CFD Simulation of Gas-Solid Two-Phase Flow in Pneumatic Conveying of Cathode Active Material
(2023) KETM05 20231Chemical Engineering (M.Sc.Eng.)
- Abstract
- This master thesis explores the mechanisms and optimization strategies of a pneumatic conveying system. By investigating the impact of process parameters on power consumption and erosion rate, the aim was to provide valuable insights for system design and operation. The research combines theoretical considerations, CFD simulations, and numerical calculations to analyse the behaviour of the system under various conditions. The findings provide a foundation for future research and development in the field, paving the way for improved system design and operation.
The thesis begins by examining power optimization in pneumatic conveying systems. Through simulations conducted in COMSOL and numerical calculations in Python, pressure drop... (More) - This master thesis explores the mechanisms and optimization strategies of a pneumatic conveying system. By investigating the impact of process parameters on power consumption and erosion rate, the aim was to provide valuable insights for system design and operation. The research combines theoretical considerations, CFD simulations, and numerical calculations to analyse the behaviour of the system under various conditions. The findings provide a foundation for future research and development in the field, paving the way for improved system design and operation.
The thesis begins by examining power optimization in pneumatic conveying systems. Through simulations conducted in COMSOL and numerical calculations in Python, pressure drop curves are evaluated for different mass flows of air and solids. The results indicate that the minimum pressure drop occurs in the range 0.25-0.35 kg/s of air for all solids mass flows. Surprisingly, it is observed that the mass flow of air has a greater influence on power consumption than the mass flow of solids. The study suggests using the lowest possible air mass flow while ensuring successful conveying and recommends further investigations into the saltation- and choking velocity specific to the conveyed material.
Furthermore, the thesis addresses the issue of erosion in pneumatic conveying systems. Eulerian-Lagrangian simulations conducted in COMSOL reveal that the gas velocity significantly impacts the pipe erosion rate, exhibiting an exponential dependence. The research proposes minimizing the gas velocity to minimize erosion and recommends investigating the lowest achievable velocity before blockages occur due to saltation or choking.
To enhance the accuracy of simulations and its relevance to industrial systems, the study suggests incorporating pressure gauges at the inlet and outlet of the transport line. This addition would enable the acquisition of precise pressure drop data during material transportation and allow for the comparison and evaluation of simulation results. (Less) - Popular Abstract (Swedish)
- Batteriet uppfans för över 200 år sen men det är under det senaste deceniet vi har åskådat en storskalig utökning av dess tillverkning, i takt med den globala elektrifieringen. Efterfrågan på batterier förväntas öka med 22-30% årligen till 2030 vilket sätter stor press på industrin att utöka produktionskapaciteten. Men stora faror kan uppstå om tillverkningsprocesserna designas med bristande kvalitetsperspektiv. Exempelvis, kan metall kontaminering från process utrustningen orsaka kortslutning i det producerade batteriet vilket kan leda till termisk flykt och i värsta fall explosion.
Detta masterarbete har därmed utforskat och optimerat pneumatiska transportsystem för katodmaterial där järn kontamineringar har identifierats på grund av... (More) - Batteriet uppfans för över 200 år sen men det är under det senaste deceniet vi har åskådat en storskalig utökning av dess tillverkning, i takt med den globala elektrifieringen. Efterfrågan på batterier förväntas öka med 22-30% årligen till 2030 vilket sätter stor press på industrin att utöka produktionskapaciteten. Men stora faror kan uppstå om tillverkningsprocesserna designas med bristande kvalitetsperspektiv. Exempelvis, kan metall kontaminering från process utrustningen orsaka kortslutning i det producerade batteriet vilket kan leda till termisk flykt och i värsta fall explosion.
Detta masterarbete har därmed utforskat och optimerat pneumatiska transportsystem för katodmaterial där järn kontamineringar har identifierats på grund av erosion av stålrören. Transporten av katodmaterial är en viktig del i tillverkningskedjan och effektivisering av denna process kan leda till förbättrad kvalitet och kostnadsbesparingar.
För att optimera pneumatiska transportsystem undersökte vi olika parametrar som påverkar transporteffektiviteten. Vi analyserade lufttryck, flödeshastighet, partikelegenskaper och rörgeometri för att förstå deras inverkan på transportprocessen. Genom att använda matematisk modellering och simulering kunde vi kvantifiera effekten av parameterarna och identifiera de optimala inställningarna för att maximera transporteffektiviteten och minska risken för erosion.
Projektets resultat visade att optimering av luftens flödeshastighet kunde förbättra transport-effektiviteten av katodmaterial avsevärt. Genom att sänka luftens flödeshastighet kunde vi visa en minskad risk för erosion och minskad strömförbrukning.
Optimeringen av pneumatiska transportsystem för katodmaterial har stor betydelse för industriella tillämpningar. Genom att effektivisera transportprocessen kan företag minska produktionskostnaderna och förbättra kvaliteten på de tillverkade produkterna. Resultaten från detta projekt ger en värdefull insikt i de optimala inställningarna för att transportera katodmaterial och kan användas som vägledning för att optimera befintliga transportsystem eller designa nya system för framtida tillverkning. (Less)
Please use this url to cite or link to this publication:
http://lup.lub.lu.se/student-papers/record/9119714
- author
- Delden, Filip LU
- supervisor
- organization
- course
- KETM05 20231
- year
- 2023
- type
- H2 - Master's Degree (Two Years)
- subject
- keywords
- Pneumatic Conveying, Cathode Active Material (CAM), Computational Fluid Dynamics (CFD), Simulation, Eulerian, Lagrangian, Erosion Minimization, Power Minimization, Chemical Engineering
- language
- English
- id
- 9119714
- date added to LUP
- 2023-06-22 10:44:33
- date last changed
- 2023-06-22 10:44:33
@misc{9119714,
abstract = {{This master thesis explores the mechanisms and optimization strategies of a pneumatic conveying system. By investigating the impact of process parameters on power consumption and erosion rate, the aim was to provide valuable insights for system design and operation. The research combines theoretical considerations, CFD simulations, and numerical calculations to analyse the behaviour of the system under various conditions. The findings provide a foundation for future research and development in the field, paving the way for improved system design and operation.
The thesis begins by examining power optimization in pneumatic conveying systems. Through simulations conducted in COMSOL and numerical calculations in Python, pressure drop curves are evaluated for different mass flows of air and solids. The results indicate that the minimum pressure drop occurs in the range 0.25-0.35 kg/s of air for all solids mass flows. Surprisingly, it is observed that the mass flow of air has a greater influence on power consumption than the mass flow of solids. The study suggests using the lowest possible air mass flow while ensuring successful conveying and recommends further investigations into the saltation- and choking velocity specific to the conveyed material.
Furthermore, the thesis addresses the issue of erosion in pneumatic conveying systems. Eulerian-Lagrangian simulations conducted in COMSOL reveal that the gas velocity significantly impacts the pipe erosion rate, exhibiting an exponential dependence. The research proposes minimizing the gas velocity to minimize erosion and recommends investigating the lowest achievable velocity before blockages occur due to saltation or choking.
To enhance the accuracy of simulations and its relevance to industrial systems, the study suggests incorporating pressure gauges at the inlet and outlet of the transport line. This addition would enable the acquisition of precise pressure drop data during material transportation and allow for the comparison and evaluation of simulation results.}},
author = {{Delden, Filip}},
language = {{eng}},
note = {{Student Paper}},
title = {{CFD Simulation of Gas-Solid Two-Phase Flow in Pneumatic Conveying of Cathode Active Material}},
year = {{2023}},
}