Modeling of a Reverse Flow Reactor for Methanol Synthesis Modeling of a Reverse Flow Reactor for Methanol Synthesis

An accurate one-dimensional, heterogeneous model taking account of axial dispersion and heat transfer to the reactor wall, and heat conduction through the reactor wall for methanol synthesis in a bench scale reactor under periodic reversal of flow direction is presented. Adjustable parameters in this model are the effectiveness factors for each of the three reactions occurring in the synthesis and a factor for the bed to wall heat transfer coefficient correlation. Experimental data were used to evaluate these parameters and reasonable values of these parameters were obtained. The model was found to closely predict the reactor performance under a wide range of operating conditions, such as carbon oxide concentrations, volumetric flow rate, and cyclic period.     

流向变换强制周期操作合成甲醇反应器的模型化

An accurate one-dimensional,heterogeneous model taking account of axial dispersion and heat transfer to the reactor wall,and heat conduction through the reactor wall for methanol synthesis in a bench scale reactor under periodic reversal of flow direction is presented.Adjustable parameters in this model are the effectiveness factors for each of the three reactions occurring in the synthesis and a factor for the bed to wall heat transfer coefficient correlation.Experimental data were used to evaluate these parameters and reasonable values of these parameters were obtained.The model was found to closely predict the reactor performance under a wide range of parameters were obtained.The model was found to closely predict the reactor preformance under a wide range of operating conditions,such as carbon oxide concentrations,volumetric flow rate,and cyclic period.     

A Numerical Study on Fully Developed Fluid Flow and Heat Transfer in a Spiral Finned Tube

In this paper, the standard k-εtwo-equation model is adopted to numerically simulate fully developed fluid flow and heat transfer in a spiral finned tube within a cracking furnace for ethylene manufacturing. By variable transformation, the orlglnal 3-D problem is converted into a 2-D problem in spiral coordinates. The algorithm of SIMPLEC is used to study the fully developed fluld flow and heat transfer in the spiral finned tube at constant periphery temperature and constant axial heat flux, The computed results agree pretty well with the experimental data obtained from the industry, Further studies on the fluid flows and temperature profiles at different Reynolds numbers within straight and spiral finned tubes are conducted and the mechanisms involved are explored. It is found that with the spiral finned tube, pressure drop increases to a great extent whereas heat transfer tends to be decreased.     

Molten waste plastic pyrolysis in a vertical falling film reactor and the influence of temperature on the pyrolysis products

Molten plastics are characterised with high viscosity and low thermal conductivity. Applying falling film pyrolysis reactor to deal with waste plastics can not only improve heat transfer efficiency, but also solve the flow problem.In this work, the pyrolysis process of molten polypropylene(PP) in a vertical falling film reactor is experimentally studied, and the influence of heating temperature on pyrolysis products is discussed. It has been found that with the temperature increases from 550 ℃ to 625 ℃, the yield of pyrolysis oil decreases from 74.4 wt%(± 2.2 wt%) to53.5 wt%(±1.3 wt%). The major compositions of the pyrolysis oil are C_9, C_(12) and C_(18), and β-scission reactions are predominant. The content of the light fraction C_6-C_(12) of pyrolysis oil is 69.7 wt%. Compared with other pyrolysis reactors, the yield of oil from vertical falling film pyrolysis reactor is slightly higher than that from tubular reactor,equal to that from rotary kiln reactor, and slightly lower than that in medium fluidised-bed reactor.     

基于MUSIG模型的竖直圆管内液氮过冷沸腾数值模拟研究(英文)

Multiple size group （MUSIG） model combined with a threedimensional twofluid model were em ployed to predict subcooled boiling flow of liquid nitrogen in a vertical upward tube. Based on the mechanism of boiling heat transfer, some important bubble model parameters were amended to be applicable to the modeling of liquid nitrogen. The distribution of different discrete bubble classes was demonstrated numerically and the distribu tion patterns of void fraction in the wallheated tube were analyzed. It was found that the average void fraction in creases nonlinearly along the axial direction with wall heat flux and it decreases with inlet mass flow rate and sub cooled temperature. The local void fraction exhibited a Ushape distribution in the radial direction. The partition of the wall heat flux along the tube was obtained. The results showed that heat flux consumed on evaporation is the leading part of surface heat transfer at the rear region of subcooled boiling. The turning point in the pressure drop curve reflects the instability of bubbly flow. Good agreement was achieved on the local heat transfer coefficient aalnst experimental measurements, which demonstrated the accuracy of the numerical model.     

扭带管内高湿空气对流凝结换热三维数值模拟(英文)

A three-dimensional numerical model is presented for studying the convection-condensation of mixture with vapor in a tube with edgefold-twisted-tape inserts under transition flow.According to the diffusion layer theory and laminar species transport,a condensation model with user defined function is proposed and compared with heat and mass transfer analogy and experimental test.With the condensation model,the influences of gap width and op-erating parameters on thermal-hydrodynamics performance are simulated.As the gap width increases,convection and condensation heat transfer increase initially and then decrease,while convection heat transfer increases sharply and then decreases slightly.Increasing vapor fraction has a significant effect on condensation heat transfer but it has little effect on convective heat transfer.With the increase of inner wall temperature both convection and condensa-tion heat transfer all decrease and the ratio of condensation to total heat decrease dramatically.Increases inlet tem-perature mainly affects convection heat transfer.     

Multi-fluid Eulerian simulation of binary particles mixing and gas–solids contacting in high solids-flux downer reactor equipped with a lateral particle feeding nozzle

The performance of binary particles mixing and gas-solids contacting,which is considered qualitatively to have a significant influence on the heat transfer in internal heated circulating fluidized beds,is carefully investigated by means of a numerical approach in the newly developed high solids-flux downer lignite pyrolyzer(φ0.1 m × 6.5 m).Since binary particles are used in this system,a reasonably validated 3 D,transient,multi-fluid model,in which three heat transfer modes relating to the convection,conduction and radiation are considered,is adopted to simulate the flow behavior,temperature profiles as well as volatile contents.The simulation results showed that the solids stream impinges the left wall surface initially and turns towards the right wall in the further downward direction and then shrinks during this process resulting in that the solids concentrate a little more at the central region.In the further downward section of the downer,the particle flow disperses near the right wall and develops uniformly.Meanwhile,the coal phase is slowly heated in the downer and it is found that most of the heat absorbed by the coal is from the convection heat transfer mode.To explore the heat transfer mechanism more quantitatively,two indexes(mixing index and contacting index) are proposed,and it is found that the mixing index initially increased fast and later remained at a relatively flat state.For the contact index,it shows a trend with a first rising and then falling,finally rising continuously.Also,it is found that the convection heat transfer is closely correlated to the contacting status of gas-coal which indicates that the improving of the gas-coal contacting efficiency should be an effective way to strengthen the coal particle heating process.     

装填有矩形切口螺旋带的管中的湍动传热和压降(英文)

Heat transfer, friction factor and thermal enhancement factor characteristics of a double pipe heat exchanger fitted with square-cut twisted tapes (STT) and plain twisted tapes (PTT) are investigated experimentally using the water as working fluid. The tapes (STT and PTT) have three twist ratios ( , 4.4 and 6.0) and the Reynolds number ranges from 2000 to 12000. The experimental results reveal that heat transfer rate, friction factor and thermal enhancement factor in the tube equipped with STT are significantly higher than those fitted with PTT. The additional disturbance and secondary flow in the vicinity of the tube wall generated by STT are higher compared to that induced by the PTT is referred as the reason for better performance. Over the range considered, the Nusselt number, friction factor and thermal enhancement factor in a tube with STT are respectively, 1.03 to 1.14, 1.05 to 1.25 and 1.02 to 1.06 times of those in tube with PTT. An empirical correlation is also formulated to match with experimental data of Nusselt number and friction factor for STT and PTT.     

带V型折流板圆管中流动结构与传热的三维数值研究(英文)

A 3D numerical investigation has been carried out to examine periodic laminar flow and heat transfer character-istics in a circular tube with 45° V-baffles with isothermal wal . The computations are based on the finite volume method (FVM), and the SIMPLE algorithm has been implemented. The fluid flow and heat transfer characteristics are presented for Reynolds numbers ranging from 100 to 2000. To generate main longitudinal vortex flows through the tested section, V-baffles with an attack angle of 45° are mounted in tandem and in-line arrangement on the opposite positions of the circular tube. Effects of tube blockage ratio, flow direction on heat transfer and pressure drop in the tube are studied. It is apparent that a pair of longitudinal twisted vortices (P-vortex) created by a V-baffle can induce impingement on a wal of the inter-baffle cavity and lead a drastic increase in heat trans-fer rate at tube wall. In addition, the larger blockage ratio results in the higher Nusselt number and friction factor values. The computational results show that the optimum thermal enhancement factor is around 3.20 at baffle height of B=0.20 and B=0.25 times of the tube diameter for the V-upstream and V-downstream, respectively. ? 2014 The Chemical Industry and Engineering Society of China, and Chemical Industry Press. Al rights reserved.     

Understanding the influence of microwave on the relative volatility used in the pyrolysis of Indonesia oil sands

In this paper, pyrolysis of Indonesian oil sands(IOS) was investigated by two different heating methods to develop a better understanding of the microwave-assisted pyrolysis. Thermogravimetric analysis was conducted to study the thermal decomposition behaviors of IOS, showing that 550 °C might be the pyrolysis final temperature. A explanation of the heat–mass transfer process was presented to demonstrate the influence of microwave-assisted pyrolysis on the liquid product distribution. The heat–mass transfer model was also useful to explain the increase of liquid product yield and heavy component content at the same heating rate by two different heating methods. Experiments were carried out using a fixed bed reactor with and without the microwave irradiation. The results showed that liquid product yield was increased during microwave induced pyrolysis,while the formation of gas and solid residue was reduced in comparison with the conventional pyrolysis. Moreover, the liquid product characterization by elemental analysis and GC–MS indicated the significant effect on the liquid chemical composition by microwave irradiation. High polarity substances(ε N 10 at 25 °C), such as oxyorganics were increased, while relatively low polarity substances(ε b 2 at 25 °C), such as aliphatic hydrocarbons were decreased, suggesting that microwave enhanced the relative volatility of high polarity substances. The yield improvement and compositional variations in the liquid product promoted by the microwave-assisted pyrolysis deserve the further exploitation in the future.     

Modelling and dynamic optimization of thermal cracking of propane for ethylene manufacturing

In tubular reactors inside a cracking furnace, heat transfer, thermal cracking reactions and coke buildup take place and closely interact with each other. It is important to understand the process and optimize its operation. A 1-dimensional (1D) pseudo-dynamic model was developed based on first principle and implemented in gPROMS^®. Coke buildup inside the tube wall was also accounted for. The model was validated dynamically. The impact of process gas temperature profile, and constant tube outer wall temperature profile on product yields and coking rate are assessed. Finally, dynamic optimization was applied to the operation of this tubular reactor. The effects of coking on reduction of production time and the decoking cost have been considered. The tube outer wall temperature profile and steam to propane ratio in the feed were used as optimization variables. Dynamic optimization investigation indicates that it can improve operating profit by 13.1%.     

Combustion and Pyrolysis Reactions in a Naphtha Cracking Furnace

Numerical simulation on combustion and pyrolysis reactions in a tubular reactor is carried out on a 100,000 t/a naphtha cracking furnace. A complex arrangement of bottom burners is contained in the furnace model. The hydrodynamic and radiation models are included for calculating the flue gas flow pattern and heat transfer. A molecular reactions model is applied on the basis of a two‐dimensional tubular reactor model. The results calculated indicate that there is recirculation of the flue gas at each side of the reactor tubes due to the high inlet velocity from the bottom burners, which contributes to the uniformity of flue gas temperature in the furnace. Higher temperature profiles of the tube skin are mainly located 15–20 m along the tubular reactor. The calculated pyrolysis product yield and the tube skin temperatures are in good agreement with experimental data.     

Wall-resolved large eddy simulation of turbulent flows in helically ribbed steam cracker reactors

Helically ribbed coils are commonly applied in steam cracking furnaces. To fully understand the impact of these ribbed wall modifications on the local heat transfer and associated pressure drop throughout the reactor, detailed experimental, and numerical studies have been performed. Experimental data based on stereo-particle image velocimetry (S-PIV) and liquid crystal thermography have been used to validate the numerical results from wall-resolved large eddy simulations using OpenFOAM. The validation shows an excellent agreement in terms of mean and fluctuating velocities, pressure drop, and heat transfer behavior in a discontinuously ribbed tube. Compared with the pressure drop in a continuously ribbed tube, an approximately 40% lower pressure drop is obtained with a discontinuously ribbed tube, at the cost of a slightly decreased heat transfer enhancement. This makes the discontinuously ribbed tube design particularly interesting for steam cracking applications. The results also show that the nonuniform heat transfer at the wall is inherently linked to the flow reattachment and recirculation zones caused by the rib. Finally, the validated numerical model was used to study comparable designs and propose novel helical rib designs. Based on the results of the study, enlarging the trailing edge of the conventional ribbed geometry will improve the thermal enhancement performance, and is therefore found most promising for steam cracking reactor design.     

Secondary Cracking of C4 Hydrocarbons from Heavy Oil Catalytic Pyrolysis

For C4 hydrocarbons from heavy oil catalytic pyrolysis, the cracking behaviours on catalyst CEP‐1 and quartz sand were investigated in a confined fluidized bed reactor. C4 hydrocarbons show a good cracking ability on CEP‐1, and butene is easier to convert than butane. Only at high reaction temperatures can butane present a good cracking ability. On catalyst CEP‐1, C4 hydrocarbons can undergo not only cracking reactions, but also such reactions as hydrogen transfer, polymerization and aromatization. The conversion of C4 hydrocarbons thermal pyrolysis is high, indicating that free radical reactions play an important part in the secondary cracking of C4 hydrocarbons. The product yields of C4 hydrocarbons pyrolysis on quartz sand are usually lower than those on catalyst CEP‐1. For both catalytic pyrolysis and thermal pyrolysis of C4 hydrocarbons, the selectivity of propene is higher than that of ethene.     

乙烯裂解炉石脑油裂解反应的数值模拟

以 SL-Ⅱ型乙烯裂解炉反应管为对象,结合烯烃厂裂解工艺参数,对管内石脑油裂解反应过程进行了模拟研究。裂解反应模型采用 Kumar 提出的分子反应模型,模拟得到了管内油气流速、温度、裂解产物的变化规律。结果表明,近壁层流层的存在使得管内油气径向速度、温度梯度较大,二维管内模型可以更全面地描述裂解反应过程。模拟得到的裂解产物收率与裂解炉的生产运行数据进行了比较,两者基本一致,验证了裂解反应模型的合理性。     

Dynamic Modeling and Simulation of Steam Cracking Furnaces

The transient modeling of thermal cracking furnaces is developed. This representation is capable of describing and predicting the unsteady‐state behavior of cracking furnaces during start‐up. To accurately predict the heat transfer to the reactor tube, the fireside conditions are coupled with the process side. The mutual interaction of these two sections is found to be very stiff in terms of convergence of the computations. The two‐dimensional transient zone model is developed for the radiative heat exchange calculation. A simplified model for the convection section is also used to predict the crossover temperature at each time increment. The main simulation outputs are the flue gas properties as well as the distributions of heat flux, refractory wall and coil skin temperatures versus time. The dynamic simulation is implemented for a conventional procedure used in the start‐up run of the olefin furnaces.     

碳氢燃料热裂解与引发裂解换热对比实验

通过流动管反应器对碳氢燃料RP-3在超临界条件下的热裂解及引发裂解进行了实验,对两种条件下的燃料吸热能力及传热特性进行了对比分析,并对裂解产物进行了采样分析。结果表明,引发裂解降低了燃料的裂解起始温度,在一定温度区间内提高了燃料的裂解率,从而有效提高了燃料热沉,在相同热通量条件下,降低了燃料温度,并降低了加热段壁面温度。对流换热受化学反应及物性变化的影响,燃料裂解吸热可增强换热,而大量气态产物的生成会降低换热,因此,裂解反应的增强不一定增强换热。     

超临界压力正癸烷在螺旋管中传热与裂解吸热现象的数值模拟

探讨了正癸烷的裂解吸热反应对流动、传热和化学组分分布的影响。结果表明,由于裂解吸热反应把加热热量转换成了燃料分子的化学能,与未考虑热裂解的计算结果相比,考虑裂解反应时出口处流体平均温度降低了约50 K,壁面温度降低了约70 K,对流传热系数提高了10%左右。这一方面是因为裂解引起的密度降低、轴向速度增加,另一方面是由于裂解反应提高了螺旋管截面的径向速度,加强了二次流动,增加了壁面湍动能。正癸烷在内侧温度较高的区域裂解度较高,因此螺旋管内侧温度降低,环向温度分布变均匀;裂解度越大,环向温度分布越均匀。与热结焦有关的烯烃类裂解产物C₂H₄,C₃H₆在温度较高的内侧质量分数较大,表明结焦更可能发生在螺旋管的内侧。     

Quench time modeling in propane ultrapyrolysis

Pyrolysis products from industrial cracking furnaces are commonly quenched indirectly in transfer line heat exchangers (TLX). To assess the performance of a TLX for a high severity furnace, a rigorous computer simulation of a TLX tube has been developed. The primary objective was to determine whether this method of indirect quenching can provide the extremely small quench times required for fast ultrapyrolysis reactions. Results indicate that extremely small quench times of approximately 10–15 ms can be achieved, typically dropping the temperature from 1100 to 900K. The model takes into account the effect of the thermal entrance region on heat transfer characteristics and can employ either a 10 equation molecular reaction scheme or an 80 equation radical reaction scheme for propane pyrolysis. The effects of adjusting the main process variables and of coke deposition on quenching performance are also discussed.     

移动床中内构件对煤热解反应过程调控作用

在外热式内构件（多级折流板和多段集气管）移动床反应器内研究了淖毛湖煤的热解特性,并与常规固定床反应器中煤热解行为进行对比,考察了两反应器内的传热速率以及热解温度对产物分布、热解气组成、焦油组成和品质等影响规律。结果表明：在450℃低温热解时,煤颗粒在内构件移动床内的升温时间比固定床缩短了60%以上,内构件具有显著提高反应器内颗粒间传热速率的作用。随着热解温度的升高,热解气中的C₂H₄/C₂H₆和C₃H₆/C₃H₈的比值变大,挥发分的二次反应程度加大,但裂解程度低于固定床。内构件移动床中的焦油产率随温度的升高先增加后降低,在550℃时达到最高为10.8%（质量分数）,比固定床增高约28.6%。当热解温度越高时,移动床所产焦油中的沥青质组分含量越低,在750℃时焦油中轻质组分质量分数达到85.17%,脂肪烃含量降低到了28.00%。通过与固定床对比,揭示了内构件（多级折流板和集气管）调控淖毛湖煤热解反应并提高热解焦油产率和品质的作用。