Literatur 1
Literatur 1
Literatur 1
ISSN: 0974-2115
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ISSN: 0974-2115
Calculating Procedure of Denudation Rate: The unit erosion rate for CFBC cyclone separator is determined by
dividing the sediment discharge of surface by area.
r = Q s A
To compute Denudation Rate, the unit erosion rate is divided by the density of the CFBC cyclone separator
material.
Ls = rs
ISSN: 0974-2115
findings reported that vortex configuration or size did not influence pressure drop. Although several vortex finder
configurations have been proposed, the existing geometries do not meet the requirement that operation pressure should
be less than 0.05MPa.
Chuah et al. compared four empirical models for prediction of cyclone pressure drop, namely Shepherd and
Lapple, Casal and Martinez, Dirgo and Coker (1993). The comparison was done for different velocities and
temperatures in numerical simulation studies. Simulation results showed that the Cokers model predicted cyclone
pressure drop far better than the other three models in different operating temperature, while Shepherd and Lapple
model showed a good pressure drop prediction with different inlet velocities Cyclone optimization based on a new
empirical model of pressure drop was carried out by Ramachandran and Leith. They were able to predict an optimum
design which gives lesser pressure drop for a given collection efficiency, by adjusting the cyclone height or cyclone
diameter or outlet duct length (vortex finder). The concept of introducing REPDS (Reducing Pressure Drop by Stick)
in a cyclone was attempted by Wang et al. When a stick is inserted within a cyclone a significant decrease in pressure
drop can be obtained for a given separation efficiency.
Design Modifications
Any reduction in separation efficiency is well compensated by the pressure drop obtained. With no more than a
5% reduction in efficiency, a pressure drop of more than 50% is achievable. So the pressure drop can be reduced by
about 20% with the same separation efficiency. Another significant factor that decides the efficient performance and
life of a cyclone separator is the denudation rate which directly measures the erosion rate and hence predicts the life of
a cyclone separator.
The objective of the present work is to develop an optimum model with reduced pressure drop and denudation
rate with minimum change in collection efficiency. To achieve the above, about 16 REPDS are attached
circumferentially to the vortex finder. A reduction in the vortex finder length is compensated by adjusting the length of
the REPDS. A comparative study is done for four different variations in the length of the vortex finder for
corresponding changes in length of REPDS (25 %, 50%, 75% and 100%). Six existing cyclone designs are chosen and
an appropriate pressure drop model is used to find the pressure drop. Expressions for calculating the denudation rate
are incorporated in the model. For each of the 6 chosen designs, CFD (Computational Fluid Dynamics) comparative
analysis is done between the existing design (without REPDS) and the design with four length modifications in
REPDS.
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ISSN: 0974-2115
From the bar chart, it is evident that simulated results show only a 10% deviation from theoretical results. The
suitability of the Coker model for simulation work is thus verified.
Simulated
Coker model
Figure 3: Software Validation Bar Chart Figure 4: Mesh and Pressure Contour of various designs
CFD Analysis: The flow analysis for the 6 cyclone designs is done for a mass flow rate value
Q = 500 m3/hr, and
inlet velocity V = 15m/s. To model the swirling turbulence in a cyclone separator, the standard K- turbulence model is
chosen. The grid used for analysis is only a square grid. In solid works, the flow volume requires 6 cells per X value,
28 cells per Y value, 8 cells per Z value and it takes a minimum gap of 0.0707m. The grid is finer at the inlet and outlet
and at other places the grid is very coarse.
From the flow analysis, it is clear that in each design, the 75% REPDS and 100% REPDS, exhibit a short
circuiting of cyclone separator, resulting in a loss of collection efficiency. Hence, 100%REPDS model and 75%REPDS
model are not preferred in all designs.
DPM optimization:
To begin with optimization, input values of denudation rate, pressure drop, and efficiency are given. These
values are operated with the selected constraints, to obtain an optimum design for all the models. In each step, a
constraint is selected and operated on the input data to obtain the optimum design for that given constraint. Mostly
constraints are the limit or starting values of input data. The optimization constraints used in our case are:
Reduction in Pressure Drop should be more than 10% of that of the existing design pressure drop.
%
Reduction in Denudation Rate should be more than 10% of that of the existing design Denudation Rate.
%
Reduction in efficiency should be less than 10% of existing Design efficiency. %
Step I: All the three input parameters for all models of cyclone separators are given.
Step II: The first two constraints, namely, Reduction in Pressure Drop more than 10% and Reduction in Denudation
Rate more than 10% are applied to the models. Results show that, for 3 lengths of the REPDS, the chosen models
satisfy the constraints in all types of cyclone separator. 25%REPDS is not quite efficient in reducing the pressure drop
and denudation rate and hence is out of design optimization. In two types of cyclone separators, the reduction in
pressure drop and denudation rate also satisfies the constraints but the value is almost very small and near to constraint
so it is neglected.
Step III: In this stage last constraint is applied which is, Reduction efficiency to be less than 10%
Step IV: The 50% REPDS design is found to be suitable for any type of CFBC Cyclone separator.
DISCUSSION
Different types of configurations for vortex finder of cyclone separator were studied with the aim of getting
reduced pressure drops and denudation rate with little variation in collection efficiency. Four kinds of variations were
introduced in vortex finder lengths using REPDS, and analyses were carried out for six chosen cyclone designs. The
Coker model was used to find pressure drop in each case. Simulation was done using Solid Works, and the optimum
design for the vortex finder was selected by the dynamic programming method.
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