Fluid nonisothermal

Computational fluid dynamics (CFD) emerged in the 1980s as a significant tool for fluid dynamics both in research and in practice, enabled by rapid development in computer hardware and software. Commercial CFD software is widely available. Computational fluid dynamics is the numerical solution of the equations or continuity and momentum (Navier-Stokes equations for incompressible Newtonian fluids) along with additional conseiwation equations for energy and material species in order to solve problems of nonisothermal flow, mixing, and chemical reaction. 

A systematic, rational analysis of both isothermal and nonisothermal tubular systems in which two fluids are flowing must be carried out, if optimal design and economic operation of these pipeline devices is to be achieved. The design of all two-phase contactors must be based on a firm knowledge of two-phase hydrodynamics. In addition, a mathematical description is needed of the heat and mass transfer and of the chemical reaction occurring within a particular system. 

In the formulation of the boundary conditions, it is presumed that there is no dispersion in the feed line and that the entering fluid is uniform in temperature and composition. In addition to the above boundary conditions, it is also necessary to formulate appropriate equations to express the energy transfer constraints imposed on the system (e.g., adiabatic, isothermal, or nonisothermal-nonadiabatic operation). For the one-dimensional models, boundary conditions 12.7.34 and 12.7.35 hold for all R, and not just at R = 0. 

With the development of modern computation techniques, more and more numerical simulations occur in the literature to predict the velocity profiles, pressure distribution, and the temperature distribution inside the extruder. Rotem and Shinnar [31] obtained numerical solutions for one-dimensional isothermal power law fluid flows. Griffith [25], Zamodits and Pearson [32], and Fenner [26] derived numerical solutions for two-dimensional fully developed, nonisothermal, and non-Newtonian flow in an infinitely wide rectangular screw channel. Karwe and Jaluria [33] completed a numerical solution for non-Newtonian fluids in a curved channel. The characteristic curves of the screw and residence time distributions were obtained. 

This is the general equation showing the time required to achieve a conversion for either isothermal or nonisothermal operation. The volume of reacting fluid and the reaction rate remain under the integral sign, for in general they both change as reaction proceeds. 

The above simple example shows that in the special case of constant fluid density the space-time is equivalent to the holding time hence, these terms can be used interchangeably. This special case includes practically all liquid phase reactions. However, for fluids of changing density, e.g., nonisothermal gas reactions or gas reactions with changing number of moles, a distinction should be made between r and t and the correct measure should be used in each situation. 

When reaction is so fast that the heat released (or absorbed) in the pellet cannot be removed rapidly enough to keep the pellet close to the temperature of the fluid, then nonisothermal effects intrude. In such a situation two different kinds of temperature effects may be encountered ... 

For exothermic reaction, heat is released and particles are hotter than the surrounding fluid, hence the nonisothermal rate is always higher than the isothermal rate as measured by the bulk stream conditions. However, for endothermic reactions the nonisothermal rate is lower than the isothermal rate because the particle is cooler than the surrounding fluid. 

Nonisothermal Effects. We may expect temperature gradients to occur either across the gas film or within the particle. However, the previous discussion indicates that for gas-solid systems the most likely effect to intrude on the rate will be the temperature gradient across the gas film. Consequently, if experiment shows that gas film resistance is absent then we may expect the particle to be at the temperature of its surrounding fluid hence, isothermal conditions may be assumed to prevail. Again see Example 18.1. 

In the years since 1940, a voluminous literature has appeared on the subject of two-phase cocurrent gas-liquid flow. Most of the work reported has been done in restricted ranges of gas or liquid flow rates, fluid properties, and pipe diameter, and has usually been specific to horizontal or vertical pipe lines. The studies have in most instances been isothermal when two components were being considered nonisothermal cases were almost entirely single-component two-phase situations. Reports of investigations of two-phase two-component cocurrent flow where one component is being transferred across the interphase boundary are nearly nonexistent. 

All pipe-line work to date has dealt with fluids which are not thixotropic and rheopectic. To an extent this may be justified because the limiting conditions (at startup—for thixotropic materials, and after long times of shear for rheopectic fluids) in pipe flow and some mixing problems are of primary importance. Design for these conditions would be similar to the techniques discussed herein for other fluids. This is not true of problems in heat transfer, however, and inception of work on the laminar flow of thixotropic fluids in round pipes would appear to be in order as a prerequisite to an understanding of such more complex nonisothermal problems. 

Extrusion and extruder design are apparently almost entirely empirical at present. This field might well defy rigorous theoretical analyses until the simpler problems of flow in annular spaces and rectangular ducts and of nonisothermal fluid flow are understood. 

Most of the models assume that neutral-species transport can be represented with either a well-mixed model or a plug flow model. The major drawback to these assumptions is that important inelastic rate processes such as molecular dissociation are usually localized in space in the reactor and are often fast compared with rates of diffusion or convection. As a result, the spatial variation of fluid flow in the reactor must be accounted for. This variation introduces a major complication in the model, because the solution of the nonisothermal Navier-Stokes equations in multidimensional geometries is expensive and difficult. 

A theory has been developed which translates observed coke-conversion selectivity, or dynamic activity, from widely-used MAT or fixed fluidized bed laboratory catalyst characterization tests to steady state risers. The analysis accounts for nonsteady state reactor operation and poor gas-phase hydrodynamics typical of small fluid bed reactors as well as the nonisothermal nature of the MAT test. Variations in catalyst type (e.g. REY versus USY) are accounted for by postulating different coke deactivation rates, activation energies and heats of reaction. For accurate translation, these parameters must be determined from independent experiments. 

We should note that the Navier-Stokes equation holds only for Newtonian fluids and incompressible flows. Yet this equation, together with the equation of continuity and with proper initial and boundary conditions, provides all the equations needed to solve (analytically or numerically) any laminar, isothermal flow problem. Solution of these equations yields the pressure and velocity fields that, in turn, give the stress and rate of strain fields and the flow rate. If the flow is nonisothermal, then simultaneously with the foregoing equations, we must solve the thermal energy equation, which is discussed later in this chapter. In this case, if the temperature differences are significant, we must also account for the temperature dependence of the viscosity, density, and thermal conductivity. 

Example 2.7 Nonisothermal Parallel Plate Drag Flow with Constant Thermophysical Properties Consider an incompressible Newtonian fluid between two infinite parallel plates at temperatures T(0) = T and T(H) — T2, in relative motion at a steady state, as shown in Fig. E2.7 The upper plate moves at velocity Vo (a) Derive the temperature profile between the plates, and (b) determine the heat fluxes at the plates. 

Parallel-Plate, Nonisothermal Newtonian Drag Flow with Constant Viscosity (a) Show that the temperature profile in steady drag flow of an incompressible Newtonian fluid between parallel plates at distance H apart, in relative motion Vo and different constant temperatures, T and T2, assuming constant thermophysical properties and temperature independent viscosity, is given by... 

Parallel-Plate, Nonisothermal Newtonian Drag Flow with Temperature-depen-dent Viscosity (a) Review the approximate linear perturbation solution given in Example 1.2-2 in R. B. Bird, R. C. Armstrong, and O. Hassager, Dynamics of Polymeric Fluids, Vol. 1, Wiley, New York, 1977. (b) Review an exact analytical solution in B. Martin, Int. J. Non-Newtonian Mech., 2, 285-301 (1967). 

Distributed Parameter Models Both non-Newtonian and shear-thinning properties of polymeric melts in particular, as well as the nonisothermal nature of the flow, significantly affect the melt extmsion process. Moreover, the non-Newtonian and nonisothermal effects interact and reinforce each other. We analyzed the non-Newtonian effect in the simple case of unidirectional parallel plate flow in Example 3.6 where Fig.E 3.6c plots flow rate versus the pressure gradient, illustrating the effect of the shear-dependent viscosity on flow rate using a Power Law model fluid. These curves are equivalent to screw characteristic curves with the cross-channel flow neglected. The Newtonian straight lines are replaced with S-shaped curves. 

Next, we explore some nonisothermal effects on of a shear-thinning temperature-dependent fluid in parallel plate flow and screw channels. The following example explores simple temperature dependent drag flow. 

Example 9.3 Nonisothermal Drag Flow of a Power Law Model Fluid Insight into the effect of nonisothermal conditions, on the velocity profile and drag flow rate, can he obtained by analyzing a relatively simple case of parallel-plate nonisothermal drag flow with the two plates at different temperatures. The nonisothermicity originates from viscous dissipation and nonuniform plate temperatures. In this example we focus on the latter. 

Still, sophisticated, exact, numerical, non-Newtonian and nonisothermal models are essential in order to reach the goal of accurately predicting final product properties from the total thermomechanical and deformation history of each fluid element passing through the extruder. A great deal more research remains to be done in order to accomplish this goal. 

The simulation is for a shear thinning fluid and nonisothermal flow. The equations of change are... 

Galili and Takserman-Krozer (20) have proposed a simple criterion that signifies when nonisothermal effects must be taken into account. The criterion is based on a perturbation solution of the coupled heat transfer and pressure flow isothermal wall problem of an incompressible Newtonian fluid. 

Koelling et al. (70) conducted nonisothermal, pressurized gas-bubble Newtonian fluid-displacement experiments. The fluid used was PB H-300. It was injected into a capillary tube maintained at 60°C. The tube was then transferred in a different temperature bath at 0°C. The penetrating gas was then injected after different delay times, t. The longer the delay time, the deeper the cooling penetration thickness will be, since it is dependent on the Fourier number,... 

---