局部磨损对α型旋风分离器内流场及分离性能的影响

doi:10.16085/j.issn.1000-6613.2021-2031

摘要/Abstract

摘要：

以α型旋风分离器为研究对象，基于欧拉-拉格朗日方法，采用雷诺应力模型（RSM）、颗粒离散相模型（DPM）、E/CRC磨损方程对分离器内流场与磨损特性进行数值模拟。通过分析速度矢量、切向速度、颗粒运动轨迹等参数的分布规律，研究了局部磨损对设备内流场及分离性能的影响。结果表明，α型旋风分离器入口正对壁面磨损最为严重，最大磨损率约为1.4×10^-5kg/(m²·s)。磨损引起壁面几何结构的改变，导致气流方向发生偏转，不利于主流的稳定与固体颗粒的分离。随局部磨损的加剧，排气管下口短路流急剧增大，从而导致排气管下口以下区域流体流量减少，外涡切向速度降低；细颗粒的逃逸现象更加明显，粗颗粒运动轨迹趋于重合，更易形成高浓度灰环加剧壁面磨损。与未磨损时相比，局部磨损厚度50mm时，3μm粒径颗粒的分离效率由74.38%降低至54.97%，分割粒径d₅₀由0.73μm增大至2.36μm；设备压降降低了约15.41%。

关键词: α型旋风分离器, 两相流, 磨损, 数值模拟

Abstract:

Flow field and erosion characteristics of α-type cyclone separator were numerically simulated by Reynolds stress model (RSM), particle discrete phase model (DPM) and E/CRC erosion equation based on Eulerian-Lagrangian approach. Effect of local erosion on flow field and separation performance of the equipment was studied by analyzing the distribution rule of velocity vector, tangential velocity and particle trajectory. The results showed that the erosion in the wall opposite to the α-type cyclone separator inlet was the most serious, and the maximum erosion rate was about 1.4×10^-5kg/(m²·s). The change of wall geometry caused by erosion led to deflection of airflow direction, which was not conducive to the stability of the main stream and the separation of solid particles. With the intensification of local erosion, the short-circuit flow at the inlet of the vortex finder increased sharply, resulting in a decrease in fluid flow in the area below the inlet of the vortex finder and a decrease in the tangential velocity of the outer vortex. The escape phenomenon of fine particles was more obvious, and the movement trajectory of coarse particles tended to coincide, and it was easier to form a high-concentration ash ring to aggravate the erosion of the wall. Compared with the condition without erosion, when the local erosion thickness was 50mm, the particle separation efficiency of 3μm particles decreased from 74.38% to 54.97%, the cut off diameter increased from 0.73μm to 2.36μm, and the pressure drop of the equipment decreased by about 15.41%. The research results provide a theoretical guidance for industrial application of cyclone separators.

Key words: α-type cyclone separator, two-phase flow, attrition, numerical simulation

中图分类号:

TQ051.8

范军领, 何昊, 张攀, 陈光辉. 局部磨损对α型旋风分离器内流场及分离性能的影响[J]. 化工进展, 2022, 41(8): 4025-4034.

FAN Junling, HE Hao, ZHANG Pan, CHEN Guanghui. Effect of local erosion on flow field and separation performance of α-type cyclone separator[J]. Chemical Industry and Engineering Progress, 2022, 41(8): 4025-4034.

图/表 13

图1 α型旋风分离器结构及网格划分简图

图2 速度测量值与模拟值对比

图3 弯管磨损测量值与模拟值对比

图4 α型旋风分离器磨损云图

图5 α型旋风分离器入口正对壁面局部磨损

图6 α型旋风分离器螺旋段速度矢量图

图7 α型旋风分离器X=0截面轴向速度矢量图

图8 不同磨损厚度下下行流量分布

表1 不同磨损厚度下短路流区域及短路流量

δ/mm	轴向位置/mm	下行流量/m³·s^-1	短路流/m³·s^-1
0	-265	0.305	0.111
	-240	0.194
15	-265	0.305	0.122
	-235	0.183
30	-265	0.305	0.142
	-225	0.163
50	-265	0.305	0.171
	-215	0.134

图9 不同磨损厚度下切向速度分布

图10 1μm颗粒运动轨迹比较

图11 30μm颗粒运动轨迹比较

图12 α型旋风分离器压降和分级效率曲线

参考文献 40

1	付鹏波, 黄渊, 王剑刚, 等. 旋流分离过程强化新技术[J]. 化工进展, 2020, 39(12): 4766-4778.
	FU Pengbo, HUANG Yuan, WANG Jiangang, et al. Process intensification technology for hydrocyclone separation[J]. Chemical Industry and Engineering Progress, 2020, 39(12): 4766-4778.
2	蒋明虎, 卢梦媚, 徐保蕊, 等. 旋流器磨损研究进展[J]. 化工进展, 2016, 35(S2): 41-45.
	JIANG Minghu, LU Mengmei, XU Baorui, et al. Recent progress of cyclone wear research[J]. Chemical Industry and Engineering Progress, 2016, 35(S2): 41-45.
3	FULCHINI F, GHADIRI M, BORISSOVA A, et al. Development of a methodology for predicting particle attrition in a cyclone by CFD-DEM[J]. Powder Technology, 2019, 357: 21-32.
4	TOFIGHIAN H, AMANI E, SAFFAR-AVVAL M. A large eddy simulation study of cyclones: The effect of sub-models on efficiency and erosion prediction[J]. Powder Technology, 2020, 360: 1237-1252.
5	金有海, 于长录, 赵新学. 旋风分离器环形空间壁面磨损的数值研究[J]. 高校化学工程学报, 2012, 26(2): 196-202.
	JIN Youhai, YU Changlu, ZHAO Xinxue. Numerical study on wall erosion of the annular space in cyclone separators[J]. Journal of Chemical Engineering of Chinese Universities, 2012, 26(2): 196-202.
6	王江云, 冯留海, 张果, 等. 单入口双进气道旋风分离器内冲蚀特性[J]. 石油学报(石油加工), 2016, 32(2): 289-296.
	WANG Jiangyun, FENG Liuhai, ZHANG Guo, et al. Erosion characteristic in a single inlet cyclone separator with double passage[J]. Acta Petrolei Sinica(Petroleum Processing Section), 2016, 32(2): 289-296.
7	李琴, 邹康, 刘海东, 等. 入口高宽比对旋风分离器壁面冲蚀的影响[J]. 流体机械, 2017, 45(7): 52-57, 11.
	LI Qin, ZOU Kang, LIU Haidong, et al. Effect of inlet aspect ratio on the wall erosion in the cyclone separator[J]. Fluid Machinery, 2017, 45(07): 52-57, 11.
8	袁惠新, 殷伟伟, 黄津, 等. 固液分离旋流器壁面磨损的数值模拟[J]. 化工进展, 2015, 34(3): 664-670.
	YUAN Huixin, YIN Weiwei, HUANG Jin, et al. Numerical simulation of the wall attrition in solid-liquid hydrocyclones[J]. Chemical Industry and Engineering Progress, 2015, 34(3): 664-670.
9	袁惠新, 吕浪, 殷伟伟, 等. 不同入口形式的固液分离旋流器壁面磨损研究[J]. 化工进展, 2015, 34(10): 3583-3588.
	YUAN Huixin, Lang LYU, YIN Weiwei, et al. Numerical simulation of the wall attrition in solid-liquid separation cyclone with different inlet forms[J]. Chemical Industry and Engineering Progress, 2015, 34(10): 3583-3588.
10	赵新学, 金有海. 排尘口直径对旋风分离器壁面磨损影响的数值模拟[J]. 机械工程学报, 2012, 48(6): 142-148.
	ZHAO Xinxue, JIN Youhai. Effect of dust discharge diameter on wall erosion in cyclone separator[J]. Journal of Mechanical Engineering, 2012, 48(6): 142-148.
11	CI H, SUN G G. Effects of wall roughness on the flow field and Vortex length of cyclone[J]. Procedia Engineering, 2015, 102: 1316-1325.
12	FOROOZESH J, PARVAZ F, HOSSEINI S H, et al. Computational fluid dynamics study of the impact of surface roughness on cyclone performance and erosion[J]. Powder Technology, 2021, 389: 339-354.
13	DUAN J H, GAO S, LU Y C, et al. Study and optimization of flow field in a novel cyclone separator with inner cylinder[J]. Advanced Powder Technology, 2020, 31(10): 4166-4179.
14	WEI J P, ZHANG H T, WANG Y G, et al. The gas-solid flow characteristics of cyclones[J]. Powder Technology, 2017, 308:178-192.
15	王薇, 焦清介. 旋风除尘器灰环磨损与锥体角度关系的研究[J]. 安全与环境学报, 2004, 4(3): 11-14.
	WANG Wei, JIAO Qingjie. Study on relation between conic angle and ash ring abrasion in cyclonic dust remover[J]. Journal of Safety and Environment, 2004, 4(3): 11-14.
16	李琴, 邹康, 刘海东, 等. 基于颗粒受力的旋风分离器冲蚀机理的研究[J]. 流体机械, 2017, 45(3): 42-47.
	LI Qin, ZOU Kang, LIU Haidong, et al. The erosion mechanism research of cyclone based on force operating of particles[J]. Fluid Machinery, 2017, 45(3): 42-47.
17	高助威, 王娟, 王江云, 等. 基于DPM模型的旋风分离器内颗粒浓度场模拟分析[J]. 石油学报(石油加工), 2018, 34(3): 507-514.
	GAO Zhuwei, WANG Juan, WANG Jiangyun, et al. Simulation analysis of particle concentration of cyclone separator using the DPM model[J]. Acta Petrolei Sinica(Petroleum Processing Section), 2018, 34(3): 507-514.
18	礼晓宇, 何兴建, 宋健斐, 等. 旋风分离器内颗粒藏量的实验测量[J]. 中国粉体技术, 2014, 20(3): 7-10.
	LI Xiaoyu, HE Xingjian, SONG Jianfei, et al. Experimental study on particle reserves in cyclone separator[J]. China Powder Science and Technology, 2014, 20(3): 7-10.
19	孔文文, 严超宇, 魏耀东. 旋风分离器料腿漏风对压降影响的实验分析[J]. 化工装备技术, 2016, 37(4): 1-4.
	KONG Wenwen, YAN Chaoyu, WEI Yaodong. Experimental analysis of dipleg gas leakage effect on pressure drop of cyclone separator[J]. Chemical Equipment Technology, 2016, 37(4): 1-4.
20	魏耀东, 刘仁桓, 燕辉, 等. 蜗壳式旋风分离器的磨损实验和分析[J]. 化工机械, 2001, 28(2): 71-75.
	WEI Yaodong, LIU Renhuan, YAN Hui, et al. Experiments and analyses of the erosion of volute cyclone separators[J]. Chemical Engineering & Machnery, 2001, 28(2): 71-75.
21	WANG S, LUO K, HU C S, et al. Particle-scale investigation of heat transfer and erosion characteristics in a three-dimensional circulating fluidized bed[J]. Industrial & Engineering Chemistry Research, 2018, 57(19): 6774-6789.
22	CHU K W, KUANG S B, YU A B, et al. Prediction of wear and its effect on the multiphase flow and separation performance of dense medium cyclone[J]. Minerals Engineering, 2014, 56: 91-101.
23	SEDREZ T A, DECKER R K, SILVA M K DA, et al. Experiments and CFD-based erosion modeling for gas-solids flow in cyclones[J]. Powder Technology, 2017, 311: 120-131.
24	邹康, 艾志久, 胡坤, 等. 基于防磨结构的旋风分离器性能优化[J]. 过程工程学报, 2015, 15(1): 9-15.
	ZOU Kang, AI Zhijiu, HU Kun, et al. Performance optimization of cyclone separator based on the wear structure[J]. The Chinese Journal of Process Engineering, 2015, 15(1): 9-15.
25	谭慧敏, 王建军, 马艳杰, 等. 排尘锥结构对旋风分离器内气固两相分离性能影响的研究[J]. 高校化学工程学报, 2011, 25(4): 590-596.
	TAN Huimin, WANG Jianjun, MA Yanjie, et al. Analysis of the influence of dust discharge cone geometry on the gas-solid flow field in tangential inlet cyclone separator[J]. Journal of Chemical Engineering of Chinese Universities, 2011, 25(4): 590-596.
26	秦明坤. 1种侧壁开缝式防磨损旋风分离器性能模拟[J]. 化工生产与技术, 2014, 21(5): 12-16, 7.
	QIN Mingkun. The simulation of the performance of wear-proof cyclone separator with slit in the side wall[J]. Chemical Production and Technology, 2014, 21(5): 12-16, 7.
27	MAZYAN W I, AHMADI A, BRINKERHOFF J, et al. Enhancement of cyclone solid particle separation performance based on geometrical modification: Numerical analysis[J]. Separation and Purification Technology, 2018, 191: 276-285.
28	PARVAZ F, HOSSEINI S H, ELSAYED K, et al. Numerical investigation of effects of inner cone on flow field, performance and erosion rate of cyclone separators[J]. Separation and Purification Technology, 2018, 201: 223-237.
29	周大伟, 向晓东. 环缝内衬固液分离耐磨旋流器磨损的数值模拟[J]. 化工进展, 2016, 35(2): 397-402.
	ZHOU Dawei, XIANG Xiaodong. Numerical simulation of the attrition in solid-liquid wear-resisting cyclones with the ring seam liner[J]. Chemical Industry and Engineering Progress, 2016, 35(2): 397-402.
30	卢梦媚, 蒋明虎, 赵立新, 等. 内嵌小锥结构固液分离旋流器磨蚀的数值模拟[J]. 流体机械, 2017, 45(12): 13-17.
	LU Mengmei, JIANG Minghu, ZHAO Lixin, et al. Numerical simulation of the erosion in embed cone structure of solid-liquid separation hydrocyclone[J].Fluid Machinery, 2017, 45(12): 13-17.
31	王伟文, 袁红燕, 陈光辉, 等. α型旋流分离器: CN101116844A[P]. 2008-02-06.
	WANG Weiwen, YUAN Hongyan, CHEN Guanghui, et al. α-type cyclone separator: CN101116844A[P]. 2008-02-06.
32	PARSI M, NAJMI K, NAJAFIFARD F, et al. A comprehensive review of solid particle erosion modeling for oil and gas wells and pipelines applications[J]. Journal of Natural Gas Science and Engineering, 2014, 21: 850-873.
33	SLACK M D, PRASAD R O, BAKKER A, et al. Advances in cyclone modelling using unstructured grids[J]. Chemical Engineering Research and Design, 2000, 78(8): 1098-1104.
34	VIEIRA R E, MANSOURI A, MCLAURY B S, et al. Experimental and computational study of erosion in elbows due to sand particles in air flow[J]. Powder Technology, 2016, 288: 339-353.
35	ZHOU L X. Two-fluid turbulence modeling of swirling gas-particle flows—A review[J]. Powder Technology, 2017, 314: 253-263.
36	SHUKLA S K, SHUKLA P, GHOSH P. Evaluation of numerical schemes using different simulation methods for the continuous phase modeling of cyclone separators.[J] Advanced Powder Technology, 2011, 22(2): 209-219.
37	MISIULIA, D, ANDERSSON A G, LUNDSTRÖM T S. Computational investigation of an industrial cyclone separator with helical-roof inlet[J]. Chemical Engineering & Technology, 2015, 38(8):1425-1434.
38	付烜, 孙国刚, 刘佳, 等. 旋风分离器短路流的估算问题及其数值计算方法的讨论[J]. 化工学报, 2011, 62(9): 2535-2540.
	FU Xuan, SUN Guogang, LIU Jia, et al. Discuss on estimation difficulties and numerical computation methods for short circuit flow in cyclone separators[J]. CIESC Journal, 2011, 62(9): 2535-2540.
39	MISIULIA, D, ANDERSSON A G, LUNDSTRÖM T S. Effects of the inlet angle on the collection efficiency of a cyclone with helical-roof inlet[J]. Powder Technology, 2017, 305: 48-55.
40	SONG C M, PEI B B, JIANG M T, et al. Numerical analysis of forces exerted on particles in cyclone separators[J]. Powder Technology, 2016, 294: 437-448.

[1]	徐若思, 谭蔚. C形管池沸腾两相流流场模拟与流固耦合分析[J]. 化工进展, 2023, 42(S1): 47-55.
[2]	郭强, 赵文凯, 肖永厚. 增强流体扰动强化变压吸附甲硫醚/氮气分离的数值模拟[J]. 化工进展, 2023, 42(S1): 64-72.
[3]	邵博识, 谭宏博. 锯齿波纹板对挥发性有机物低温脱除过程强化模拟分析[J]. 化工进展, 2023, 42(S1): 84-93.
[4]	王太, 苏硕, 李晟瑞, 马小龙, 刘春涛. 交流电场中贴壁气泡的动力学行为[J]. 化工进展, 2023, 42(S1): 133-141.
[5]	赵晨, 苗天泽, 张朝阳, 洪芳军, 汪大海. 负压状态窄缝通道乙二醇水溶液传热特性[J]. 化工进展, 2023, 42(S1): 148-157.
[6]	陈匡胤, 李蕊兰, 童杨, 沈建华. 质子交换膜燃料电池气体扩散层结构与设计研究进展[J]. 化工进展, 2023, 42(S1): 246-259.
[7]	刘炫麟, 王驿凯, 戴苏洲, 殷勇高. 热泵中氨基甲酸铵分解反应特性及反应器结构优化[J]. 化工进展, 2023, 42(9): 4522-4530.
[8]	罗成, 范晓勇, 朱永红, 田丰, 崔楼伟, 杜崇鹏, 王飞利, 李冬, 郑化安. 中低温煤焦油加氢反应器不同分配器中液体分布的CFD模拟[J]. 化工进展, 2023, 42(9): 4538-4549.
[9]	赵曦, 马浩然, 李平, 黄爱玲. 错位碰撞型微混合器混合性能的模拟分析与优化设计[J]. 化工进展, 2023, 42(9): 4559-4572.
[10]	卜治丞, 焦波, 林海花, 孙洪源. 脉动热管计算流体力学模型与研究进展[J]. 化工进展, 2023, 42(8): 4167-4181.
[11]	叶振东, 刘涵, 吕静, 张亚宁, 刘洪芝. 基于钙镁二元盐的热化学储能反应器的性能优化[J]. 化工进展, 2023, 42(8): 4307-4314.
[12]	俞俊楠, 俞建峰, 程洋, 齐一搏, 化春键, 蒋毅. 基于深度学习的变宽度浓度梯度芯片性能预测[J]. 化工进展, 2023, 42(7): 3383-3393.
[13]	单雪影, 张濛, 张家傅, 李玲玉, 宋艳, 李锦春. 阻燃型环氧树脂的燃烧数值模拟[J]. 化工进展, 2023, 42(7): 3413-3419.
[14]	王硕, 张亚新, 朱博韬. 基于灰色预测模型的水煤浆输送管道冲蚀磨损寿命预测[J]. 化工进展, 2023, 42(7): 3431-3442.
[15]	周龙大, 赵立新, 徐保蕊, 张爽, 刘琳. 电场-旋流耦合强化多相介质分离研究进展[J]. 化工进展, 2023, 42(7): 3443-3456.