Search results for: impeller

Authors: Rouhollah Torabi, Ashkan Chavoshi, Sheyda Almasi, Shima Almasi

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In this paper the effect of impeller trim on centrifugal pump performance is studied and the most important effect which is decreasing the flow rate, differential head and efficiency is analyzed. For this case a low specific speed centrifugal pump is simulated with CFD. Total flow inside the pump including the secondary flow in sidewall gap which form internal leakage is modeled simultaneously in CFX software. The flow field in different area of pumps such as inside impeller, volute, balance holes and leakage through wear rings are studied. To validate the results experimental tests are done for various impeller diameters. Results also compared with analytic equations which predict pump performance with trimmed impeller.

Keywords: centrifugal pump, CFD, impeller, trim

Procedia PDF Downloads 377

Authors: Noraishah Othman, Siti K. Kamarudin, Norinsan K. Othman, Mohd S. Takriff, Masli I. Rosli, Engku M. Fahmi, Mior A. Khusaini

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The present work describes hydrodynamics of mixing characteristics of two dual hybrid impeller consisting of, radial and axial impeller using radiotracer technique. Type A mixer, a Rushton turbine is mounted above a Pitched Blade Turbine (PBT) at common shaft and Type B mixer, a Rushton turbine is mounted below PBT. The objectives of this paper are to investigate the residence time distribution (RTD) of two hybrid mixers and to represent the respective mixers by RTD model. Each type of mixer will experience five radiotracer experiments using Tc99m as source of tracer and scintillation detectors NaI(Tl) are used for tracer detection. The results showed that mixer in parallel model and mixers in series with exchange can represent the flow model in mixer A whereas only mixer in parallel model can represent Type B mixer well than other models. In conclusion, Type A impeller, Rushton impeller above PBT, reduced the presence of dead zone in the mixer significantly rather than Type B.

Keywords: hybrid impeller, residence time distribution (RTD), radiotracer experiments, RTD model

Procedia PDF Downloads 322

Authors: Nader Zirak, Mohammadali Shirinbayan, Abbas Tcharkhtchi

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Additive manufacturing is referred to as a method for fabrication of parts with a mechanism of layer by layer. Suitable economic efficiency and the ability to fabrication complex parts have made this method the focus of studies and industry. In recent years many studies focused on the fabrication of impellers, which is referred to as a key component of turbomachinery, through this technique. This study considers the important effect of the final surface quality of the impeller on the performance of the system, investigates the fabricated printed rotors through the fused deposition modeling with different process parameters. In this regard, the surface of each impeller was analyzed through the 3D scanner. The results show the vital role of surface quality on the final performance of the centrifugal compressor.

Keywords: additive manufacturing, impeller, centrifugal compressor, performance

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Authors: Y. Galerkin, A. Rekstin, K. Soldatova

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Universal modeling method well proven for industrial compressors was applied for design of the high flow rate supersonic stage. Results were checked by ANSYS CFX and NUMECA Fine Turbo calculations. The impeller appeared to be very effective at transonic flow velocities. Stator elements efficiency is acceptable at design Mach numbers too. Their loss coefficient versus inlet flow angle performances correlates well with Universal modeling prediction. The impeller demonstrated ability of satisfactory operation at design flow rate. Supersonic flow behavior in the impeller inducer at the shroud blade to blade surface Φdes deserves additional study.

Keywords: centrifugal compressor stage, supersonic impeller, inlet flow angle, loss coefficient, return channel, shock wave, vane diffuser

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Authors: A. Kaćunić, M. Ćosić, N. Kuzmanić

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Interaction between mixing and crystallization is often ignored despite the fact that it affects almost every aspect of the operation including nucleation, growth, and maintenance of the crystal slurry. This is especially pronounced in multiple impeller systems where flow complexity is increased. By choosing proper mixing parameters, what closely depends on the knowledge of the hydrodynamics in a mixing vessel, the process of batch cooling crystallization may considerably be improved. The values that render useful information when making this choice are mixing time and power consumption. The predominant motivation for this work was to investigate the extent to which radial dual impeller configuration influences mixing time, power consumption and consequently the values of metastable zone width and nucleation rate. In this research, crystallization of borax was conducted in a 15 dm3 baffled batch cooling crystallizer with an aspect ratio (H/T) of 1.3. Mixing was performed using two straight blade turbines (4-SBT) mounted on the same shaft that generated radial fluid flow. Experiments were conducted at different values of N/NJS ratio (impeller speed/ minimum impeller speed for complete suspension), D/T ratio (impeller diameter/crystallizer diameter), c/D ratio (lower impeller off-bottom clearance/impeller diameter), and s/D ratio (spacing between impellers/impeller diameter). Mother liquor was saturated at 30°C and was cooled at the rate of 6°C/h. Its concentration was monitored in line by Na-ion selective electrode. From the values of supersaturation that was monitored continuously over process time, it was possible to determine the metastable zone width and subsequently the nucleation rate using the Mersmann’s nucleation criterion. For all applied dual impeller configurations, the mixing time was determined by potentiometric method using a pulse technique, while the power consumption was determined using a torque meter produced by Himmelstein & Co. Results obtained in this investigation show that dual impeller configuration significantly influences the values of mixing time, power consumption as well as the metastable zone width and nucleation rate. A special attention should be addressed to the impeller spacing considering the flow interaction that could be more or less pronounced depending on the spacing value.

Keywords: dual impeller crystallizer, mixing time, power consumption, metastable zone width, nucleation rate

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Authors: Jagtar Singh, Kulwinder Singh

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Slurry erosion is a type of erosion wherein material is removed from the target surface due to impingement of solid particles entrained in liquid medium. Slurry erosion performance of deep cryogenic treatment on impeller steel SS 316 L has been investigated. Slurry collected from an actual irrigation pump used as the abrasive media in an erosion test rig. An attempt has been made to study the effect of velocity of fluid and impingement angle by constant concentration (ppm) on the slurry erosion behavior of these cryotreated steels under different experimental conditions. The slurry erosion wear analysis of cryotreated and untreated steels was done. The slurry erosion performance of cryotreated SS 316L impeller steel has been found to superior to that of untreated steel. Metallurgical investigation, hardness as well as %age of carbide in both types of steel was also investigated.

Keywords: deep cryogenic treatment, impeller, Irrigation pumps SS316L, slurry erosion

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Authors: A. Čelan, M. Ćosić, D. Rušić, N. Kuzmanić

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Conducting crystallization in an agitated vessel requires a proper selection of mixing parameters that would result in a production of crystals of specific properties. In dual impeller systems, which are characterized by a more complex hydrodynamics due to the possible fluid flow interactions, revealing a clear link between mixing parameters and crystallization kinetics is still an open issue. The aim of this work is to establish this connection by investigating how fluid flow patterns, generated by two impellers mounted on the same shaft, reflect on metastable zone width of borax decahydrate, one of the most important parameters of the crystallization process. Investigation was carried out in a 15-dm³ bench scale batch cooling crystallizer with an aspect ratio (H/T) equal to 1.3. For this reason, two radial straight blade turbines (4-SBT) were used for agitation. Experiments were conducted at different impeller spacings at the state of complete suspension. During the process of an unseeded batch cooling crystallization, solution temperature and supersaturation were continuously monitored what enabled a determination of the metastable zone width. Hydrodynamic conditions in the vessel achieved at different impeller spacings investigated were analyzed in detail. This was done firstly by measuring the mixing time required to attain the desired level of homogeneity. Secondly, fluid flow patterns generated in a described dual impeller system were both photographed and simulated by VisiMix Turbulent software. Also, a comparison of these two visualization methods was performed. Experimentally obtained results showed that metastable zone width is definitely affected by the hydrodynamics in the crystallizer. This means that this crystallization parameter can be controlled not only by adjusting the saturation temperature or cooling rate, as is usually done, but also by choosing a suitable impeller spacing that will result in a formation of crystals of wanted size distribution.

Keywords: dual impeller crystallizer, fluid flow pattern, metastable zone width, mixing time, radial impeller

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Authors: Draoui Belkacem, Rahmani Lakhdar, Benachour Elhadj, Seghier Oussama

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Rheology is known to have a strong impact on the flow behavior and the power consumption of mechanically agitated vessels. The laminar 2D agitation flow and power consumption of viscoplastic fluids with an anchor impeller in a stirring tank is studied by using computational fluid dynamics (CFD). In this work the objective of this paper is: to evaluate the power consumption for yield stress fluids in standard mixing system. The power consumption is calculated for the different types of anchor impeller configurations and an optimum configuration is proposed.The hydrodynamic fields of incompressible yield stress fluid with model of Bingham in a cylindrical vessel not chicaned equipped with anchor stirrer was undertaken by means of numerical simulation. The flow structures, and especially the effect of inertia, the plasticity and the yield stress, are discussed.

Keywords: rheology, 2D, numerical, anchor, rotating vissel, non-Newtonien fluid

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Authors: Mahdi Hamzehei, Homan Alimoradzadeh, Mahdi Shahriyari

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In this paper, vibration of the industrial centrifugal pumps studied by measuring analysis and computational simulation. Effects of different parameters on pump vibration were investigated. Also, simulation of cavitation in the centrifugal pump was down. First, via CF-TURBO software, the pump impeller and the fluid passing through the pump is modelled and finally, the phenomenon of cavitation in the impeller has been modelled by Ansys software. Also, the effects of changes in the amount of NPSH and bubbles generation in the pump impeller were investigated. By simulation of piping with pipe flow software, effect of fluid velocity and pressure on hydraulics and vibration were studied computationally by applying Computational Fluid Dynamic (CFD) techniques, fluent software and experimentally. Furthermore, this comparison showed that the model can predict hydraulics and vibration behaviour.

Keywords: cavitation, vibration, centrifugal pumps, performance curves, NPSH

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Authors: Y. Galerkin, E. Popova, K. Soldatova

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There is an evident trend to elevate pressure ratio of a single stage of a turbo compressors - axial compressors in particular. Whilst there was an opinion recently that a pressure ratio 1,9 was a reasonable limit, later appeared information on successful modeling tested of stages with pressure ratio up to 2,8. The Authors recon that lack of information on high pressure stages makes actual a study of rational choice of design parameters before high supersonic flow problems solving. The computer program of an engineering type was developed. Below is presented a sample of its application to study possible parameters of the impeller of the stage with pressure ratio π*=3,0. Influence of two main design parameters on expected efficiency, periphery blade speed and flow structure is demonstrated. The results had lead to choose a variant for further analysis and improvement by CFD methods.

Keywords: supersonic stage, impeller, efficiency, flow rate coefficient, work coefficient, loss coefficient, oblique shock, direct shock

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Authors: Jie Dong, Binjie Hu, Andrzej W Pacek, Xiaogang Yang, Nicholas J. Miles

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The effect of the shape of the vessel bottom and the length of baffles on the velocity distributions in a turbulent and in a transitional flow has been simulated. The turbulent flow was simulated using standard k-ε model and simulation was verified using LES whereas transitional flow was simulated using only LES. It has been found that both the shape of tank bottom and the baffles’ length has significant effect on the flow pattern and velocity distribution below the impeller. In the dished bottom tank with baffles reaching the edge of the dish, the large rotating volume of liquid was formed below the impeller. Liquid in this rotating region was not fully mixing. A dead zone was formed here. The size and the intensity of circulation within this zone calculated by k-ε model and LES were practically identical what reinforces the accuracy of the numerical simulations. Both types of simulations also show that employing full-length baffles can reduce the size of dead zone formed below the impeller. The LES was also used to simulate the velocity distribution below the impeller in transitional flow and it has been found that secondary circulation loops were formed near the tank bottom in all investigated geometries. However, in this case the length of baffles has smaller effect on the volume of rotating liquid than in the turbulent flow.

Keywords: baffles length, dished bottom, dead zone, flow field

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Authors: Thiyam Tamphasana Devi, Bimlesh Kumar

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A Computational Fluid Dynamics (CFD) technique has been applied to simulate the gas-liquid phase in double stirred tank of Rushton impeller. Eulerian-Eulerian model was adopted to simulate the multiphase with standard correlation of Schiller and Naumann for drag co-efficient. The turbulence was modeled by using standard k-ε turbulence model. The present CFD model predicts flow pattern, local gas hold-up, and local specific area. It also predicts local kLa (mass transfer rate) for single impeller. The predicted results were compared with experimental and CFD results of published literature. The predicted results are slightly over predicted with the experimental results; however, it is in reasonable agreement with other simulated results of published literature.

Keywords: Eulerian-Eulerian, gas-hold up, gas-liquid phase, local mass transfer rate, local specific area, Rushton Impeller

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Authors: Iqra Noor, Ihtzaz Qamar

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Pitot-tube Jet pump, single-stage pump with low flow rate and high head, consists of a radial impeller that feeds water to rotating cavity. Water then enters stationary pitot-tube collector (diffuser), which discharges to the outside. By means of ANSYS Fluent 15.0, the internal flow characteristics for Pitot-tube Jet pump with standard pitot and curved pitot are studied. Under design condition, realizable k-e turbulence model and SIMPLEC algorithm are used to calculate 3D flow field inside both pumps. The simulation results reveal that energy is imparted to the flow by impeller and inside the rotor, forced vortex type flow is observed. Total pressure decreases inside pitot-tube whereas static pressure increases. Changing pitot-tube from standard to curved shape results in minimum flow circulation inside pitot-tube and leads to a higher pump performance.

Keywords: CFD, flow circulation, high pressure pump, impeller, internal flow, pickup tube pump, rectangle channels, rotating casing, turbulence

Procedia PDF Downloads 129

Authors: Mohammadreza DaqiqShirazi, Rouhollah Torabi, Alireza Riasi, Ahmad Nourbakhsh

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In this paper, the flow in a sidewall gap of an impeller which belongs to a centrifugal pump is studied using numerical method. The flow in sidewall gap forms internal leakage and is the source of “disk friction loss” which is the most important cause of reduced efficiency in low specific speed centrifugal pumps. Simulation is done using CFX software and a high quality mesh, therefore the modeling error has been reduced. Navier-Stokes equations have been solved for this domain. In order to predict the turbulence effects the SST model has been employed.

Keywords: numerical study, centrifugal pumps, disk friction loss, sidewall gap

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Authors: K. Soldatova, Y. Galerkin

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A loading factor performance is necessary for the modeling of centrifugal compressor gas dynamic performance curve. Measured loading factors are linear function of a flow coefficient at an impeller exit. The performance does not depend on the compressibility criterion. To simulate loading factor performances, the authors present two parameters: a loading factor at zero flow rate and an angle between an ordinate and performance line. The calculated loading factor performances of non-viscous are linear too and close to experimental performances. Loading factor performances of several dozens of impellers with different blade exit angles, blade thickness and number, ratio of blade exit/inlet height, and two different type of blade mean line configuration. There are some trends of influence, which are evident – comparatively small blade thickness influence, and influence of geometry parameters is more for impellers with bigger blade exit angles, etc. Approximating equations for both parameters are suggested. The next phase of work will be simulating of experimental performances with the suggested approximation equations as a base.

Keywords: loading factor performance, centrifugal compressor, impeller, modeling

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Authors: Simon Caba, Raja Abou Ackl, Svend Rasmussen, Nicholas E. Pedersen

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It is a challenge to directly monitor cavitation in a pump application during operation because of a lack of visual access to validate the presence of cavitation and its form of appearance. In this work, experimental investigations are carried out in an inline single-stage centrifugal pump with optical access. Hence, it gives the opportunity to enhance the value of CFD tools and standard cavitation measurements. Experiments are conducted using two impellers running in the same volute at 3000 rpm and the same flow rate. One of the impellers used is optimized for lower NPSH₃% by its blade design, whereas the other one is manufactured using a standard casting method. The cavitation is detected by pump performance measurements, vibration measurements and high-speed image recordings. The head drop and the pump casing vibration caused by cavitation are correlated with the visual appearance of the cavitation. The vibration data is recorded in an axial direction of the impeller using accelerometers recording at a sample rate of 131 kHz. The vibration frequency domain data (up to 20 kHz) and the time domain data are analyzed as well as the root mean square values. The high-speed recordings, focusing on the impeller suction side, are taken at 10,240 fps to provide insight into the flow patterns and the cavitation behavior in the rotating impeller. The videos are synchronized with the vibration time signals by a trigger signal. A clear correlation between cloud collapses and abrupt peaks in the vibration signal can be observed. The vibration peaks clearly indicate cavitation, especially at higher NPSHA values where the hydraulic performance is not affected. It is also observed that below a certain NPSHA value, the cavitation started in the inlet bend of the pump. Above this value, cavitation occurs exclusively on the impeller blades. The impeller optimized for NPSH₃% does show a lower NPSH₃% than the standard impeller, but the head drop starts at a higher NPSHA value and is more gradual. Instabilities in the head drop curve of the optimized impeller were observed in addition to a higher vibration level. Furthermore, the cavitation clouds on the suction side appear more unsteady when using the optimized impeller. The shape and location of the cavitation are compared to 3D fluid flow simulations. The simulation results are in good agreement with the experimental investigations. In conclusion, these investigations attempt to give a more holistic view on the appearance of cavitation by comparing the head drop, vibration spectral data, vibration time signals, image recordings and simulation results. Data indicates that a criterion for cavitation detection could be derived from the vibration time-domain measurements, which requires further investigation. Usually, spectral data is used to analyze cavitation, but these investigations indicate that the time domain could be more appropriate for some applications.

Keywords: cavitation, centrifugal pump, head drop, high-speed image recordings, pump vibration

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Authors: Joseph Amponsah

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This research proposes an equation to predict and determine the momentum source equation term after factoring in the radial friction between the fluid and the blades and the impeller's propulsive power. This research aims to look at how CFD software can be used to predict the effect of flows in nuclear reactor stirred tanks through a momentum source equation and the concentration distribution of tracers that have been introduced in reactor tanks. The estimated findings, including the dimensionless concentration curves, power, and pumping numbers, dimensionless velocity profiles, and mixing times 4, were contrasted with results from tests in stirred containers. The investigation was carried out in Part I for vessels that were agitated by one impeller on a central shaft. The two types of impellers employed were an ordinary Rushton turbine and a 6-bladed 45° pitched blade turbine. The simulations made use of numerous reference frame techniques and the common k-e turbulence model. The impact of the grid type was also examined; unstructured, structured, and unique user-defined grids were looked at. The CFD model was used to simulate the flow field within the Rushton turbine nuclear reactor stirred tank. This method was validated using experimental data that were available close to the impeller tip and in the bulk area. Additionally, analyses of the computational efficiency and time using MRF and SM were done.

Keywords: Ansys fluent, momentum equation, CFD, prediction

Procedia PDF Downloads 49

Authors: Nafsi K. Ashraf, C. V. Vipin, V. Anantha Subramanian

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This paper reports the design of a waterjet propulsion system for an amphibious vehicle based on circulation distribution over the camber line for the sections of the impeller and stator. In contrast with the conventional waterjet design, the inlet duct is straight for water entry parallel and in line with the nozzle exit. The extended nozzle after the stator bowl makes the flow more axial further improving thrust delivery. Waterjet works on the principle of volume flow rate through the system and unlike the propeller, it is an internal flow system. The major difference between the propeller and the waterjet occurs at the flow passing the actuator. Though a ducted propeller could constitute the equivalent of waterjet propulsion, in a realistic situation, the nozzle area for the Waterjet would be proportionately larger to the inlet area and propeller disc area. Moreover, the flow rate through impeller disk is controlled by nozzle area. For these reasons the waterjet design is based on pump systems rather than propellers and therefore it is important to bring out the characteristics of the flow from this point of view. The analysis is carried out using computational fluid dynamics. Design of waterjet propulsion is carried out adapting the axial flow pump design and performance analysis was done with three-dimensional computational fluid dynamics (CFD) code. With the varying environmental conditions as well as with the necessity of high discharge and low head along with the space confinement for the given amphibious vehicle, an axial pump design is suitable. The major problem of inlet velocity distribution is the large variation of velocity in the circumferential direction which gives rise to heavy blade loading that varies with time. The cavitation criteria have also been taken into account as per the hydrodynamic pump design. Generally, waterjet propulsion system can be parted into the inlet, the pump, the nozzle and the steering device. The pump further comprises an impeller and a stator. Analytical and numerical approaches such as RANSE solver has been undertaken to understand the performance of designed waterjet propulsion system. Unlike in case of propellers the analysis was based on head flow curve with efficiency and power curves. The modeling of the impeller is performed using rigid body motion approach. The realizable k-ϵ model has been used for turbulence modeling. The appropriate boundary conditions are applied for the domain, domain size and grid dependence studies are carried out.

Keywords: amphibious vehicle, CFD, impeller design, waterjet propulsion

Procedia PDF Downloads 180

Authors: Desmond Appiah, Fan Zhang, Shouqi Yuan, Wei Xueyuan, Stephen N. Asomani

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The side channel pump has distinctive hydraulic performance characteristics over other vane pumps because of its generation of high pressure heads in only one impeller revolution. Hence, there is soaring utilization and application in the fields of petrochemical, food processing fields, automotive and aerospace fuel pumping where high heads are required at low flows. The side channel pump is characterized by unstable flow because after fluid flows into the impeller passage, it moves into the side channel and comes back to the impeller again and then moves to the next circulation. Consequently, the flow leaves the side channel pump following a helical path. However, the pressure fluctuation exhibited in the flow greatly contributes to the unwanted noise and vibration which is associated with the flow. In this paper, a side channel pump prototype was examined thoroughly through numerical calculations based on SST k-ω turbulence model to ascertain the pressure fluctuation behavior. The pressure fluctuation intensity of the 3D unstable flow dynamics were carefully investigated under different working conditions 0.8QBEP, 1.0 QBEP and 1.2QBEP. The results showed that the pressure fluctuation distribution around the pressure side of the blade is greater than the suction side at the impeller and side channel interface (z=0) for all three operating conditions. Part-load condition 0.8QBEP recorded the highest pressure fluctuation distribution because of the high circulation velocity thus causing an intense exchanged flow between the impeller and side channel. Time and frequency domains spectra of the pressure fluctuation patterns in the impeller and the side channel were also analyzed under the best efficiency point value, QBEP using the solution from the numerical calculations. It was observed from the time-domain analysis that the pressure fluctuation characteristics in the impeller flow passage increased steadily until the flow reached the interrupter which separates low-pressure at the inflow from high pressure at the outflow. The pressure fluctuation amplitudes in the frequency domain spectrum at the different monitoring points depicted a gentle decreasing trend of the pressure amplitudes which was common among the operating conditions. The frequency domain also revealed that the main excitation frequencies occurred at 600Hz, 1200Hz, and 1800Hz and continued in the integers of the rotating shaft frequency. Also, the mass flow exchange plots indicated that the side channel pump is characterized with many vortex flows. Operating conditions 0.8QBEP, 1.0 QBEP depicted less and similar vortex flow while 1.2Q recorded many vortex flows around the inflow, middle and outflow regions. The results of the numerical calculations were finally verified experimentally. The performance characteristics curves from the simulated results showed that 0.8QBEP working condition recorded a head increase of 43.03% and efficiency decrease of 6.73% compared to 1.0QBEP. It can be concluded that for industrial applications where the high heads are mostly required, the side channel pump can be designed to operate at part-load conditions. This paper can serve as a source of information in order to optimize a reliable performance and widen the applications of the side channel pumps.

Keywords: exchanged flow, pressure fluctuation, numerical simulation, side channel pump

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Authors: Z. Q. Zhang, Y. Zhang, D. L. Li

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To overcome the some shortcomings associated with traditional flotation machines and columns in collophanite flotation, a flotation device was designed and fabricated in the laboratory. A multi-impeller pump with same function as a mechanical cell was used instead of the injection sparger and circulation pump in column flotation unit. The influence of main operational parameters of the device like feed flow rate, air flow rate and impellers’ speed on collophanite flotation was analyzed. Experiment results indicate that the influence of the operational parameters were significant on flotation recovery and grade of phosphate concentrate. The best operating conditions of the device were: feed flow rate 0.62 L/min, air flow rate 6.67 L/min and impellers speed 900 rpm. At these conditions, a phosphate concentrate assaying about 30.5% P₂O₅ and 1% MgO with a P₂O₅ recovery of about 81% was obtained from a Yuan'an phosphate ore sample containing about 22.30% P₂O₅ and 3.2% MgO.

Keywords: collophanite flotation, flotation columns, flotation machines, multi-impeller pump

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Authors: Edwin Cartledge, Jack Clark, Mazaher Molaei-Chalchooghi

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The mixing in the crystallization step of active pharmaceutical ingredient manufacturers was studied via advanced modeling tools to enable a successful scale-up. A virtual representation of the vessel was created, and computational fluid dynamics were used to simulate multiphase flow and, thus, the mixing environment within this vessel. The study identified a significant dead zone in the vessel underneath the impeller and found that increasing the impeller speed and power did not improve the mixing. A series of sensitivity analyses found that to improve mixing, the vessel had to be redesigned, and found that optimal mixing could be obtained by adding two extra cylindrical baffles. The same two baffles from the simulated environment were then constructed and added to the process vessel. By identifying these potential issues before starting the manufacture and modifying the vessel to ensure good mixing, this study mitigated a failed crystallization and potential batch disposal, which could have resulted in a significant loss of high-value material.

Keywords: active pharmaceutical ingredient, baffles, computational fluid dynamics, mixing, modelling

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Authors: Jantakan Jullawateelert, Korakod Haonoo, Sutipong Sananseang, Sarun Torpaiboon, Thanunthon Bowornsakulwong, Lalintip Hocharoen

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Process scale-up is essential for the biological process to increase production capacity from bench-scale bioreactors to either pilot or commercial production. Scale-up based on constant volumetric oxygen mass transfer coefficient (KLa) is mostly used as a scale-up factor since oxygen supply is one of the key limiting factors for cell growth. However, to estimate KLa of culture vessels operated with different conditions are time-consuming since it is considerably influenced by a lot of factors. To overcome the issue, this study aimed to establish correlation equations of KLa and operating parameters in 0.5 L and 5 L bioreactor employed with pitched-blade impeller and gas sparger. Temperature, gas flow rate, agitation speed, and impeller position were selected as process parameters and equations were created using response surface methodology (RSM) based on central composite design (CCD). In addition, the effects of these parameters on KLa were also investigated. Based on RSM, second-order polynomial models for 0.5 L and 5 L bioreactor were obtained with an acceptable determination coefficient (R²) as 0.9736 and 0.9190, respectively. These models were validated, and experimental values showed differences less than 10% from the predicted values. Moreover, RSM revealed that gas flow rate is the most significant parameter while temperature and agitation speed were also found to greatly affect the KLa in both bioreactors. Nevertheless, impeller position was shown to influence KLa in only 5L system. To sum up, these modeled correlations can be used to accurately predict KLa within the specified range of process parameters of two different sizes of bioreactors for further scale-up application.

Keywords: response surface methodology, scale-up, stirred-tank bioreactor, volumetric oxygen mass transfer coefficient

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Authors: Wanru Huang, Fujun Wang, Chaoyue Wang, Yuan Tang, Zhifeng Yao, Ruofu Xiao, Xin Chen

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Rotating stall in centrifugal pump is an unsteady flow phenomenon that causes instabilities and high hydraulic losses. It typically occurs at low flow rates due to large flow separation in impeller blade passage. In order to reveal the influence of incoming flow conditions on rotating stall in centrifugal pump, a numerical method for investigating rotating stall was established. This method is based on a modified SST k-ω turbulence model and a fine mesh model was adopted. The calculated flow velocity in impeller by this method was in good agreement with PIV results. The effects of flow rate and sealing-ring leakage on stall characteristics of centrifugal pump were studied by using the proposed numerical approach. The flow structures in impeller under typical flow rates and typical sealing-ring leakages were analyzed. It is found that the stall vortex frequency and circumferential propagation velocity increase as flow rate decreases. With the flow rate decreases from 0.40Qd to 0.30Qd, the stall vortex frequency increases from 1.50Hz to 2.34Hz, the circumferential propagation velocity of the stall vortex increases from 3.14rad/s to 4.90rad/s. Under almost all flow rate conditions where rotating stall is present, there is low frequency of pressure pulsation between 0Hz-5Hz. The corresponding pressure pulsation amplitude increases with flow rate decreases. Taking the measuring point at the leading edge of the blade pressure surface as an example, the flow rate decreases from 0.40Qd to 0.30Qd, the pressure fluctuation amplitude increases by 86.9%. With the increase of leakage, the flow structure in the impeller becomes more complex, and the 8-shaped stall vortex is no longer stable. On the basis of the 8-shaped stall vortex, new vortex nuclei are constantly generated and fused with the original vortex nuclei under large leakage. The upstream and downstream vortex structures of the 8-shaped stall vortex have different degrees of swimming in the flow passage, and the downstream vortex swimming is more obvious. The results show that the proposed numerical approach could capture the detail vortex characteristics, and the incoming flow conditions have significant effects on the stall vortex in centrifugal pumps.

Keywords: centrifugal pump, rotating stall, numerical simulation, flow condition, vortex frequency

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Authors: Prasanjit Das, M .M. K. Khan, M. G. Rasul, Jie Wu, I. Youn

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Crystallisation scale occurs when dissolved minerals precipitate from an aqueous solution. To investigate the crystallisation scale growth of normal solubility salt, a lab-scale agitation tank with and without baffles were used as a benchmark using potassium nitrate as the test fluid. Potassium nitrate (KNO3) solution in this test leads to crystallisation scale on heat transfer surfaces. This experimental investigation has focused on the effect of surface crystallisation of potassium nitrate on the low-temperature heat exchange surfaces on the wall of the agitation tank. The impeller agitation rate affects the scaling rate at the low-temperature agitation wall and it shows a decreasing scaling rate with an increasing agitation rate. It was observed that there was a significant variation of heat transfer coefficients and scaling resistance coefficients with different agitation rate as well as with varying impeller size, tank with and without baffles and solution concentration.

Keywords: crystallisation, heat transfer coefficient, scale, resistance

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Authors: Prasanjit Das, M. M. K. Khan, M. G. Rasul, Jie Wu, I. Youn

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Mineral scale formation is undoubtedly a more serious problem in the mineral industry than other process industries. To better understand scale growth and suppression, an experimental model is proposed in this study for supersaturated crystallised solutions commonly found in mineral process plants. In this experiment, surface crystallisation of potassium nitrate (KNO3) on the wall of the agitation tank and agitation effects on the scale growth and suppression are studied. The new quantitative scale suppression model predicts that at lower agitation speed, the scale growth rate is enhanced and at higher agitation speed, the scale suppression rate increases due to the increased flow erosion effect. A lab-scale agitation tank with and without baffles were used as a benchmark in this study. The fluid dynamic effects on scale growth and suppression in the agitation tank with three different size impellers (diameter 86, 114, 160 mm and model A310 with flow number 0.56) at various ranges of rotational speed (up to 700 rpm) and solution with different concentration (4.5, 4.75 and 5.25 mol/dm3) were investigated. For more elucidation, the effects of the different size of the impeller on wall surface scale growth and suppression rate as well as bottom settled scale accumulation rate are also discussed. Emphasis was placed on applications in the mineral industry, although results are also relevant to other industrial applications.

Keywords: agitation tank, crystallisation, impeller speed, scale

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Authors: Chandra Gupt Porwal

Abstract:

Excessive vibration means increased wear, increased repair efforts, bad product selection & quality and high energy consumption. This may be sometimes experienced by cavitation or suction/discharge re-circulation which could occur only when net positive suction head available NPSHA drops below the net positive suction head required NPSHR. Cavitation can cause axial surging if it is excessive, will damage mechanical seals, bearings, possibly other pump components frequently and shorten the life of the impeller. Efforts have been made to explain Suction Energy (SE), Specific Speed (Ns), Suction Specific Speed (Nss), NPSHA, NPSHR & their significance, possible reasons of cavitation /internal re-circulation, its diagnostics and remedial measures to arrest and prevent cavitation in this paper. A case study is presented by the author highlighting that the root cause of unwanted noise and vibration is due to cavitation, caused by high specific speeds or inadequate net- positive suction head available which results in damages to material surfaces of impeller & suction bells and degradation of machine performance, its capacity and efficiency too. The author strongly recommends revisiting the technical specifications of CW pumps to provide sufficient NPSH margin ratios > 1.5, for future projects and Nss be limited to 8500 -9000 for cavitation free operation.

Keywords: best efficiency point (BEP), net positive suction head NPSHA, NPSHR, specific speed NS, suction specific speed NSS

Procedia PDF Downloads 223

Authors: Anuj Srivastava, Kuldeep Kumar

Abstract:

This paper proposes a numerical study of volute tongue design, which affects the centrifugal compressor operating range and pressure recovery. Increased efficiency has been the traditional importance of compressor design. However, the increased operating range has become important in an age of ever-increasing productivity and energy costs in the turbomachinery industry. Efficiency and overall operating range are the two most important parameters studied to evaluate the aerodynamic performance of centrifugal compressor. Volute is one of the components that have significant effect on these two parameters. Choice of volute tongue geometry has major role in compressor performance, also affects performance map. The author evaluates the trade-off on using pull-back tongue geometry on centrifugal compressor performance. In present paper, three different tongue positions and shapes are discussed. These designs are compared in terms of pressure recovery coefficient, pressure loss coefficient, and stable operating range. The detailed flow structures for various volute geometries and pull back angle near tongue are studied extensively to explore the fluid behavior. The viscous Navier-Stokes equations are used to simulate the flow inside the volute. The numerical calculations are compared with thermodynamic 1-D calculations. Author concludes that the increment in compression ratio accompanies with more uniform pressure distribution in the modified tongue shape and location, a uniform static pressure around the circumferential which build a more uniform flow in the impeller and diffuser. Also, the blockage at the tongue of the volute was causing circumferentially nonuniformed pressure along the volute. This nonuniformity may lead impeller and diffuser to operate unstably. However, it is not the volute that directly controls the stall.

Keywords: centrifugal compressor volute, tongue geometry, pull-back, compressor performance, flow instability

Procedia PDF Downloads 125

Authors: Siri Marthe Arbo, Afaf Saai, Sture Sørli, Mette Nedreberg

Abstract:

This work aims to establish a reliable approach for optimizing a Laser Metal Deposition (LMD) process for a critical maritime component, based on the material properties and structural performance required by the maritime industry. The component of interest is a water jet impeller, for which specific requirements for material properties are defined. The developed approach is based on the assessment of the effects of LMD process parameters on microstructure and material performance of standard AM 2205 duplex stainless steel powder. Duplex stainless steel offers attractive properties for maritime applications, combining high strength, enhanced ductility and excellent corrosion resistance due to the specific amounts of ferrite and austenite. These properties are strongly affected by the microstructural characteristics in addition to microstructural defects such as porosity and welding defects, all strongly influenced by the chosen LMD process parameters. In this study, the influence of deposition speed and heat input was evaluated. First, the influences of deposition speed and heat input on the microstructure characteristics, including ferrite/austenite fraction, amount of porosity and welding defects, were evaluated. Then, the achieved mechanical properties were evaluated by standard testing methods, measuring the hardness, tensile strength and elongation, bending force and impact energy. The measured properties were compared to the requirements of the water jet impeller. The results show that the required amounts of ferrite and austenite can be achieved directly by the LMD process without post-weld heat treatments. No intermetallic phases were observed in the material produced by the investigated process parameters. A high deposition speed was found to reduce the ductility due to the formation of welding defects. An increased heat input was associated with reduced strength due to the coarsening of the ferrite/austenite microstructure. The microstructure characterizations and measured mechanical performance demonstrate the great potential of the LMD process and generate a valuable database for the optimization of the LMD process for duplex stainless steels.

Keywords: duplex stainless steel, laser metal deposition, process optimization, microstructure, mechanical properties

Procedia PDF Downloads 175

Authors: Bhupinder Singh, Joy Prakash Misra

Abstract:

This article provides the information regarding machining of hastelloy-X on wire electro spark machining (WEDM). Experimental investigation has been carried out by varying pulse-on time (TON), pulse-off time (TOFF), peak current (IP) and spark gap voltage (SV). Effect of these parameters is studied on material removal rate (MRR). Experiments are designed as per box-behnken design (BBD) technique of response surface methodology (RSM). Analysis of variance (ANOVA) results indicates that TON, TOFF, IP, SV, TON x IP are significant parameters that influenced the MRR, and it is depicted that value of MRR is more at high discharge energy (HDE) and less at low discharge energy (LDE). Furthermore, miniature impeller and miniature gear (OD≤10MM) is fabricated by WEDM at optimized condition.

Keywords: advanced manufacturing, WEDM, super alloy, gear

Procedia PDF Downloads 190

Authors: Sérgio S. de Jesus, Aline Santana, Rubens Maciel Filho

Abstract:

Global oxygen transfer coefficient (kLa) was characterized in a mechanically agitated airlift bio reactor. The experiments were carried out in an airlift bio reactor (3.2 L) with internal re circulation (a concentric draft-tube airlift vessel device); the agitation is carried out through a turbine Rushton impeller located along with the gas sparger in the region comprised in the riser. The experiments were conducted using xanthan gum (0.6%) at 250 C and a constant rotation velocity of 0 and 800 rpm, as well as in the absence of agitation (airlift mode); the superficial gas velocity varied from 0.0157 to 0.0262 ms-1. The volumetric oxygen transfer coefficient dependence of the rotational speed revealed that the presence of agitation increased up to two times the kLa value.

Keywords: aeration, mass transfer, non-Newtonian fluids, stirred airlift bioreactor

Procedia PDF Downloads 420