Wet steam drying: Microwave-assisted droplet evaporation in open-cell ceramic foams

Abstract

In many energy and process engineering systems where fluids are processed, droplet-laden gas flows may occur. As droplets are often detrimental to the system’s operation, they are required to be removed. According to the state-of-the-art, industrial droplet removal is achieved through a sequential arrangement of several separators followed by droplet collection and discharge. This results in a high-quality gas stream, yet at the expense of bulky and expensive systems that are difficult to retrofit to existing facilities. In addition, the multiple sequential separators produce high pressure drops, further increasing operating costs. Alternatively, a single droplet separation stage and in situ evaporation would provide compact solutions for facilities. However, compact engineering solutions for the removal of entrained droplets are difficult to achieve with conventional flow control and conduction heat transfer approaches such as Joule heating. Joule heating requires a well-defined and homogeneous electrical resistance to ensure uniform heating, which is technically challenging to apply in fine separators and thus compact removal devices are hence often costly and ineffective. Therefore, it becomes necessary to investigate alternative heating approaches to overcome these challenges, such as volumetric heating using microwaves. The research conducted in this thesis aims to analyze the potential of a compact microwave solution approach for droplet removal. The compactness of the approach relies on a novel fine separator structure enhanced by microwave-heat transfer for efficient in-flow droplet evaporation. The investigation targets at fundamental studies of the combined effect of droplet flow filtering and heat transfer from numerical calculations and experimentation. As novel fine separators, solid open-cell foams are a promising alternative for the separation of liquid droplets suspended in gas flows at comparably low pressure drops. Using susceptors, such as dielectric materials, for the skeleton and exposing them to microwaves is an efficient way to use them as heating elements. Silicon carbide (SiC) based open-cell foam samples were considered for the study as they are good susceptor materials. First, pore-scale fluid numerical simulations on representative foam models were used to obtain a deeper insight into the effects of pore size and pore density on the droplet retention time within foams. Numerical findings were reported considering the pressure gradient and the residence time distribution of droplets under different superficial flow velocities, droplet sizes, porosities and pore densities. Next, the temperature-dependent permittivity of SiC-based foam materials was determined by the cavity perturbation technique using a waveguide resonator at a microwave frequency of 2.45 GHz up to 200 °C. The permittivity was of particular interest as it is a crucial parameter for predicting and designing systems utilizing microwave heating. Along the permittivity measurements, electromagnetic wave propagation simulations were used to derive novel mixing relations describing the effective permittivity of foams while considering their skeletal morphology. The derived relations facilitate an efficient and reliable estimation of the effective permittivity of open-cell foams, producing good agreement to experimental data. Using the foams dielectric properties and the fluid characteristics of droplet-laden streams, a microwave applicator was designed to concentrate the electric field on the open-cell foams. The applicator was constructed for carrying out experimental studies on droplet evaporation removal under different flow velocities, microwave power and different SiC-based foams. Measurements of droplet size, velocity, number density and flux at the inlet and outlet streams of the applicator were performed using a 2D-phase Doppler interferometer. Eventually, it was found from the experimental data analysis that the application of open-cell ceramic foams as a filter medium reduced 99.9 % of the volumetric flow of droplets, while additional microwave exposure increased the reduction to 99.99 %. In addition, microwave-heated foams prevent droplet re-entrainment and structure-borne liquid accumulation within foams, thus avoiding water clogging and flooding. Hence, open-cell foams can be used as fine droplet separators as long as microwave heating may effectively evaporate accumulations of liquid. An important factor in designing future devices based on this microwave heating approach is the temperature, as it changes the arcing breakdown voltage of the gas, thus limiting the microwave input power and droplet flow velocity. Although more investigations are needed to develop an applicable and optimal product, the results presented in this thesis provide a first insight into the viability of using microwave heating and fine filtering as a compact solution for droplet removal