The document discusses using computational fluid dynamics to optimize the mixture design of slurry transported through pipelines by varying the concentrations of bottom ash, fly ash, additives, and water as well as the pipeline diameter and velocity. A series of simulations were run to analyze the pressure drop through the pipeline under different conditions. The results from the simulations are presented in a table showing the input parameters and resulting pressure drops for each run.
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Synergizing mixture do e with cfd for ash slurry optimization
1. By
Dr. Bikram Jit Singh
Professor
MMDU Mullana
OPTIMIZATION OF SLURRY CONTENT
ALONG WITH PIPE DIAMETER AND VELOCITY
FOR MINIMUM PRESSURE DROP
THROUGH MIXTURE DESIGN OF EXPERIMENTS
2. A B C D P1 P2
Levels Bottom Ash Fly Ash Additive Water Velocity Pipe Diameter
Lower 4% 6% 1.50% 40% 25m/s 350mm
Upper 40% 50% 3% 70% 40m/s 450mm
Factors with Levels
Linear Constraint
A + B ≤ 55%
3. COMPUTATIONAL SIMULATION OF PIPELINE
Computational Fluid Dynamic [CFD] is the analysis of system
involving fluid flow by means of computer based simulation.
Computers are used to perform the calculations required to
simulate the interaction of liquids with surfaces defined by
boundary conditions.
8. SOLUTION PARAMETERS
• Three-dimensional meshing with double-precision (3-ddp) solver is
extremely useful when dealing with very sensitive analysis like
aerodynamic drag prediction, multiphase flow systems. Meshing is
an important factor to obtain the better results.
• Standard K- € model is selected for pipeline flow simulation. This
model gives very useful results for turbulent flow.
• A convergence criterion in the simulation is 10-3. Advance
computers are required to increase the criteria of convergence for
simulation of fluid flow.
• Second-order scheme with limiters is one of the more popular
numerical schemes because of its combination of accuracy and
stability.
• In computational fluid dynamics (CFD), simple algorithm is a
widely used numerical procedure to solve the Navier-Stokes
equations. Since then it has been extensively used by many
researchers to solve different kinds of fluid flow and heat transfer
problems.
9. BOUNDARY CONDITIONS
• Velocity inlet: It is applied on inlet face of pipeline.
• Pressure outlet: It is applied on outlet face of delivery pipeline.
• Slurry is added in material list by giving soot conditions
density and molar mass. For bottom ash density and molar
mass is taken 2250 kg/m3 and 36.281g/mol. In case of fly ash
density is taken 1950kg/m3and 28.12 g/mol.
• Bottom ash specified diameter is taken as 162 micron and for
fly ash 57 micron.
• Simulations are done on 25 and 40m/s.
Differentconcentrations are taken for fly and bottom ash.
• 4 % turbulence intensity and turbulence viscosity ratio of 10 is
taken for inlet condition.
• 4% backflow turbulence intensity and backflow turbulence
viscosity ratio of 10 is taken for outlet condition.
13. Extreme Vertices Design
Components: 4 Design points: 100
Process variables: 2 Design degree: 1
Mixture total: 1.00000
Number of Boundaries for Each Dimension
Point Type 1 2 3 0
Dimension 0 1 2 3
Number 12 18 8 1
Number of Design Points for Each Type
Point Type 1 2 3 4 0 -1
Distinct 48 0 0 0 4 48
Replicates 1 0 0 0 1 1
Total number 48 0 0 0 4 48
Bounds of Mixture Components
Amount Proportion Pseudo component
Comp Lower Upper Lower Upper Lower Upper
A 0.040000 0.400000 0.040000 0.400000 0.000000 0.774194
B 0.060000 0.500000 0.060000 0.500000 0.000000 0.946237
C 0.015000 0.030000 0.015000 0.030000 0.000000 0.032258
D 0.420000 0.700000 0.420000 0.700000 0.000000 0.602151
* NOTE * Bounds were adjusted to accommodate specified constraints.
Linear Constraints of Mixture Components
Constraint Lower A B C D Upper
1 1.000000 1.000000 0.000000 0.000000 0.550000
17. Regression for Mixtures: Pressure Drop versus Mixture Constituents &
Process Parameters
Estimated Regression Coefficients for Pressure Drop (component proportions)
Term Coef SE Coef T P VIF
Bottom Ash -9197 3811 * * 4.508
Fly Ash -10918 3772 * * 7.133
Additive 6008 68868 * * 15.309
Water 22605 4121 * * 29.948
Bottom Ash*Water*(-) 142848 34848 4.10 0.000 8.100
Water*Velocity 27694 12018 2.30 0.024 254.675
Additive*Water*(-)*Velocity 1362719 501408 2.72 0.008 72.720
1/Additive*Velocity -119 71 -1.69 0.094 72.633
Bottom Ash*Water*(-)2*Pipe Diameter 133896 63273 2.12 0.037 4.783
Additive*Water*(-)2*Pipe Diameter -730580 218899 -3.34 0.001 4.783
* NOTE * Coefficients are calculated for coded process variables.
S = 4090.14 PRESS = 2806387601
R-Sq = 37.22% R-Sq(pred) = 0.00% R-Sq(adj) = 30.94%
18. Analysis of Variance for Pressure Drop (component proportions)
Source DF Seq SS Adj SS Adj MS
Regression 9 892733445 892733445 99192605
Component Only
Linear 3 154468287 423716329 141238776
Full Cubic 1 281112490 281112490 281112490
Bottom A*Water*(-) 1 281112490 281112490 281112490
Component* Velocity
Linear 1 14967245 88835039 88835039
Water*Velocity 1 14967245 88835039 88835039
Full Cubic 1 149818160 123568498 123568498
Additive*Water*(-)*Velocity 1 149818160 123568498 123568498
Inverse 1 47930436 47930436 47930436
1/Additive*Velocity 1 47930436 47930436 47930436
Component* Pipe Diameter
Full Quartic1 2 244436827 244436827 122218413
Bottom A*Water*(-)2*Pipe Diameter 1 58088163 74915126 74915126
Additive*Water*(-)2*Pipe Diameter 1 186348664 186348664 186348664
Residual Error 90 1505634238 1505634238 16729269
Total 99 2398367683
Source F P
Regression 5.93 0.000
Component Only
Linear 8.44 0.000
Full Cubic 16.80 0.000
Bottom A*Water*(-) 16.80 0.000
Component* Velocity
Linear 5.31 0.024
Water*Velocity 5.31 0.024
Full Cubic 7.39 0.008
Additive*Water*(-)*Velocity 7.39 0.008
Inverse 2.87 0.094
1/Additive*Velocity 2.87 0.094
Component* Pipe Diameter
Full Quartic1 7.31 0.001
Bottom A*Water*(-)2*Pipe Diameter 4.48 0.037
Additive*Water*(-)2*Pipe Diameter 11.14 0.001
19. Pressure Drop = -9197 Bottom Ash – 10918 Fly Ash + 6008
Additive + 22605 Water + 142848 (Bottom
ash X Water) + 27694 (Water X Velocity) +
1362719 (Additive X Water X (-) Velocity)–
119 (1/Additive X Velocity) + 133896
Bottom Ash X Water X (-)2 X Pipe Diameter)
– 730580 (Additive X Water X (-) 2 X Pipe
Diameter)
Statistical Model
25. (1)
Bottom A sh
0.040
0.505
Fly A sh
0.525
0.060
A dditive
0.480
0.015
(2)
Bottom A sh
0.040
0.505
Fly A sh
0.525
0.060
A dditive
0.480
0.015
(3)
Bottom A sh
0.040
0.505
Fly A sh
0.525
0.060
A dditive
0.480
0.015
(4)
Bottom A sh
0.040
0.505
Fly A sh
0.525
0.060
A dditive
0.480
0.015
Water 0.42
Velocity 25
Pipe Diameter 450
Velocity 40
Pipe Diameter 450
Velocity 25
Pipe Diameter 350
Velocity 40
Pipe Diameter 350
(1)
(2)
(3)
(4)
Hold Values
>
–
–
–
–
–
< 0
0 2000
2000 4000
4000 6000
6000 8000
8000 10000
10000
Pressure Drop
Multiple Mixture Contour Plot for Pressure Drop
(component amounts)
26. (1)
Fly A sh
0.060
0.525
A dditive
0.480
0.015
Water
0.885
0.420
(2)
Fly A sh
0.060
0.525
A dditive
0.480
0.015
Water
0.885
0.420
(3)
Fly A sh
0.060
0.525
A dditive
0.480
0.015
Water
0.885
0.420
(4)
Fly A sh
0.060
0.525
A dditive
0.480
0.015
Water
0.885
0.420
Bottom Ash 0.04
Velocity 25
Pipe Diameter 450
Velocity 40
Pipe Diameter 450
Velocity 25
Pipe Diameter 350
Velocity 40
Pipe Diameter 350
(1)
(2)
(3)
(4)
Hold Values
>
–
–
–
–
–
< -10000
-10000 0
0 10000
10000 20000
20000 30000
30000 40000
40000
Pressure Drop
Multiple Mixture Contour Plot for Pressure Drop
(component amounts)
33. Bottom A sh
0.040
0.365
Fly A sh
0.385
0.060
A dditive
0.340
0.015
Bottom A sh
0.040
0.497
Fly A sh
0.517
0.060
Water
0.877
0.420
Bottom A sh
0.040
0.285
A dditive
0.260
0.015
Water
0.665
0.420
Fly A sh
0.060
0.345
A dditive
0.300
0.015
Water
0.705
0.420
Bottom Ash 0.22
Fly Ash 0.28
Additive 0.0225
Water 0.56
Velocity 40
Pipe Diameter 450
Hold Values
>
–
–
–
–
–
< -5000
-5000 -2500
-2500 0
0 2500
2500 5000
5000 7500
7500
Pressure Drop
(component amounts)
Matrix of Closed Mixture Contour Plots for Pressure Drop
34. Response Optimization
Parameters
Goal Lower Target Upper Weight Import
Pressure Drop Minimum 1000 1000 4473 1 1
Starting Point
Components
Bottom Ash = 0.04
Fly Ash = 0.06
Additive = 0.015
Water = 0.40
Process Variables
Velocity = 25
Pipe Diameter = 350
Global Solution
Components
Bottom Ash = 0.2199
Fly Ash = 0.320
Additive = 0.0178
Water = 0.4423
Process Variables
Velocity = 34
Pipe Diameter = 440
Predicted Responses
Pressure Drop = 1185.7543 ,
Desirability = 0.94651
35. Cur
High
Low0.94651
D
New
d = 0.94651
Minimum
Pressure
y = 1185.7543
0.94651
Desirability
Composite
350.0
450.0
25.0
40.0
0.420
0.70
0.0150
0.030
0.1148
0.50
0.040
0.40
[ ]:Fly Ash [ ]:Additive [ ]:Water Velocity Pipe Dia[ ]:Bottom A
[0.2199] [0.320] [0.0178] [0.4423] [34.0] [440.0]