the vaporization process. Following the tests, a thorough inspection was made of materials in the combustion module and on the gas turbine, which came into contact with the vaporized fuel or with the combustion gas. The inspection revealed no harmful effects on any of the components due to the use of VFO. 

In vertical downward flow as well as in upward and downward inclined flows, the flow patterns that can be observed are essentially similar to those described above, and the definitions used can be applied. Experimental data on flow patterns and the transition boundaries are usually mapped on a two dimensional plot. Two basic types of coordinates are generally used for this mapping - one that uses dimensional coordinates such as superficial velocities, mass superficial velocities, or momentum flux and another that uses dimensionless coordinates in which some kind of dimensionless groups are used as coordinates. The dimensional coordinates maps are inherently limited to the range of data and flow conditions under which the experiments were conducted. In spite of this limitation, it is widely used because of its simplicity and ease of use. Figure 24 provides an example of such a map. 

The flow pattern is ealeulated from eonservation equations for mass and mometum, in eombination with the Algebraie Stress Model (ASM) for the turbulent Reynolds stresses, using the Fluent V3.03 solver. These equations ean be found in numerous textbooks and will not be reiterated here. Onee the flow pattern is known, the mixing and transport of ehemieal speeies ean be ealeulated from the following model equation ... 

The problems that arise when experiments are carried out in a greatly reduced scale can be overcome if the Reynolds number is high and the flow pattern is governed mainly by fully developed turbulence. It is possible to ignore the Reynolds number, the Schmidt number, and the Prandtl number because the structure of the turbulence and the flow pattern at a sufficiently high level of velocity will be similar at different supply velocities and therefore independent of the Reynolds number. The transport of thermal energy and mass by turbulent eddies will likewise dominate the molecular diffusion and will therefore also be independent of the Prandtl number and the Schmidt number. 

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