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2 Polish Journal of Chemical Technology

2 2024

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Numerical modeling of heat transfer and flow field in a novel calcinator

Zhou Tie-zhuang, Yang Bin, Wang Cheng-qiang

Polish Journal of Chemical Technology

2024

Vol. 26, nr 2

31--41

This study focused on investigating the heat transfer and flow dynamics of a catalyst granule within a pilot calciner, employing both numerical modeling and computational fluid dynamics. The research comprised two primary components: (1) Simulation of the gas flow within the pilot calciner using the Eulerian–Eulerian approach, treating gases and catalyst particles as distinct phases – gas and granular. The model, encapsulating both heat transfer and flow processes, was developed in Fluent software version 16.0. Its accuracy was confirmed against empirical data from a pilot-scale calciner unit. (2) Subsequent to validation, the model was utilized to examine the distribution characteristics within the flow field, including the temperature profiles of gas and particles, the vector velocity field of the gas across different phases, and the overall heat transfer coefficient. This investigation aims to enhance the understanding of the complex heat transfer and flow dynamics in calciners, facilitating the optimization of operational parameters, performance, and structure of pilot-scale equipment. Furthermore, it provides foundational data pertinent to the future exploration of real-world industrial applications.

Impact of structure parameters on the critical performance of a novel calciner—a DEM-based study

Zhou Tiezhuang, Zhang Fagen, Xu Run, Gao Yan, Xie Genghua, Xiao Kai, Yang Bin, Jiang Wenchun

Polish Journal of Chemical Technology

2024

Vol. 26, nr 4

25--33

Fracture in a revolving tube due to creep deformation and thermal-mechanical fatigue is a growing concern in industrial equipment research and production, especially after long-term exposure to corrosion and high-temperature conditions in roasting furnaces. The calcination temperature and residence time are crucial in the catalyst production process, with optimal conditions en-hancing catalyst activity and stability. To improve the longevity of roasting furnaces, optimizing the construction structure of the calciner is critical. This study develops a novel calciner structure and mathematical models to understand the effect of structural parameters on critical performance. Computer simulations, predictive modelling, and rotational velocity analysis of the novel calciner were performed using a DEM. The effects of the baffle angle and overlap ratio on the flow pattern and MRT were studied through simulations and experiments. The main conclusions are as follows: (1) The operating parameter with the greatest effect on the MRT was the rotational angular velocity, followed by the baffle angle and overlap ratio. (2) The MRT calculation based on the numerical method model showed an error of no more than 10.0% compared to the actual measurement data, confirming the model’s accuracy. Our study provides a theoretical foundation for a deeper understanding of the complex MRT and flow field processes within this novel calciner. It also aids in optimizing the working parameters, performance, and structure of pilot equipment while offering fundamental data for future industrial applications.