EnSight: A Powerful Tool for Visualizing Fluid Flow Coupled with ...
EnSight: A Powerful Tool for Visualizing Fluid Flow Coupled with Particle Simulation
Nicolas Spogis, Ph.D. Business Coordinator E-mail: [email protected]
Daniel Schiochet Nasato Business Analist E-mail: [email protected]
Acknowledgements Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods Andrew Hobbs Research Engineer Astec, Inc.
Simulation of Grain Cleaning System Using Coupled CFD, DEM and FEA Methods Alberto Hö her Junior Product Engineering - Combines AGCO do Brasil
www.esss.com.br
Agenda • ESSS – The company • Multi-physics – Coupled Physics
• Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods • Simulation of Grain Cleaning System Using Coupled CFD, DEM and FEA Methods • Concluding Remarks www.esss.com.br
“Developing scientific software and providing leading-edge technology for engineering problems, ESSS brings to the market know-how in numerical methods and computer science available only in advanced research centers.”
Appliances EMBRACO WHIRLPOOL ELECTROLUX CARRIER WEG TECUMSEH ARNO
Aerospace EMBRAER CTA INPE CONIDA EQUATORIAL
Auto
ALSTOM DAIMLER SIEMENS FORD VDO LUK MAHLE
Oil & Gas PETROBRAS MAERSK LINE SAUDI ARAMCO PDVSA CHEVRON STATION EXXONMOBIL
Metals MAGNESITA CSN ARCELORMITTAL VALE CODELCO GERDAU
Turbomachinery ALSTOM EDELCA IMPSA KSB VOITH EAFIT THEBE
~ 500 Customers www.esss.com.br
Team
Divisions Computer Aided Engineering
Sales Support Training Consulting
~100 Members
Offices Software Development
Custom Software Development Software Customization
www.esss.com.br
Multi-Physics
www.esss.com.br
Multi-physics • As companies start producing
more innovative and higher Fluids
quality products, the simulation of individual physics is no longer adequate for the design of many
Thermal
Structural
products. • Multi-physics simulation allows engineers and designers to
+ -
evaluate their designs operating
DEM u(t)
D(s)
Plant
y(t)
Emag
under real-world conditions.
www.esss.com.br
Why do Coupled Simulations? • Most industrial processes involve more than one type of physics • In many problems, the surrounding fluid effects the particulate phase or the structure and vice versa • Often, continuum methods alone cannot capture bulk particle behavior, fluid/particle interaction or the particle/particle interaction • A multi-physics approach is needed: DEM (particle phase) +
CFD (fluid phase)
+
FEA (Structure)
www.esss.com.br
Multi-Physics Post-Processor - EnSight • EnSight allows engineers and designers to post-process the interaction between: – – – – – – –
Structural mechanics (FEA) Heat transfer (FEA, CFD) Fluid flow (CFD) Acoustics (FEM) Particles (DEM) Electromagnetics (FEM) Import CAD Geometries
• All within a single interface!
www.esss.com.br
CFD-DEM Coupling
www.esss.com.br
Characteristics of particle-fluid systems • Dilute – Cyclone separation – Agitation: fluidized and spouted beds – Entrainment: erosion, cleaning
• Dilute dense – Filtration, sedimentation
• Dense – Dense phase conveying – Slurry transport – Mixing
www.esss.com.br
EDEM / FLUENT Coupling • EDEM can be coupled with ANSYS-FLUENT for simulation of multi-phase flows at the particlescale.
• The coupling enhances ANSYS-FLUENT multiphase models by including particle characteristics (size distribution, shape, mechanical properties, surface forces, etc.) which strongly influence both particle and fluid dynamics
www.esss.com.br
EDEM / FLUENT Coupling Method
Fluid velocity vector
FLUENT iterated to convergence
Drag forces on DEM particles calculated
DEM iteration performed
Particle parameters updated
Momentum sinks / sources added to the CFD mesh cells
www.esss.com.br
Eulerian CFD-DEM Coupling Theory Particle Reynolds Number
Free Stream Drag Force
Fluid Mass Conservation
cellL v Re 24 / Re cD 24(1.0 0.25 Re0.687) / Re 0.44
Fd 0.5cD A v v
Re 0.5 0.5 Re 1000 Re 1000
F F F F vF 0 t n
Momentum Conservation
F
F F vF F F vF vF F p F F F g i t V
D
www.esss.com.br
Eulerian CFD-DEM Coupling Theory Heat Transfer
QPF hPF AP TPF
Ranz & Marshall
Nu 2 0.6 Re1P/ 2 Pr1 / 3
Li & Mason
hPF
K F Nu P dP
2 0.6 Fn Re1P/ 2 Pr1 / 3 Re P 200 Nu 2 0.5 Fn Re1P/ 2 0.02 Fn Re 0P.8 Pr1 / 3 200 Re P 1500 5 n 1.8 2 4 . 5 e Re Re P 1500 F P
Mass fraction calculated using sample points
m p t
particles
p ncVp N
www.esss.com.br
DEM-FEA Coupling
www.esss.com.br
Multi-Physics • The ANSYS Multi-field solver provides the ability to solve coupled-field problems such as the following: – MEMS Actuation (electrostatic/structural without fluid coupling) – Electric Machines (magneto/thermal/structural coupling) – Joule Heating (thermal/electric/structural coupling)
– Induction Heating (harmonic electromagnetic/thermal coupling) – Induction Stirring (harmonic electromagnetic/thermal/fluid coupling) – RF Heating (high-frequency electromagnetic/thermal/structural coupling) – Thermal/Stress Analysis (thermal/structural coupling) – Fluid Solid Interaction Analysis (fluid/structural coupling)
ESSS and DEM Solutions are implementing
EDEM / ANSYS Coupling
www.esss.com.br
EDEM / ANSYS Coupling • EDEM simulates the geometry movement and calculate loads on the structure due to particle interaction • ANSYS calculates the stresses using loadsets provided by EDEM.
EDEM Model
Interpolate loads on ANSYS mesh
• Objective – Prediction of structural response for different geometries and materials.
Solve ANSYS Model
www.esss.com.br
DEM-FEA Coupling Procedures • 1-Way DEM-FEA
developed
– Coupling - Steady State
EDEM
– Get one time-step EDEM result and interpolate loads on ANSYS Mesh
Under development
ANSYS
•
1-Way DEM-FEA – Coupling - Transient
EDEM
– Transient EDEM loads interpolated on ANSYS Mesh – Load Steps
•
2-Way DEM-FEA – Coupling - Transient
ANSYS
www.esss.com.br
Bucket Search Method • The bucket search method is designed to alleviate the inefficiency problem that the global method has when the number of nodes increases. • Interpolation Methods: – – •
Conservative interpolation Profile preserving interpolation
Computational Nonlinear Mechanics in Aerospace Engineering, American Institute of Aeronautics and Astronautics, edited by S. Atluri, ISBN 1563470446, Chapter 5, Fast Projection Algorithm for Unstructured Meshes by K. Jansen, F. Shakib, and T. Hughes, 1992.
Area-weighted Interpolation
www.esss.com.br
EDEM-ANSYS 1-Way Coupling Setup ANSYS Model
Create Named Surface
Run EDEM Model Export EDEM Loads
Interpolate Loads With APDL
Solve and Evaluate ANSYS Results
www.esss.com.br
Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods
Andrew Hobbs Research Engineer Astec, Inc.
www.esss.com.br
Astec Industries, Inc. America’s leading manufacturer of equipment for aggregate processing, asphalt road building and pipeline and utility trenching
• 2007 Revenues $869 million • Asphalt Group $240 million Astec, Inc. (Asphalt Group) based in Chattanooga, Tennessee
www.esss.com.br
Drying Rock in a HMA Drum Mixer • Hot Mix Asphalt (HMA) is made of various sizes of rock aggregates mixed with liquid asphalt cement (AC) binder • For the binder to adhere properly the aggregate must be completely dry • 5% aggregate moisture is common for most locations • Plant output of 350 Tons per hour = 35,000 lbs/hr H2O
• Approximately half total heat input goes towards the evaporation of H2O
Drying efficiency is a key aspect of the HMA production process
www.esss.com.br
Drying Rock in a HMA Drum Mixer Wet material in Burner
Dry material out
www.esss.com.br
FLUENT Parameters • Hex/tet hybrid mesh 1.7 million cells • Eulerian multiphase • Realizable k-ε • Eddy Dissipation with 2 step CH4 reaction • Premixed fuel/air velocity inlet • Adiabatic wall conditions
Fluent 6.3
www.esss.com.br
Coupled Simulation Methodology • Geometry creation
• FLUENT grid without interior features • Converge steady, multiphase FLUENT case with reacting natural gas flame • Change to FLUENT case to unsteady • Setup EDEM, rotating drum with interior features
• Couple to EDEM as E-E with heat transfer between phases • Run….
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation of Grain Cleaning System using Coupled CFD, DEM and FEA Methods
Alberto Höher Junior Product Engineering - Combines
AGCO do Brasil
www.esss.com.br
Agricultural Innovations
• Massey Ferguson is part of AGCO Corporation. As an individual brand, it is one of the biggest names in farm equipment throughout the world with a 150 year history and heritage that confirms its leading role in global agriculture. • MF is truly international in its breadth of experience and sells its products in more than 140 countries through a network of over 5000 dealers.
www.esss.com.br
Grain Cleaning System Simulation Initial Studies • Objective: –
Simulate Straw material and Soybean separation on a Cleaning System
• Straw Material modeled as 14 spheres of 3mm radius
• Soy grain – 3mm radius
www.esss.com.br
Cleaning System • An 11 inch or 13 inch diameter fan assures high volume, low pressure air flow for increased cleaning capacity and exceptional grain quality. • EDEM + FLUENT+ ANSYS Analysis – Evaluate particles trajectory. – Ensure good particles separation.
• Identify the ideal air velocity: – To carryon raw material – Keep the grains on the screens
• EDEM / ANSYS Analysis – Evaluate possible grain waste and wear.
www.esss.com.br
Cleaning System Details
Outlet (storage)
Grain transport
Particles Inlet
Air blower
Grain / raw material separation
www.esss.com.br
Vibrating Screens Details Displacement: y = 18.7mm z= 58.4mm frequency 5.67Hz
Air Blower Top Screen
displacement: y = 17.9mm z= 81.4mm frequency 5.67Hz
Air Blower Bottom Screen Feed distributor
www.esss.com.br
Air Blow System Details
Particle Inlet from Feed distributor
Air: 10m/s
Air: 6m/s
www.esss.com.br
Simulation Results Outlet to Storage Particles Inlet
Screw Auger Separated Soybeans
Screw Auger Particles Recirculation
www.esss.com.br
Simulation Results
www.esss.com.br
Thank You! – Andrew Hobbs - Astec, Inc.
– Höher Junior - AGCO do Brasil – All CEI staff, especially Darin McKinnis and Amanda Baley – Sriram Ramanathan - DEM Solutions – Fabiano Nunes Diesel - ESSS Brazil
www.esss.com.br
Nicolas Spogis, Ph.D. Business Coordinator E-mail: [email protected]
Daniel Schiochet Nasato Business Analist E-mail: [email protected]
Acknowledgements Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods Andrew Hobbs Research Engineer Astec, Inc.
Simulation of Grain Cleaning System Using Coupled CFD, DEM and FEA Methods Alberto Hö her Junior Product Engineering - Combines AGCO do Brasil
www.esss.com.br
Agenda • ESSS – The company • Multi-physics – Coupled Physics
• Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods • Simulation of Grain Cleaning System Using Coupled CFD, DEM and FEA Methods • Concluding Remarks www.esss.com.br
“Developing scientific software and providing leading-edge technology for engineering problems, ESSS brings to the market know-how in numerical methods and computer science available only in advanced research centers.”
Appliances EMBRACO WHIRLPOOL ELECTROLUX CARRIER WEG TECUMSEH ARNO
Aerospace EMBRAER CTA INPE CONIDA EQUATORIAL
Auto
ALSTOM DAIMLER SIEMENS FORD VDO LUK MAHLE
Oil & Gas PETROBRAS MAERSK LINE SAUDI ARAMCO PDVSA CHEVRON STATION EXXONMOBIL
Metals MAGNESITA CSN ARCELORMITTAL VALE CODELCO GERDAU
Turbomachinery ALSTOM EDELCA IMPSA KSB VOITH EAFIT THEBE
~ 500 Customers www.esss.com.br
Team
Divisions Computer Aided Engineering
Sales Support Training Consulting
~100 Members
Offices Software Development
Custom Software Development Software Customization
www.esss.com.br
Multi-Physics
www.esss.com.br
Multi-physics • As companies start producing
more innovative and higher Fluids
quality products, the simulation of individual physics is no longer adequate for the design of many
Thermal
Structural
products. • Multi-physics simulation allows engineers and designers to
+ -
evaluate their designs operating
DEM u(t)
D(s)
Plant
y(t)
Emag
under real-world conditions.
www.esss.com.br
Why do Coupled Simulations? • Most industrial processes involve more than one type of physics • In many problems, the surrounding fluid effects the particulate phase or the structure and vice versa • Often, continuum methods alone cannot capture bulk particle behavior, fluid/particle interaction or the particle/particle interaction • A multi-physics approach is needed: DEM (particle phase) +
CFD (fluid phase)
+
FEA (Structure)
www.esss.com.br
Multi-Physics Post-Processor - EnSight • EnSight allows engineers and designers to post-process the interaction between: – – – – – – –
Structural mechanics (FEA) Heat transfer (FEA, CFD) Fluid flow (CFD) Acoustics (FEM) Particles (DEM) Electromagnetics (FEM) Import CAD Geometries
• All within a single interface!
www.esss.com.br
CFD-DEM Coupling
www.esss.com.br
Characteristics of particle-fluid systems • Dilute – Cyclone separation – Agitation: fluidized and spouted beds – Entrainment: erosion, cleaning
• Dilute dense – Filtration, sedimentation
• Dense – Dense phase conveying – Slurry transport – Mixing
www.esss.com.br
EDEM / FLUENT Coupling • EDEM can be coupled with ANSYS-FLUENT for simulation of multi-phase flows at the particlescale.
• The coupling enhances ANSYS-FLUENT multiphase models by including particle characteristics (size distribution, shape, mechanical properties, surface forces, etc.) which strongly influence both particle and fluid dynamics
www.esss.com.br
EDEM / FLUENT Coupling Method
Fluid velocity vector
FLUENT iterated to convergence
Drag forces on DEM particles calculated
DEM iteration performed
Particle parameters updated
Momentum sinks / sources added to the CFD mesh cells
www.esss.com.br
Eulerian CFD-DEM Coupling Theory Particle Reynolds Number
Free Stream Drag Force
Fluid Mass Conservation
cellL v Re 24 / Re cD 24(1.0 0.25 Re0.687) / Re 0.44
Fd 0.5cD A v v
Re 0.5 0.5 Re 1000 Re 1000
F F F F vF 0 t n
Momentum Conservation
F
F F vF F F vF vF F p F F F g i t V
D
www.esss.com.br
Eulerian CFD-DEM Coupling Theory Heat Transfer
QPF hPF AP TPF
Ranz & Marshall
Nu 2 0.6 Re1P/ 2 Pr1 / 3
Li & Mason
hPF
K F Nu P dP
2 0.6 Fn Re1P/ 2 Pr1 / 3 Re P 200 Nu 2 0.5 Fn Re1P/ 2 0.02 Fn Re 0P.8 Pr1 / 3 200 Re P 1500 5 n 1.8 2 4 . 5 e Re Re P 1500 F P
Mass fraction calculated using sample points
m p t
particles
p ncVp N
www.esss.com.br
DEM-FEA Coupling
www.esss.com.br
Multi-Physics • The ANSYS Multi-field solver provides the ability to solve coupled-field problems such as the following: – MEMS Actuation (electrostatic/structural without fluid coupling) – Electric Machines (magneto/thermal/structural coupling) – Joule Heating (thermal/electric/structural coupling)
– Induction Heating (harmonic electromagnetic/thermal coupling) – Induction Stirring (harmonic electromagnetic/thermal/fluid coupling) – RF Heating (high-frequency electromagnetic/thermal/structural coupling) – Thermal/Stress Analysis (thermal/structural coupling) – Fluid Solid Interaction Analysis (fluid/structural coupling)
ESSS and DEM Solutions are implementing
EDEM / ANSYS Coupling
www.esss.com.br
EDEM / ANSYS Coupling • EDEM simulates the geometry movement and calculate loads on the structure due to particle interaction • ANSYS calculates the stresses using loadsets provided by EDEM.
EDEM Model
Interpolate loads on ANSYS mesh
• Objective – Prediction of structural response for different geometries and materials.
Solve ANSYS Model
www.esss.com.br
DEM-FEA Coupling Procedures • 1-Way DEM-FEA
developed
– Coupling - Steady State
EDEM
– Get one time-step EDEM result and interpolate loads on ANSYS Mesh
Under development
ANSYS
•
1-Way DEM-FEA – Coupling - Transient
EDEM
– Transient EDEM loads interpolated on ANSYS Mesh – Load Steps
•
2-Way DEM-FEA – Coupling - Transient
ANSYS
www.esss.com.br
Bucket Search Method • The bucket search method is designed to alleviate the inefficiency problem that the global method has when the number of nodes increases. • Interpolation Methods: – – •
Conservative interpolation Profile preserving interpolation
Computational Nonlinear Mechanics in Aerospace Engineering, American Institute of Aeronautics and Astronautics, edited by S. Atluri, ISBN 1563470446, Chapter 5, Fast Projection Algorithm for Unstructured Meshes by K. Jansen, F. Shakib, and T. Hughes, 1992.
Area-weighted Interpolation
www.esss.com.br
EDEM-ANSYS 1-Way Coupling Setup ANSYS Model
Create Named Surface
Run EDEM Model Export EDEM Loads
Interpolate Loads With APDL
Solve and Evaluate ANSYS Results
www.esss.com.br
Simulation of an Aggregate Dryer Using Coupled CFD and DEM Methods
Andrew Hobbs Research Engineer Astec, Inc.
www.esss.com.br
Astec Industries, Inc. America’s leading manufacturer of equipment for aggregate processing, asphalt road building and pipeline and utility trenching
• 2007 Revenues $869 million • Asphalt Group $240 million Astec, Inc. (Asphalt Group) based in Chattanooga, Tennessee
www.esss.com.br
Drying Rock in a HMA Drum Mixer • Hot Mix Asphalt (HMA) is made of various sizes of rock aggregates mixed with liquid asphalt cement (AC) binder • For the binder to adhere properly the aggregate must be completely dry • 5% aggregate moisture is common for most locations • Plant output of 350 Tons per hour = 35,000 lbs/hr H2O
• Approximately half total heat input goes towards the evaporation of H2O
Drying efficiency is a key aspect of the HMA production process
www.esss.com.br
Drying Rock in a HMA Drum Mixer Wet material in Burner
Dry material out
www.esss.com.br
FLUENT Parameters • Hex/tet hybrid mesh 1.7 million cells • Eulerian multiphase • Realizable k-ε • Eddy Dissipation with 2 step CH4 reaction • Premixed fuel/air velocity inlet • Adiabatic wall conditions
Fluent 6.3
www.esss.com.br
Coupled Simulation Methodology • Geometry creation
• FLUENT grid without interior features • Converge steady, multiphase FLUENT case with reacting natural gas flame • Change to FLUENT case to unsteady • Setup EDEM, rotating drum with interior features
• Couple to EDEM as E-E with heat transfer between phases • Run….
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation Results
www.esss.com.br
Simulation of Grain Cleaning System using Coupled CFD, DEM and FEA Methods
Alberto Höher Junior Product Engineering - Combines
AGCO do Brasil
www.esss.com.br
Agricultural Innovations
• Massey Ferguson is part of AGCO Corporation. As an individual brand, it is one of the biggest names in farm equipment throughout the world with a 150 year history and heritage that confirms its leading role in global agriculture. • MF is truly international in its breadth of experience and sells its products in more than 140 countries through a network of over 5000 dealers.
www.esss.com.br
Grain Cleaning System Simulation Initial Studies • Objective: –
Simulate Straw material and Soybean separation on a Cleaning System
• Straw Material modeled as 14 spheres of 3mm radius
• Soy grain – 3mm radius
www.esss.com.br
Cleaning System • An 11 inch or 13 inch diameter fan assures high volume, low pressure air flow for increased cleaning capacity and exceptional grain quality. • EDEM + FLUENT+ ANSYS Analysis – Evaluate particles trajectory. – Ensure good particles separation.
• Identify the ideal air velocity: – To carryon raw material – Keep the grains on the screens
• EDEM / ANSYS Analysis – Evaluate possible grain waste and wear.
www.esss.com.br
Cleaning System Details
Outlet (storage)
Grain transport
Particles Inlet
Air blower
Grain / raw material separation
www.esss.com.br
Vibrating Screens Details Displacement: y = 18.7mm z= 58.4mm frequency 5.67Hz
Air Blower Top Screen
displacement: y = 17.9mm z= 81.4mm frequency 5.67Hz
Air Blower Bottom Screen Feed distributor
www.esss.com.br
Air Blow System Details
Particle Inlet from Feed distributor
Air: 10m/s
Air: 6m/s
www.esss.com.br
Simulation Results Outlet to Storage Particles Inlet
Screw Auger Separated Soybeans
Screw Auger Particles Recirculation
www.esss.com.br
Simulation Results
www.esss.com.br
Thank You! – Andrew Hobbs - Astec, Inc.
– Höher Junior - AGCO do Brasil – All CEI staff, especially Darin McKinnis and Amanda Baley – Sriram Ramanathan - DEM Solutions – Fabiano Nunes Diesel - ESSS Brazil
www.esss.com.br
