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Numerical simulation and optimization of red mud separation thickener with self-dilute feed

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Journal of Central South University 2014年第1期21卷 344-350页

作者：周天李茂周谦周孑民 School of Energy Science and Engineering Central South University Hunan Key Laboratory of Energy Conservation in Process Industry Department of Mechanical Engineering Purdue University Calumet

In order to acquire the flow pattern and investigate the settling behavior of the red mud in the separation thickener,computational fluid dynamics(CFD),custom subroutines and agglomerates settling theory were employed to simulate the three-dimensional flow field in an industrial scale thickener with the introduction of a self-dilute feed *** simulation results show good agreement with the measurement onsite and the flow patterns of the thickener are presented and discussed on both velocity and concentration *** experiments on feed well and self-dilute system were also carried out,and indicate that the optimal thickener system can dilute the solid concentration in feed well from 110 g/L to 86 g/L which would help the agglomerates' formation and improve the red mud settling ***,the additional power of recirculation pump can be saved and flocculants dosage was reduced from 105g/t to 85g/t in the operation.

关键词： separation thickener self-dilute feed system numerical simulation optimization experiments computational fluiddynamics

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平底沉降槽内固液分离与赤泥沉降的数值模拟

过程工程学报 2014年第2期14卷 189-196页

作者：李茂李秋龙周天雷波周孑民 zhou chenn-qian 中南大学能源科学与工程学院湖南长沙410083 Center for Innovation through Visualization and Simulation Purdue University CalumetHammondIN46323USA

采用计算流体力学软件Fluent、简化的三维Eulerian两相流和Realizable k-ε湍流模型,并结合SIMPLE算法对直径40 m的氧化铝赤泥沉降槽内的固液分离过程进行数值模拟,以得到槽内流场形态和赤泥浓度的分布规律.通过对比计算结果和现场测试... 详细信息

采用计算流体力学软件Fluent、简化的三维Eulerian两相流和Realizable k-ε湍流模型,并结合SIMPLE算法对直径40 m的氧化铝赤泥沉降槽内的固液分离过程进行数值模拟,以得到槽内流场形态和赤泥浓度的分布规律.通过对比计算结果和现场测试数据,并结合自定义分析评价指标,分析了有无溢流围堰和中心下料桶的不同进料方式下沉降槽的固液分离和赤泥沉降的流动规律.结果表明,去掉沉降槽的溢流围堰后浆液的固相浓度降低84.3%;采用自吸式射流进料管,60～64 g/L固相浓度范围内的浆液在中心桶内所占体积由3.70%提高到14.36%,可有效促进中心桶内赤泥浓度分布的均匀性,提高平底沉降槽内赤泥的沉降分离效率.

关键词：赤泥沉降槽沉降氧化铝固液分离数值模拟

Numerical simulation of flow regions in red mud separation thickener's feedwell by analysis of residence-time distribution

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Transactions of Nonferrous Metals Society of China 2014年第4期24卷 1117-1124页

作者：周天李茂李秋龙雷波周谦周孑民中南大学能源科学与工程学院长沙410083 中南大学流程工业节能湖南省重点实验室长沙410083 Department of Mechanical Engineering Purdue University Calumet

The residence-time distribution （RTD） and the compartment model were applied to characterizing the flow regions in red mud separation thickener’s feedwells. Combined with the experimental work, validated mathematical model as well as three-dimensional computational fluid dynamics （CFD） model was established to analyze the flow regions of feedwells on an industrial scale. The concept of RTD, although a well-known method for the characterization of mixing behavior in conventional mixers and reactors, is still a novel measure for the characterization of mixing in feedwells. Numerical simulation results show that the inlet feed rate and the aspect ratio of feedwells are the most critical parameters which affect the RTD of feedwell. Further simulation experiments were then carried out. Under the optimal operation conditions, the volume fraction of dead zone can reduce by10.8% and an increasement of mixing flow volume fraction by 6.5% is also observed. There is an optimum feed inlet rate depending on the feedwell design. The CFD model in conjunction with the RTD analysis then can be used as an effective tool in the design, evaluation and optimization of thickener feedwell in the red mud separation.

关键词： computational fluid dynamics residence-time distribution compartment model feedwell

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高炉炉缸内衬形状预测研究

工程热物理学报 2019年第7期40卷 1577-1582页

作者：李佳玲朱蓉甲周萍阳春华周谦中南大学能源科学与工程学院长沙410083 中南大学信息科学与工程学院长沙410083 Center for Innovation through Visualization and Simulation Purdue University Northwest Hammond 46323 USA

高炉炉缸是高炉生产过程中环境最为恶劣的区域,炉缸内衬的侵蚀状况决定了高炉的工作寿命,因此实现炉缸内衬形状的预测具有十分重要的意义。本文结合炉缸内部流动传热CFD正解模型和一维传热逆解模型预测炉缸的内衬热面形状,该计算模型考... 详细信息

高炉炉缸是高炉生产过程中环境最为恶劣的区域,炉缸内衬的侵蚀状况决定了高炉的工作寿命,因此实现炉缸内衬形状的预测具有十分重要的意义。本文结合炉缸内部流动传热CFD正解模型和一维传热逆解模型预测炉缸的内衬热面形状,该计算模型考虑了耐火砖内温度变化对导热系数的影响,并利用1150℃等温线对热面形状的预测作为初始值。结果显示预测后的计算温度和工厂热电偶测量温度很好地吻合,验证了热面形状预测方法的准确性和有效性。

关键词：高炉炉缸 CFD 传热侵蚀

Finite Element Analysis of a Vertical Edger Longevity

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Finite Element Analysis of a Vertical Edger Longevity

“第十届中国钢铁年会”暨“第六届宝钢学术年会”

作者： zhou chenn Sun Yuanbang Wu Bin Nolar Mitchell Cox Jeffery Klootwyk Jason Chatman Cliff Center for Innovation through Visualization and Simulation(CIVS) Purdue University ArcelorMittal 3210 Watling Street 2-975 East ChicagoINUSA 46312

A vertical edger is a critical component of the roughing mill, used to reduce the width of steel slabs. When a vertical edgerexperiences a failure, it directly affects the production of the roughing mill. One such failure that has occurred took place in the R2 housing, which is not a typical location for failure to *** housing is designed to withstand significant force, but the maximum threshold for duration and intensity before failure occur are unknown. In addition to the force, many other factors affect theremaining life of a component, and life prediction is difficult predict. Furthermore, new steels seem to be pushing the roughing mills harder than before, and it is crucial to know how far they can be pushed before components break. The purpose of this research is to simulate the edging process using Finite Element Analysis（FEA） *** performing a numerical analysis of the components in a vertical edger, an improved understanding of the mechanical behavior and potential failures can be identified to improve safety.

关键词： roughing mill vertical edger FEA longevity extrapolation fatigue analysis

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料层孔隙率对高炉炉身传热传质过程的影响

工程热物理学报 2017年第12期38卷 2706-2712页

作者：周萍文麒筌伍东玲石朋雨周谦中南大学能源科学与工程学院长沙410083 Center for Innovation through Visualization and Simulation Purdue University CalumetHammond 46323

为研究料层孔隙率对高炉炉身内部传热与传质过程的影响,分别对料层孔隙率为常数、随化学反应程度变化两种条件下的高炉炉身传热与传质过程进行了数值模拟。料层结构由自编程的料层分布程序计算而得,炉腰下部入口处的气流速度、温度以及... 详细信息

为研究料层孔隙率对高炉炉身内部传热与传质过程的影响,分别对料层孔隙率为常数、随化学反应程度变化两种条件下的高炉炉身传热与传质过程进行了数值模拟。料层结构由自编程的料层分布程序计算而得,炉腰下部入口处的气流速度、温度以及组分质量分数等数据取自于回旋区喷煤过程的数值模拟结果。数值模拟结果表明,两种模型下炉身内部压差分布、煤气速度分布、气固两相温度分布、CO和CO_2质量分数分布态势相同,但具体数值存在不同程度的差异,非定常孔隙率模型的预测结果与现场检测结果更为吻合,定常孔隙率模型对炉身压差的预测结果与生产实践数据的相对误差较大,因此采用非定常料层孔隙率有利于提高高炉炉身传热传质过程数值模拟精度.

关键词：高炉料层软熔带数值模拟

Evaluation of Burden Descent Model for Burden Distribution in Blast Furnace

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Journal of Iron and Steel Research International 2016年第8期23卷 765-771页

作者： Ping zhou Peng-yu SHI Yan-po SONG Kai-le TANG Dong FU chenn Q.zhou School of Energy Science and Engineering Central South University Center for Innovation through Visualization and Simulation Purdue University Calumet

Mathematical models for burden descending process have been applied to obtain whole burden structures in blast furnace,whereas the accuracy of those burden descent models has not been sufficiently *** evaluation method based on timeline burden profiles was established to quantitatively evaluate the error between experimental and modeled burden *** existing burden descent models were utilized to describe the burden structure of a 1/20 scaled warm blast *** modeling conditions including initial burden profile,descending volumes in each time interval,and normalized descending velocity distribution were determined via special image processing *** burden structures were evaluated combined with the published experimental *** is found that all the models caught the main profile of the burden ***,the improved nonuniform descent model（Model IV）shows the highest level of precision especially when burden descends with unstable velocity distribution ***,the traditional nonuniform descent model（Model III）may also be desirable to model the burden descending process when the burden descending velocity presents a linear ***,the uniform descent model（Model I）might be the first option for roughly predicting burden structure.

关键词： burden descending descent normalized utilized scaled sufficiently modeled desirable quantitatively

CFD modelling and optimization of oxygen supply mode in KIVCET smelting process

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Transactions of Nonferrous Metals Society of China 2019年第7期29卷 1560-1568页

作者： Jia-dong LI Ping zhou zhou LIAO Li-yuan CHAI chenn Q. zhou Ling ZHANG School of Energy Science and Engineering Central South UniversityChangsha 410083China Zhuzhou Smelter Group Company Limited Zhuzhou 412004China School of Metallurgy and Environment Central South UniversityChangsha 410083China Center for Innovation through Visualization and Simulation Purdue University Northwest2200 169th StreetHammondIN 46323USA Changsha Nonferrous Metallurgy Design and Research Institute Company Limited Changsha 410019China

The influence of oxygen supply mode on the KIVCET (a Russian acronym for flash?cyclone?oxygen?electric?smelting) process was investigated using numerical simulation. The mass rate ratio (MRR) of central oxygen to lateral oxygen of the central jet distributor (CJD) burner was defined to express the oxygen supply mode, and the KIVCET process with an MRR ranging from 0.09 to 0.39 was simulated. The results show that there are four efficient reaction regions that correspond to four CJD burners. A higher central oxygen flow improves the mixing between particles and oxygen, thus enhancing reactions and shortening the reaction regions. However, a higher dust rate is induced due to the spread of the particle columns. The optimal MRR for a KIVCET furnace with a smelting capacity of 50000 kg/h is suggested to be 0.31. In this case, the chemical reactions associated with the feed are completed with an acceptable dust rate.

关键词： KIVCET furnace central jet distributor (CJD) burner computational fluid dynamics (CFD) central oxygen lateral oxygen optimization

Evaluation of flow behavior in copper electro-refining cell with different inlet arrangements

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Transactions of Nonferrous Metals Society of China 2017年第10期27卷 2282-2290页

作者： Ping zhou Hai-bo MA Zi-wei XIE Hong-jie YAN chenn Q. zhou School of Energy Science and Engineering Central South University Changsha 410083 China Center for Innovation through Visualization and Simulation Purdue University Northwest 2200 169th Street Hammond IN 46323 USA

The arrangement of electrolyte inlet in the copper electro-refining(ER)cell has a great influence on the local flow field,which affects the distribution of electrical current density in *** order to understand the complicated phenomena ofelectrolyte flow behavior in vertical counter electrodes in full-scale copper ER cell,the three-dimensional computational fluiddynamics(CFD)models with four different arrangements of electrolyte inlets,i.e.,single inlet(SI),central bottom inlets(CBI),topside interlaced inlets(TII),and bottom side interlaced inlets(BII),were established to simulate the flow *** resultshave revealed that the parallel injection devices help to improve the electrolyte velocity between electrodes,and while the relativerange of electrolyte velocity in CBI exceeds that of TII and BII,which is more than4times,indicating its severer unequal ***,the average velocity of electrolyte in BII is4times larger than that of SI due to its higher ***,one of the efficient ways to supply fresh copper solution rapidly and uniformly into the inter-electrode space is toadapt the arrangement of *** utilizing such an arrangement,the electro-refining under high electrical current density is possible,and the productivity can be increased in sequence.

关键词： copper electro-refining electrolyte inlet arrangement flow uniformity computational fluid dynamics