SEMINAR REPORT
ON
CFD STUDY OF MULTICOMPONENT GRANULAR
MATERIAL
(GAS-SOLID SYSTEM)
By
RAVALIYA PARTH JAYANTKUMAR
School of Chemical Engineering
Dr. Vishwanath Karad MIT World Peace University
Paud Road, Kothrud, Pune – 411038
2022-2023
SEMINAR REPORT
ON
CFD STUDY OF MULTICOMPONENT GRANULAR
MATERIAL
(GAS-SOLID SYSTEM)
Guided by
Dr. RUPALI SONOLIKAR
School of Chemical Engineering
Dr. Vishwanath Karad MIT World Peace University
Paud Road, Kothrud, Pune – 411038
2022-23
Dr. Vishwanath Karad MIT World Peace University
Paud Road, Kothrud, Pune – 411038
School of Chemical Engineering
CERTIFICATE
STUDY OF
MULTICOMPONENT GRANULAR MATERIAL (GAS-SOLID
SYSTEM)” as been carried out by RAVALIYA PARTH JAYANTKUMAR
This
is
to
certify
that
the
project
entitled
“CFD
under my guidance in partial fulfillment of the degree of master’s of Engineering
in chemical Engineering of MIT- WORLD PEACE UNIVERSITY during the
academic year 2022-2023. To the best of my knowledge and belief this work has
not been submitted elsewhere for the award of any other degree.
Guide
Head of the Department
Dr. Rupali Sonolikar
Dr. V. D. Gaikwad
Date: 22nd MAY 2023
Place: Pune, Maharashtra
ACKNOWLEDGEMENT
My heart leaps with joy at the prospect of thanking the people who assisted me in
completing the project. The opportunity to recognise everyone who contributed to
the report is the most ideal aspect of presenting it. Unfortunately, no matter how
long the list of acknowledgments is, it is always incomplete and insufficient.
Indeed, my website of thanks will never be able to match the generosity of
individuals who have offered me assistance. First and foremost, I would like to
express my appreciation and obligations to Dr. Rupali Sonolikar for allowing me
to introduce the current issue, as well as for his inspiring guidance, constructive
judgement, and helpful propositions throughout this report effort. I would also like
to thank Dr. V.D. Gaikwad(Head of Department) for entrusting me with this
interesting project and for his helpful recommendations and encouragement at
various phases of the job. A combination of this sort could never have been
undertaken without referencing and drawing inspiration from the efforts of others,
the specifics of which are listed in the reference section. I am grateful to each and
every one of them. Last but not least, I want to express my heartfelt gratitude to all
of my friends who have patiently offered various forms of assistance in order to
complete this project.
RAVALIYA PARTH JAYANTKUMAR
PAGE INDEX
PAGE INDEX
S.NO.
TOPIC
1
ABSTRACT
2
INTRODUCTION
2.1 Significance of gas-solid system
2.2 Application of gas-solid system
What is computational fluid dynamics? & its importance.
3
3.1
Modelling approach used for CFD
What is cyclone separator & its importance ?
4
Application of cyclone separator
4.1
Advantages & Disadvantages of experimental &
simulation setup
5
6
5.1
Advantages & Disadvantages of experimental setup
5.2
Advantages & Disadvantages of simulation setup
Why CFD simulation ?
6.1 Basically how CFD works?
6.2 Boundary constraints of CFD cyclone separator
6.3 Advantages & Disadvantages of CFD simulation
7
Conclusion
8
REFERENCES
PAGE
NO.
FIGURE INDEX
FIGURE INDEX
S.NO.
1
TOPIC
Summary of modelling approach for gassolid flows
PAGE
NO.
1. ABSTRACT
Computational fluid dynamics (CFD) has become a powerful tool for
analyzing and predicting fluid flows in many engineering applications. In
this Summary, we focus on the application of CFD to study oil-solids,
including the oil phase and the interface between particles. The aim is to
understand the complex behavior of such systems and to improve their
design and performance. Simulating petroleum products presents special
challenges because of the many stages of fluid flow, including the
complexities associated with particle-particle and particle-liquid
interactions. This short section introduces the main concepts and methods
used in CFD modeling of gas equipment. First, the governing equations,
namely the Navier-Stokes equation and the continuity equation, were
extended to account for the presence of material. Other models, such as
the Euler-Euler or Euler-Lagrange method, are used to capture the
kinetics of gas and solid phases. Many closed models, such as the cable
model, the power transmission model, and the dynamic model, are
combined to accurately represent the phase interaction. Discretization
methods used in CFD, such as the finite volume method or the finite
element method, are suitable for analysis with polyphase flow equations.
Efficient numerical algorithms and solutions are used to solve systems of
equations that consider a large number of numerical computations and
particle tracking.
Keywords: Gas-solid system, Multiphase flow, Fluid dynamics, Navier-Stokes
equations, Continuity equation, particle-particle interactions, particle-fluid
interactions, System optimization.
2. INTRODUCTION:
In industries & natural phenomena there are many process that include
multiphase flow i.e. gas-solid such as sand storms, cosmetic dust, etc.[1]The
study of effect of each system or particle is important because that small
changes affect the whole process or disturb the quality of the process.Many
industrial processes involving the transport of solid particles through a gas
and liquid phase are affected by erosive wear. The resulting damage can
have serious financial and environmental consequences during process
operation, sometimes resulting in unplanned downtime. Erosive wear is
characterized by a loss of material due to the impact of solid particles on the
surface.[5]The gas-solid system has been widely used in chemical and
industrial process for many years due to the characteristics of good solid
phase mixing, high heat transfer efficiency and fast chemical reaction.[6]So,
the study aero-dynamics & hydro-dynamics of this system becomes
necessary because due to effect of this particle can the whole system may be
disturb and it mat cause tremendous effect to process.
2.1
Significance of gas-solid system
1. A thorough understanding of gas-solid flows is necessary to optimize the
design and operation of industrial processes, as well as to understand the
natural phenomena involving gas-solid flows.
2. For accurate predictions of the behavior of solids, it is necessary to
choose a numerical method that takes into account not only particle-fluid
interactions, but also particle-wall and particle-particle interactions in
three dimensions and in any distribution particle size. [2]
3. Compared to low velocity systems, technology offers several advantages
such as better gas-particle contact, reduced cross section for the same
superficial gas velocity, good control capability and operational
flexibility [3].
4. The main problem in modeling flow dynamics for industrial,is due to the
presence of small scale phenomena in large process vessels and
insufficient knowledge to relate the different scales [3].
5. Gas-solid systems involve complex interactions between gas and solid
particles, such as particle-fluid interactions, multiphase flows, and
turbulent mixing. CFD provides a powerful tool to simulate and analyze
these phenomena, offering insights into the behavior and dynamics of
gas-solid systems that are difficult to obtain experimentally [1].
6. CFD simulations enable the optimization of gas-solid systems' design
and operation. By accurately modeling the flow behavior, particle
trajectories, and heat/mass transfer, CFD allows for the exploration of
different design options, leading to improved system performance,
efficiency, and cost-effectiveness [1].
7. CFD facilitates the identification and mitigation of operational
inefficiencies in gas-solid systems. By analyzing flow patterns, pressure
drops, and particle distributions, CFD simulations help optimize system
components, such as reactors, fluidized beds, and cyclones, leading to
enhanced process efficiency and reduced energy consumption.
8. CFD enables the scaling up of gas-solid systems from laboratory-scale
to industrial-scale. By accounting for the effects of flow rates, particle
sizes, and geometrical considerations, CFD simulations assist in
predicting system behavior and performance in large-scale applications,
aiding in the successful scale-up of processes.
2.2
Applications of gas-solid systems
➢ Some applications are as follows :1. Pneumatic conveying units
2. Hoppers
3. Solids separation units such as cyclones
4. Bubbling and circulating fluidized beds used in gasification
5. carbon capture
Among this application we are going to work on solid separation units using CFD.
3.
What is computational fluid dynamics? & its importance.
➢ Computational fluid dynamics (CFD) is a science that, with the help of
digital computers, produces quantitative predictions of fluid-flow
phenomena based on the conservation laws (conservation of mass,
momentum, and energy) governing fluid motion.
➢ To predict the properties of complex fluid flow CFD is used.
➢ In engineering, CFD is used to analyze the hydrodynamics & aerodynamics,
where quantities such as lift and drag or field properties as pressures and
velocities are obtained of fluid flow systems like fluid-fluid system, fluidgas system & fluid-solid system.
➢ CFD analysis is much deeper or detailed then experimental data.
➢ And it also gives accurate results & satisfied model approach for the systems.
3.1
Modelling Approaches used for CFD
CFD modeling of gas-solids multiphase
flows
Eulerian-Lagrangian
approach
Gas phase – Eulerian
Eulerian-Eulerian
approach
Eulerian–Eulerian
model for
granular flows
p-p interactions:
KTGF
DPM
p-p
interactions:
ignored
DDPM-KTGF
p-p
interactions:
KTGF
CFD-DEM
p-p
interactions:
soft sphere
model
Fig: Summary of model approaches for gas-solids multiphase flow modelling.
4. What is cyclone separator & its importance ?
MP-PIC
p-p
interactions
: particle
normal
➢ Cyclone separators are equipment for separating waste from pollution,
power generation, gas turbines, chemical processes, etc. It has been used for
a long time in industries such as [7].
➢ The Cyclone is one of many pollution control devices called pre-cleaners
because they usually removes larger particles. The separator is a device that
uses radial centrifugal force to separate solids from liquids. The
➢ Cyclone Separator typically achieves great results by separating 99% of dust
larger than 10 microns from the air stream and placing it in a bag. The
➢ Cyclone Separator offers the best solution for collecting dust, material and
transporting bark and debris.
➢ Cyclone separators are used with vacuum and dust removal equipment to
remove more than 85% to 99% of dust before it reaches the filter.
4.1
Application of cyclone separator
➢ In the dairy industry, cyclone separators are used to separate fines from the
air in dryers and dryers to increase efficiency and reduce pollution [7].
➢ In the pharmaceutical industry, cyclones capture excess powder from
powder processes (eg tablet presses, capsule filling machines). It has no
filters and moving parts, but instead uses cyclones to separate particles from
the air.
➢ cyclone separator is used to separate crystal slurry such as lactose and
sodium bisulfate.
➢ cyclone separator is used in sectors such as food industry, rubber industry
and energy transmission industry[8].
➢ Separation of solids using electric separator in cement industry [10].
5. Advantages & disadvantages of experimental & simulation
setup
5.1
Merits & Demerits of experimental setup
5.1.1 Demerits of experimental setup
➢ Skill full operator is required.
➢ Inside operation can’t be seen.
➢ Cleaning of equipment increases.
➢ Operating cost of equipment also increases.
➢ Not able to collect the particle size less the 10 microns
5.1.2 Merits of experimental setup
➢ Good & faster results are obtained.
➢ Desired material is obtained
➢ After detailed study, Scale-up also becomes easily.
➢ It can be operated according to need.
5.2
Merits & Demerits of simulation setup
5.2.1 merits of simulation setup
➢ All type of equipment can be design easily.
➢ Detailed study of behavior & dynamics is possible.
➢ Every obstacles can be identified easily and can be solved.
➢ Detailed report is obtained.
➢ Interaction between the phases can be determined.
5.2.2 Demerits of simulation setup
➢ Software may not be available easily, and if available then their might be
some restrictions.
➢ Detailed knowledge of software is required.
➢ For scale-up process we have to design new model.
➢ Analysis of model takes much time.
➢ If the model is complex then error can’t be determined easily
6. Why CFD simulation?
➢ CFD allows us to understand fluid behavior by solving. fluid flow
equations. It helps us understand how fluids move, interact with
boundaries, and exchange energy and mass[12].
➢ CFD allows designers to test and optimize designs and configurations
before prototyping. By simulating fluid flow, the
➢ CFD can predict the performance of materials and systems such as
aircraft wings, fuselages, pumps, electronics and connected components.
➢ CFD can help identify problems and diagnose causes of unexpected
behavior in fluids.
➢ CFD simulations can be used to simulate situations that are difficult or
dangerous to reproduce in real experiments, such as air operations,
emergencies or high-speed traffic [12].
6.1
Basically how CFD works?
➢ Basically, CFD works on Navier’s-strokes equations
➢ Above equation is general navier’s strokes equation
➢ The energy equation of the Navier-Stokes system follows the energy
conservation law, which equates the total energy of a system to the sum
of work and heat added to the system. In CFD simulations, the NavierStokes energy equation provides the basic explanation of energy
associated with the flow behavior [8].
➢ Here are some navier’s strokes equation for different dynamics.
➢ This is equation for fluid mechanics [9]
➢ This equation is for incompressible fluids[12].
➢ Here is the equation for compressible fluids
➢ For every system there are different navier’s strokes equation depending
upon the bound constraints. Similarly for designing of different
equipment there are discrete equations for with contrasting bound
condition.
6.2
Boundary constraints of CFD cyclone separator
➢ The inlet boundary condition represents the flow entering the cyclone
separator. The properties of the inlet flow, such as velocity, temperature,
and turbulence intensity, need to be specified. In practice, the inlet flow
can be assumed to be axial and can be modeled as a specified velocity
profile or a mass flow rate.
➢ The outlet boundary condition represents the flow exiting the cyclone
separator. Typically, a pressure outlet boundary condition is applied,
assuming atmospheric pressure or a specified back pressure. The velocity
components at the outlet are usually set to zero gradient, allowing the
flow to exit freely.
➢ The cyclone separator's walls are modeled as solid surfaces, and
appropriate wall boundary conditions are applied. A no-slip condition is
typically used, assuming that the fluid velocity at the wall is zero. The
temperature of the wall can be set to a specified value or modeled as
adiabatic.
➢ In some cases, a symmetry plane can be used to reduce computational
costs by simulating only half of the cyclone separator geometry. A
symmetry boundary condition assumes that the flow properties are
symmetric across the specified plane.
➢ If there are multiple fluid phases involved in the simulation, such as solid
particles or liquid droplets in the cyclone separator, an interface boundary
condition is required. The interaction between the fluid phases needs to
be appropriately modeled, considering phenomena such as momentum
exchange, heat transfer, and phase change.
6.3
Merits & Demerits of Computational Fluid Dynamics
6.3.1 Merits of Computational Fluid Dynamics
➢ Validation of designs before more expensive testing.
➢ Significantly reduced test and prototyping requirement.
➢ Shorter development cycles and associated risk.
➢ Improved product performance.
➢ Optimized performance over a range of operating conditions.
➢ Reduced pressure losses.
➢ Improved performance predictions.
➢ Comprehensive flow data is available.
➢ Flow visualization provides greater understanding of flow behavior.
6.3.2 Demerits of Computational Fluid Dynamics
➢ errors may occur due to simple flow models or simplified boundary
conditions
➢ possible uncertainties caused by too little computing values per cell and
hence therefore resulting interpolation errors
➢ computation time may extend for large models
➢ the costs may be much higher due to wrong consulting compared to
experiments
➢ CFD simulations can be complex to set up and run, requiring specialized
software and expertise in fluid dynamics and numerical methods.
➢ CFD simulations can be computationally intensive, requiring significant
computational resources, including powerful computers and highperformance computing systems.
➢ CFD simulations must be validated against experimental or physical data
to ensure accuracy, and this can be a time-consuming and expensive
process.
➢ CFD simulations can take a long time to run, especially for large and
complex systems, which can be a disadvantage in time-critical design
processes.
7. CONCLUSION
➢
As we know that world is advancing towards the technologies so ,
industrial process or equipments should be developed as soon as
possible ,so with the help of simulation any equipment can be
optimized easily & it can be done cost-effectively
➢
As per my research CFD can be much use full for the simulating &
optimizing the equipment.
8. REFERENCES
1. W.K. Hiromi Ariyaratne E.V.P.J. Manjula Chandana Ratnayake Morten
C. Melaaen CFD Approaches for Modeling Gas-Solids Multiphase Flows –
A Review DOI: http://dx.doi.org/10.3384/ecp17142680
2. Murat koksal Feridun hamdullahpur CFD Simulation of the Gas-Solid
Flow in the Riser of a Circulating Fluidized Bed with Secondary Air
Injection. DOI: http://dx.doi.org/10.1080/009864490522713
3. Srujal Shah , Kari Myöhänen , Sirpa Kallio , Jouni Ritvanen , Timo
Hyppänen CFD modeling of gas–solids flow in a large scale circulating
fluidized bed furnace. DOI: https://doi.org/10.1016/j.powtec.2015.01.019
4. Arijit Ganguli and Viraj Bhatt CFD simulations to study bed characteristics
in gas–Solid fluidized beds with binary mixtures of Geldart-B particles: A
qualitative analysis. DOI: https://doi.org/10.3389/fenrg.2023.1059503
5. Thiana Alexandra Sedrez, Rodrigo Koerich Decker, Marcela Kotsuka da
Silva, Dirceu Noriler, Henry Franc¸a Meier Experiments and CFD-based
erosion modeling for gas-solids flow in cyclones.
DOI:http://dx.doi.org/10.1016/j.powtec.2016.12.059
6. Hadi Wahyudi , Kaiwei Chu , Aibing Yu 3D particle-scale modeling of
gas–solids flow and heat transfer in fluidized beds with an immersed tube.
DOI: https://doi.org/10.1016/j.ijheatmasstransfer.2016.02.038
7. Osamu kitamura Makoto yamamoto Proposal of a Reynolds Stress Model
for Gas-Particle Turbulent Flows and its Application to Cyclone Separators.
DOI: https://doi.org/10.1016/B978-008043328-8/50086-2
8. O.J. McCarthy Plant and Equipment | Centrifuges and Separators:
Applications in the Dairy Industry DOI: https://doi.org/10.1016/B978-012-374407-4.00463-5
9. Ramona Strob Adrian Dobrowolski Markus Thommes Preparation of
spray dried submicron particles: Part A – Particle generation by aerosol
conditioning. DOI: https://doi.org/10.1016/j.ijpharm.2018.06.067
10.Shivangi Srivastava Vinay Kumar Pandey Iqra Bashir Recent insights on
electrostatic filtration and its potential applications in food industry DOI:
https://doi.org/10.1016/j.tifs.2023.05.002
11.R. Vivek S. Venkatesh V.manoj Mohana Sundaram A brief review on
improving materials particulates using cyclone separator by geometrical
and turbulence factors. DOI: https://doi.org/10.1016/j.matpr.2022.08.170
12.aJuan Vicente Gutirrez-Santacreu Marko Antonio Rojas-Medar On the
approximation of turbulent fluid flows by the Navier–Stokes-equations on
bounded domains.DOI: https://doi.org/10.1016/j.physd.2023.133724
13. Qiangchang Ju Zhao Wang Convergence of the relaxed compressible
Navier–Stokes equations to the incompressible Navier–Stokes equations.
DOI: https://doi.org/10.1016/j.aml.2023.108625
14.Introducing the Compressible Navier-Stokes Equation by cadence system
analysis. https://resources.system-analysis.cadence.com/blog/msa2021introducing-the-compressible-navier-stokes-equation
15.P. Katare ,A. Krupan , A. Dewasthale , A. Datar , A.S. Dalkilic CFD
analysis of cyclone separator used for fine filtration in separation industry.
DOI: https://doi.org/10.1016/j.csite.2021.101384
16.Mahmoud A. El-Emam Ling Zhou Chen Han Performance evaluation of
standard cyclone separators by using CFD–DEM simulation with realistic
bio-particulate matter DOI: https://doi.org/10.1016/j.powtec.2021.03.006