Computational simulation of liquid-fuelled HVOF thermal spraying

Liquid-fuelled high-velocity oxygen–fuel (HVOF) thermal spraying systems are gaining more attentions due to their advantage of producing denser coatings in comparison to their gas-fuelled counterparts. The flow through a HVOF gun is characterized by a complex array of thermodynamic phenomena involving combustion, turbulence and compressible flow. Advanced computational models have been developed to gain insight to the thermochemical processes of thermal spraying, however little work has been reported for the liquid-fuelled systems. This investigation employs a commercial finite volume CFD code to simulate the flow field through the most widely used liquid-fuel HVOF gun, JP5000 (Praxair, US). By combining numerical combustion and discrete phase models the turbulent spray flame is captured and the development of supersonic gas flow is revealed. The flow field is thoroughly examined by adjusting the nozzle throat diameter and combustion chamber size. The influence of fuel droplet size on the flame shame shape and combusting gas flow is also examined.<br/

Effects of angular injection, and effervescent atomization on high-velocity suspension flame spray process

This work presents the nanostructured coating formation using suspension thermal spraying through the HVOF torch. The nanostructured coating formation requires nanosize powder particles to be injected inside a thermal spray torch using liquid feedstock. The liquid feedstock needs to be atomized when injected into the high-velocity oxygen fuel (HVOF) torch. This paper presents the effects of angular injection and effervescent atomization of the liquid feedstock on gas and droplet dynamics, vaporization rate, and secondary breakup in the high-velocity suspension flame spray (HVSFS) process. Different angular injections are tested to obtain the optimum value of the angle of injection. Moreover, effervescent atomization technique based on twin-fluid injection has been studied to increase the efficiency of the HVSFS process. Different solid nanoparticle concentrations in suspension droplets are considered. In angular injection the droplets are injected into the core of the combustion zone; this immediately evaporates the droplets, and evaporation is completed within the torch. The value of 10°–15° is selected as the optimal angle of injection to improve the gas and droplet dynamics inside the torch, and to avoid the collision with the torch's wall. The efficiency of the effervescent atomization can be enhanced by using high gas-to-liquid mass flow rate ratio, to increase the spray cone angle for injecting the suspension liquid directly into the combustion flame. It is also found that the increment in the nanoparticle concentration has no considerable effects on the droplet disintegration process. However, the location of evaporation is significantly different for homogeneous and non-homogeneous droplets

Numerical study of molten and semi-molten ceramic impingement by using coupled Eulerian and Lagrangian method

Large temperature gradients are present within ceramic powder particles during plasma spray deposition due to their low thermal conductivity. The particles often impinge at the substrate in a semi-molten form which in turn substantially affects the final characteristics of the coating being formed. This study is dedicated to a novel modeling approach of a coupled Eulerian and Lagrangian (CEL) method for both fully molten and semi-molten droplet impingement processes. The simulation provides an insight to the deformation mechanism of the solid core YSZ and illustrates the freezing-induced break-up and spreading at the splat periphery. A 30 μm fully molten YSZ particle and an 80 μm semi-molten YSZ particle with different core sizes and initial velocity ranging from 100 to 240 m/s were examined. The flattened degree for both cases were obtained and compared with experimental and analytical data

Application of a high density ratio lattice-Boltzmann model for the droplet impingement on flat and spherical surfaces

In the current study, a 3-dimensional lattice Boltzmann model which can tolerate high density ratios is employed to simulate the impingement of a liquid droplet onto a flat and a spherical target. The four phases of droplet impact on a flat surface, namely, the kinematic, spreading, relaxation and equilibrium phase, have been obtained for a range of Weber and Reynolds numbers. The predicted maximum spread factor is in good agreement with experimental data published in the literature. For the impact of the liquid droplet onto a spherical target, the temporal variation of the film thickness on the target surface is investigated. The three different temporal phases of the film dynamics, namely, the initial drop deformation phase, the inertia dominated phase and the viscosity dominated phase are reproduced and studied. The effect of the droplet Reynolds number and the target-to-drop size ratio on the film flow dynamics is investigated

Non-enclosure methods for non-suspended microalgae cultivation: literature review and research needs

Microalgae are getting more interests from industry and science communities. Applications of these small, unicellular microorganisms are countless: from fourth generation biofuels, through fish feed to pharmaceuticals. Ordinary methods of cultivation may be associated with many problems such as high costs, high energy consumption, and low product yield. It is difficult to control contaminations in open ponds while photobioreactors are mainly at laboratory scale and expensive to scale-up. Scientists are investigating various methods of microalgae cultivation and processing to overcome those problems. One of the novel approaches is the non-suspended method for microalgae culturing, where microalgae are grown on attached surfaces. Growing microalgae on surfaces is an attractive option and showing promising results. In comparison with ordinary suspended photobioreactors, the attached systems offer higher biomass yields, easy to scale-up with better light distribution within the reactor and better control of contamination. Moreover, the consumption of water can be drastically reduced. So far, there is not enough research for this method. Limited studies have been reported on enclosure mode of this approach with algae encapsulation into matrix. It is found that this mode would be difficult to scale up due to high costs of the enclosure material and difficulty of separating microalgae from matrix. Non-enclosure mode is more promising way of non-suspended cultivation. So far, no work has been carried out to conduct non-suspended culturing with the use of aeroterrestrial microalgae. They are species growing on the surfaces at highly humid environments. Using them in attached cultivation systems could potentially lower the water consumption to minimum. Studies have shown that the biomass of lower water content can be produced if compared to non-suspended cultivation methods. In addition, mechanization of the cultivation and harvesting processes would be less complex, as the product will not be immersed in the liquid. There would be no need for glass reactors, as lights can be placed in the spaces between surfaces. The light distribution is predicted to be the highest among all existing methods, as there would be no free floating particles absorbing and reflecting light. It will only need humid conditions, rich in CO2 between attachment surfaces. To evaluate potential advantages for non-suspended culturing of aeroterrestrial microalgae in non-enclosure way, proper experiments need to be conducted. In this review, basic concepts of attached cultivation system are discussed, focusing on the studies of biofilm formation including factors affecting deposition and systems. The detailed description of aeroterrestrial microalgae is included to give insight into potential applications of the species into attached cultivation systems

Techno-economic performance analysis of biofuel production and miniature electric power generation from biomass fast pyrolysis and bio-oil upgrading

The techno-economic performance analysis of biofuel production and electric power generation from biomass fast pyrolysis and bio-oil hydroprocessing is explored through process simulation. In this work, a process model of 72 MT/day pine wood fast pyrolysis and bio-oil hydroprocessing plant was developed with rate based chemical reactions using Aspen Plus® process simulator. It was observed from simulation results that 1 kg s−1 pine wooddb generate 0.64 kg s−1 bio-oil, 0.22 kg s−1 gas and 0.14 kg s−1 char. Simulation results also show that the energy required for drying and fast pyrolysis operations can be provided from the combustion of pyrolysis by-products, mainly, char and non-condensable gas with sufficient residual energy for miniature electric power generation. The intermediate bio-oil product from the fast pyrolysis process is upgraded into gasoline and diesel via a two-stage hydrotreating process, which was implemented by a pseudo-first order reaction of lumped bio-oil species followed by the hydrocracking process in this work. Simulation results indicate that about 0.24 kg s−1 of gasoline and diesel range products and 96 W of electric power can be produced from 1 kg s−1 pine wooddb. The effect of initial biomass moisture content on the amount of electric power generated and the effect of biomass feed composition on product yields were also reported in this study. Aspen Process Economic Analyser® was used for equipment sizing and cost estimation for an nth plant and the product value was estimated from discounted cash flow analysis assuming the plant operates for 20 years at a 10% annual discount rate. Economic analysis indicates that the plant will require £16.6 million of capital investment and product value is estimated at £6.25/GGE. Furthermore, the effect of key process and economic parameters on product value and the impact of electric power generation equipment on capital cost and energy efficiency were also discussed in this study

Numerical investigation of microwave-assisted pyrolysis of lignin

A comprehensive three-dimensional mathematical model is developed for studying the microwave-assisted pyrolysis of biomass. Kraft Lignin is considered as biomass feedstock in the model, and a mixture of lignin and char, is used as the sample for pyrolysis. A lumped kinetic model which considers three lumped pyrolysis products (gas, liquid and remaining solid fractions) is coupled with the governing equations for the microwave field, heat transfer, mass transfer, Darcy fluid flow and a transient numerical analysis is performed. The distribution of electric field in the microwave cavity, and the distribution of electric field, temperature, and pyrolysis products within the lignin sample are presented. The lignin sample is predicted to undergo volumetric heating when subjected to microwave heating. Accordingly the reaction zone extends from the center of the biomass sample bed towards the outer surface. Preliminary evaluation of the applicability of the model for assessing the effect of different parameters on the microwave pyrolysis of lignin is also carried out

Three-dimensional modelling on the hydrodynamics of a circulating fluidised bed

The rapid depletion of oil and the environmentalimpact of combustion has motivated the search for cleancombustion technologies. Fluidised bed combustion (FBC)technology works by suspending a fuel over a fast air inletwhilst sustaining the required temperatures. Using biomassor a mixture of coal/biomass as the fuel, FBC provides alow-carbon combustion technology whilst operating at lowtemperatures. Understanding the hydrodynamic processes influidised beds is essential as the flow behaviours causing heatdistributions and mixing determine the combustion processes.The inlet velocities and different particle sizes influence theflow behaviour significantly, particularly on the transitionfrom bubbling to fast fluidising regimes. Computationalmodelling has shown great advancement in its predictive capabilityand reliability over recent years. Whilst 3D modellingis preferred over 2D modelling, the majority of studies use2D models for multiphase models due to computational costconsideration. In this paper, two-fluid modelling (TFM) isused to model a 3D circulating fluidised bed (CFB) initiallyfocussing on fluid catalytic cracker (FCC) particles. Thetransition from bubbling to fast fluidisation over a rangeof velocities is explored, whilst the effects on the bubblediameter, particle distributions and bed expansion for differentparticle properties including particle sizes are compared. Dragmodels are also compared to study the effects of particleclustering at the meso-scale

A numerical model for the fractional condensation of pyrolysis vapours

Experimentation on the fast pyrolysis process has been primarily focused on the pyrolysis reactor itself, with less emphasis given to the liquid collection system (LCS). More importantly, the physics behind the vapour condensation process in LCSs has not been thoroughly researched mainly due to the complexity of the phenomena involved. The present work focusses on providing detailed information of the condensation process within the LCS, which consists of a water cooled indirect contact condenser. In an effort to understand the mass transfer phenomena within the LCS, a numerical simulation was performed using the Eulerian approach. A multiphase multi-component model, with the condensable vapours and non-condensable gases as the gaseous phase and the condensed bio-oil as the liquid phase, has been created. Species transport modelling has been used to capture the detailed physical phenomena of 11 major compounds present in the pyrolysis vapours. The development of the condensation model relies on the saturation pressures of the individual compounds based on the corresponding states correlations and assuming that the pyrolysis vapours form an ideal mixture. After the numerical analysis, results showed that different species condense at different times and at different rates. In this simulation, acidic components like acetic acid and formic acids were not condensed as it was also evident in experimental works, were the pH value of the condensed oil is higher than subsequent stages. In the future, the current computational model can provide significant aid in the design and optimization of different types of LCSs

Comparative evaluation of GHG emissions from the use of Miscanthus for bio-hydrocarbon production via fast pyrolysis and bio-oil upgrading

This study examines the GHG emissions associated with producing bio-hydrocarbons via fast pyrolysis of Miscanthus. The feedstock is then upgraded to bio-oil products via hydroprocessing and zeolite cracking. Inventory data for this study were obtained from current commercial cultivation practices of Miscanthus in the UK and state-of-the-art process models developed in Aspen Plus®. The system boundary considered spans from the cultivation of Miscanthus to conversion of the pyrolysis-derived bio-oil into bio-hydrocarbons up to the refinery gate. The Miscanthus cultivation subsystem considers three scenarios for soil organic carbon (SOC) sequestration rates. These were assumed as follows: (i) excluding (SOC), (ii) low SOC and (iii) high (SOC) for best and worst cases. Overall, Miscanthus cultivation contributed moderate to negative values to GHG emissions, from analysis of excluding SOC to high SOC scenarios. Furthermore, the rate of SOC in the Miscanthus cultivation subsystem has significant effects on total GHG emissions. Where SOC is excluded, the fast pyrolysis subsystem shows the highest positive contribution to GHG emissions, while the credit for exported electricity was the main ‘negative’ GHG emission contributor for both upgrading pathways. Comparison between the bio-hydrocarbons produced from the two upgrading routes and fossil fuels indicates GHG emission savings between 68% and 87%. Sensitivity analysis reveals that bio-hydrocarbon yield and nitrogen gas feed to the fast pyrolysis reactor are the main parameters that influence the total GHG emissions for both pathways