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CFD Validation of Cyclone Separator Using Star CCM+

Detailed analysis and validation of cyclone separator model using star ccm+. The model considered is a stairmand high efficiency cyclone

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satyaseshadri
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1K views

CFD Validation of Cyclone Separator Using Star CCM+

Detailed analysis and validation of cyclone separator model using star ccm+. The model considered is a stairmand high efficiency cyclone

Uploaded by

satyaseshadri
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Cyclone Separator

STAR-CCM+ v6.02

Introduction

Cyclones are employed for removal of particulate


contaminants from polluted air streams in a wide variety of
engineering applications
Nature of flow-particle dynamics in the cyclone lends itself
as an excellent example for demonstrating the Lagrangian
Particle Transport (LPT) approach
In this tutorial, we have outlined the methodology to set-up
a simulation to characterize the performance of a cyclone;
Incidentally, results of the current effort also serve to
validate the applicability of STAR-CCM+ for similar
applications (strong swirling flows)
Further, additional information elucidating the fluid and
particle behaviour inside the cyclone are presented

Simulation of Cyclone Separators with STAR-CCM+

Geometry and Operating Conditions


De

D = 0.2 m
a/D

b/D

De/D

S/D

h/D

H/D

B/D

.5

.25

.5

.625

2.

4.

.25

b
H

Air

PRESSURE
OUTLET (1 bar)

velocity, m/s
density, kg/m3

20
1.205

VELOCITY INLET
Solid Particles

Air + Solid particles


Reference: Numerical Study of Gas-Solid
Flow in a Cyclone Seperator, Wang et al.,
Third International Conference on CFD in
the Mineral and Process Industries,
CSIRO, Australia, PP 371-376, 2003
Simulation of Cyclone Separators with STAR-CCM+

velocity, m/s

20

density, kg/m3

3320

volume fraction

3%

size, mm

5x10-3

Models & Reference Conditions

The following models were involved in the problem setup:

Three-dimensional, Gravity
Constant Density Gas (Air)
Implicit Unsteady
Turbulent, Reynolds-Averaged Navier-Stokes
Reynolds Stress Turbulence
Two-layer All Y+ Wall Treatment
Linear Pressure Strain Two-layer
Segregated Flow
Segregated Fluid Isothermal

Reference Conditions

Pressure: Atmospheric
Temperature: 300 K
Turbulent Intensity and Viscosity Ratio: 1 % & 10

Modeling Information

CAD model of the geometry was created in star-design


based on data provided in the reference
Geometry imported into STAR-CCM+
Surface and Volume meshing performed using the Surface
Remesher and Polyhedral Volume Mesher
Prism layer option was activated at the volume meshing
stage to generate prism layers on all wall boundaries
Final computational mesh comprised polyhedral cells and
two prismatic cells (of total thickness 5 mm) at all wall
boundaries
Mesh count (trimmer + 2 prism layers on the walls)
35732

Polyhedral Mesh

2 prism layers

Number of cells:
35732

Simulation of Cyclone Separators with STAR-CCM+

Boundary Conditions

Velocity inlet (with base case value of 20 m/s)


Pressure outlet (with atmospheric pressure)
Rest all boundaries treated as no-slip walls
Simulations performed in the implicit unsteady fashion
with a time step 0.01 sec
Continued till the residuals attained a steady value @
which time a four-order reduction in the residuals was
observed
Further, a plot of mass-flow averaged inlet pressure value
was also monitored to judge convergence
For validation purposes, simulations were repeated at six
more inlet velocity values (ranging from 5 to 35 m/s) to
generate the pressure drop curve as a function of velocity

Simulation of Cyclone Separators with STAR-CCM+

Velocity and Static Pressure Contours(@ 20 m/s)

Simulation of Cyclone Separators with STAR-CCM+

Velocity and Static Pressure Contours(@ 20 m/s)

Simulation of Cyclone Separators with STAR-CCM+

Velocity Vectors and Streamlines

Simulation of Cyclone Separators with STAR-CCM+

Axial and Tangential Velocity @ Line Probe

Location
Simulation of Cyclone Separators with STAR-CCM+

Comparison @ Different Inlet Velocities


(35, 20 and 5 m/s)

Simulation of Cyclone Separators with STAR-CCM+

Validation (Expt & FLUENT data from reference)

Simulation of Cyclone Separators with STAR-CCM+

Performance Characterization

Performance of a Cyclone is normally characterized by


its ability to classify particles of different sizes
For a particular geometrical configuration, a unique
curve expressing the classification (particle collection
efficiency in the outflow stream) as a function of particle
size is obtained for a particular flow rate
The detailed procedure to generate the classification
curve for the base case (20 m/s) is outlined in the next
few slides
Further salient features with respect to particle tracking
are illustrated using

Particle Tracking

One-way coupling (from gas to particle) was assumed


between the gas and particle phases
Particle tracking performed under the steady flow mode
Spherical particles (parcels) with client supplied density
were tracked on the converged flow field
Drag (Schiller-Neumann), Virtual Mass and turbulence
dispersion forces were considered to act on the particles
Particles (parcels) impacting on the wall surfaces were
assumed to be rebounding except the bottom one where
they were assumed to escape
Particles were released on the presentation grid and
tracked till they exited either the bottom wall (or) the top
outlet

Injection Definition
Particle injection into the domain can be achieved by different mechanisms
In the present case, a presentation grid (as shown in the illustration below)
was defined and located just downstream of the inlet patch
Injection points were uniformally distributed in a grid 8 x 16 = 128 total points

Simulation of Cyclone Separators with STAR-CCM+

Methodology

Specified number of mono-disperse particles (parcels) of


different sizes (ranging from a minimum to a maximum
value) are seeded at the inlet boundary and tracked in
succession through the frozen flow field
A no-slip condition is assumed for the parcels seeded at the
inlet boundary
Efficiency of separation for each particle (parcel) size is
estimated by calculating the fraction of the total number of
parcels seeded at the inlet boundary that reach the either
boundary (top/bottom outlet)
In the present case, we have estimated the separation
efficiency based on the fraction collected at both the bottom
as well as the top outlet

Classification Characteristics [@ 20 m/s]

Simulation of Cyclone Separators with STAR-CCM+

Observations

Results of the LPT indicate that the cut point diameter


(particle size corresponding to 50% separation) is of the
order of 1.2 mm
Separation performance for particle sizes 1.5 mm and
above is ~ 95% and above, whereas, that for 0.75 mm
and below is ~ 5 % and below
Classification curve seen to be pretty steep with a
sharpness of cut (D95%/D5%) of ~2

Simulation of Cyclone Separators with STAR-CCM+, CD-adapco Torino Office

Tracks for 1 mm, 1.25 mm, 1.5 mm Particles

Simulation of Cyclone Separators with STAR-CCM+

Velocity/Residence Time for 0.5 mm & 2.0 mm

Simulation of Cyclone Separators with STAR-CCM+

Animation Depicting 25 Tracks (1.25 mm)


(individual tracks)

Simulation of Cyclone Separators with STAR-CCM+

Animation Depicting Transport of 25 Tracks (1.25 mm)


(gradual progress as a group)

Simulation of Cyclone Separators with STAR-CCM+

Summary

Detailed step-wide procedure involved in setting up a


LPT routine to simulate fluid-particle flow in a cyclone
separator was demonstrated
Predicted pressure drop curve @ various flow rates
generated from simulation results seen to be in very
good comparison to experimental results
Methodology to generate the particle classification curve
for the cyclone was elucidated
Classification curve generated for the base flow rate
value seen to be pretty steep (value ~2) ; cut point
diameter seems to be ~ 1.2 mm

Simulation of Cyclone Separators with STAR-CCM+

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