CN107330150B - Method for optimizing guide cylinder of DTB (draw texturing yarn) crystallizer based on Fluent - Google Patents
Method for optimizing guide cylinder of DTB (draw texturing yarn) crystallizer based on Fluent Download PDFInfo
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Abstract
The invention discloses a method for optimizing a guide cylinder of a DTB crystallizer based on Fluent, which comprises the following steps: firstly, establishing a plurality of DTB crystallizer geometric models; secondly, carrying out grid division on each DTB crystallizer geometric model by using Gambit preprocessing software; then, performing single-phase simulation by adopting computational fluid dynamics software Fluent, and simulating a series of DTB crystallizer flow fields with different stirring rates for DTB crystallizers with the same geometric structure; and finally, acquiring the volume circulation flow and the torque of the guide shell of different DTB crystallizers at different stirring speeds by using a report function, calculating the stirring power according to the torque, drawing a circulation flow-power curve, comparing the circulation flow-power curve, and selecting a model corresponding to the rightmost curve as an optimized guide shell model. The invention provides a new guide cylinder size design optimization scheme, which improves the structural design and optimization efficiency of the guide cylinder of the DTB crystallizer, and the obtained optimized crystallizer has high operation efficiency and low equipment operation energy consumption and can play a good energy-saving role.
Description
Technical Field
The invention relates to a DTB crystallizer, in particular to a numerical simulation method for optimizing a guide cylinder of the DTB crystallizer based on Fluent.
Background
The DTB crystallizer, which is a crystallizer with higher performance appearing in the late 50 s, is one of the main forms of continuous crystallizers and can be used in the crystallization process of vacuum cooling, evaporation, direct contact and reaction methods. The feed liquid in the crystallizer forms a circulating channel along the guide cylinder to circularly flow, and the circulating amount has important influence on material mixing, contact of crystals and saturated solution and subsequent crystal growth and is an important index in DTB design.
The DTB crystallizer usually realizes material circulation in a stirring mode, and in order to ensure that the circulation volume is large enough, an optimization method of increasing the diameters of a guide cylinder and a paddle can be adopted so as to enlarge a liquid circulation zone and achieve the required effect. However, the power is increased by increasing the stirring paddle, which increases the energy consumption to some extent and is not beneficial to the purpose of energy saving. Therefore, the method finds out the proper guide shell size optimization value between the increase of the circulation amount and the reduction of the energy consumption as much as possible, and has important significance for the crystallization industry.
The DTB crystallizer has a complex structure, and pure theoretical hydromechanics is completely powerless. At present, the design and optimization of the DTB crystallizer are usually required to acquire data through a large amount of experimental research, and a better equipment structure is obtained through experimental data analysis. The method needs to manufacture a large number of DTB crystallizer structures with different sizes, and simultaneously needs long experimental study time, so the design and optimization method has high economic cost and time cost, and low equipment design and optimization efficiency. Another common method is to design the device structure purely by the past experience, for example, the area of the internal circulation channel of the guide shell is equal to the area of the external circulation channel. This purely empirical design method often results in equipment that produces poor product quality and less efficient operation.
Disclosure of Invention
The invention aims to provide a numerical calculation method for determining the reasonable guide shell size of the DTB crystallizer, and the optimal guide shell size of the DTB crystallizer designed by the method can improve the operation efficiency of the DTB crystallizer and reduce the operation energy consumption of equipment.
The technical scheme adopted by the invention is as follows: a method for optimizing a guide cylinder of a DTB crystallizer based on Fluent comprises the following steps:
the method comprises the following steps of firstly, establishing a plurality of DTB crystallizer geometric models, wherein the sizes of the rest parts in the DTB crystallizer geometric models are completely consistent except the diameter of a guide cylinder, the diameter of a stirring paddle and the height of the stirring paddle;
step two, carrying out grid division on each DTB crystallizer geometric model in the step one by utilizing Gambit preprocessing software to obtain a corresponding DTB crystallizer grid file;
step three, guiding the DTB crystallizer grid files obtained in the step two into computational fluid dynamics software Fluent to carry out single-phase simulation, selecting a mathematical model, setting material properties, solving conditions and boundary conditions, simulating a series of DTB crystallizer flow fields under different stirring rates for the DTB crystallizer with the same geometric structure, generating data files, and completing the flow field simulation of all DTB crystallizer grid files under different stirring rates;
and step four, acquiring the volume circulation flow and the torque of the guide cylinder of different DTB crystallizers at different stirring speeds by applying a report function to the data file obtained in the step three, calculating the stirring power according to the torque, drawing circulation flow-power curves of simulation models of the DTB crystallizers in the same coordinate system, comparing the circulation flow-power curves, and selecting the model corresponding to the rightmost curve as the optimal model of the guide cylinder.
Further, in the second step, after grid division is performed on each DTB crystallizer geometric model, grid independence verification is performed, and the specific method is as follows: and (3) encrypting the grids by using the grid self-adaption function of the computational fluid dynamics software Fluent, wherein if the deviation of the grid calculation result is within 1%, the calculation result is irrelevant to the grid quantity, and the grids do not need to be continuously encrypted.
Further, in the third step, whether the simulated flow field at each stirring speed is reasonable is analyzed, the subsequent steps are performed if the flow field information is reasonable, and the parameters are adjusted if the flow field information is unreasonable to continue simulating the flow field at the stirring speed until the flow field information is reasonable.
Furthermore, in the fourth step, the circulation volume-power curve is drawn under the same coordinate system, the rightmost curve has the smallest corresponding power under the same circulation volume and the largest corresponding circulation volume under the same power, and the size of the model guide cylinder corresponding to the curve is the optimal value.
The invention has the beneficial effects that:
(1) in the numerical simulation method, the case files stored by Fluent for the first time can be used for reading different grid models, changing the rotating speed of the paddle area, storing the setting result and reducing the repetitive work;
(2) the invention provides a new guide cylinder size design optimization scheme, which greatly improves the structural design and optimization efficiency of the guide cylinder of the DTB crystallizer, and the obtained optimized crystallizer has high operation efficiency and low equipment operation energy consumption and can play a good energy-saving role.
Drawings
FIG. 1 is an exemplary 530mm draft tube model mesh;
FIG. 2 is a front view of a 530mm draft tube model according to an embodiment;
FIG. 3 is a graph of lower circulation versus power for different draft tube diameters according to an embodiment;
FIG. 4 is a model mesh of an embodiment two 630mm draft tube;
FIG. 5 is a front view of a 630mm pod model according to an embodiment;
FIG. 6 is a graph of lower circulation versus power for two different draft tube diameters of the example;
FIG. 7 is an example three 260mm draft tube model mesh;
FIG. 8 is a front view of a model of an embodiment three 260mm draft tube;
FIG. 9 is a graph of lower circulation versus power for three different draft tube diameters of the example embodiment.
Detailed Description
The invention is further described with reference to the following figures and examples.
With the improvement of computer performance and the emergence of increasingly perfect Computational Fluid Dynamics (CFD) simulation software, the design and optimization of the equipment structure by utilizing the CFD simulation software become possible.
A method for optimizing a guide cylinder of a DTB crystallizer based on Fluent comprises the following steps:
step one, establishing a plurality of DTB crystallizer geometric models (adopting Gambit or other modeling software), wherein the sizes of the rest parts in the DTB crystallizer geometric models are completely consistent except the diameter of a guide cylinder, the diameter of a stirring paddle and the height of the stirring paddle.
Step two, carrying out grid division on each DTB crystallizer geometric model in the step one by utilizing Gambit preprocessing software to obtain a corresponding DTB crystallizer grid file, and dividing the DTB crystallizer grid file into two calculation domains: paddle area and other areas. After grid division is carried out on each DTB crystallizer geometric model, grid independence verification is carried out, and the method specifically comprises the following steps: and (3) encrypting the grids by using the grid self-adaption function of the computational fluid dynamics software Fluent, wherein if the deviation of the grid calculation result is within 1%, the calculation result is irrelevant to the grid quantity, and the grids do not need to be continuously encrypted.
And step three, introducing the DTB crystallizer grid files obtained in the step two into computational fluid dynamics software Fluent to perform single-phase simulation, selecting a mathematical model, setting material properties, solving conditions and boundary conditions, simulating a series of DTB crystallizer flow fields under different stirring rates for the DTB crystallizer with the same geometric structure, generating data files, and completing the flow field simulation of all DTB crystallizer grid files under different stirring rates. And if the flow field information is not reasonable, adjusting parameters (solving conditions, boundary conditions and the like) to continuously simulate the flow field at the stirring speed until the flow field information is reasonable.
The method specifically comprises the steps of adopting steady-state simulation based on a pressure solver, adopting a multi-reference-system method, adopting a dynamic reference system for a paddle area, adopting a static reference system for other areas, arranging interface on the connection surface of the paddle area and other areas, adopting SIMP L E algorithm to solve, wherein the discrete format is first-order precision, the inlet is arranged as a speed inlet, the outlet is arranged as a pressure outlet, the paddle surface is a rotating surface, adopting a Navie-Stokes equation, and adopting a standard k-equation for a turbulence model to ensure faster convergence rate.
And step four, acquiring the volume circulation flow and the torque of guide cylinders of different DTB crystallizers at different stirring speeds by applying a report function to the data file obtained in the step three, calculating stirring power according to the torque, drawing circulation quantity-power curves of simulation models of the DTB crystallizers in the same coordinate system, comparing the circulation quantity-power curves, enabling the rightmost curve to have the minimum corresponding power under the same circulation quantity and the maximum corresponding circulation quantity under the same power, enabling the size of the model guide cylinder corresponding to the curve to be the optimal value, and selecting the model corresponding to the curve as the optimal guide cylinder model.
Example one
A method for optimizing a guide cylinder of a DTB crystallizer based on Fluent provides a numerical calculation method for determining a reasonable size of the guide cylinder of the DTB crystallizer, and is realized according to the following steps:
the method comprises the following steps: DTB crystallizer geometric model establishment
The method comprises the steps of establishing 5 DTB crystallizer geometric models by using Gambit software, taking a z axis as a rotating shaft, enabling the dimensions of the 5 DTB crystallizer geometric models except the diameter of a guide cylinder and the diameter and height of a stirring paddle to be completely consistent, enabling the height of the guide cylinder of each DTB crystallizer geometric model to be the same, enabling the diameter of each guide cylinder to be 530mm, 730mm, 930mm, 1030mm, 1130mm and 530mm in sequence, enabling the diameter of the stirring paddle to be 500mm and the height of each stirring paddle to be 120mm, and enabling the diameter and the height of the stirring paddle of the other models to be determined by multiplying the ratio of the diameter of each guide cylinder to 530.
Step two: simulation model meshing
The geometric model of the whole DTB crystallizer is divided into 2 parts, namely a paddle area and other areas, which are all tetrahedrally meshed, the paddle area encrypts partial meshes of the blades by a pro function, and the minimum size is 12, the maximum size is 100, the mesh sizes of the other areas are 100, and the sizes of an inlet and an outlet are 40.
And (3) grid independence verification:
the simulation precision is closely related to the accuracy and the number of grids, the larger the number of grids is, the smaller the size is, the dispersion error is reduced, however, the increase of the number can cause the increase of the calculation amount, and even cause the increase of the iteration error, so the accuracy and the number of grids have balance, and the reasonable number of grids needs to be determined before calculation, namely the independence problem. The method is characterized in that large grid size division within a reasonable range is used for specific problems, the grids are encrypted by using the self-adaptive function of the Fluent grids, and the quantity of the grids is considered to be irrelevant to the calculation result until the deviation of the calculation result of the encrypted grids is within 1%, namely, the grid independence is ensured. According to the requirement of a calculation task, a velocity field and a circulation volume are used as main monitoring objects, a guide cylinder diameter 530mm model is taken as an example, the independence verification result is shown in table 1, wherein the known grid number is over 46 ten thousand, the calculation accuracy can be guaranteed, other models are the same as the verification mode, and finally the grid number of all models is determined between 45 ten thousand and 50 ten thousand.
Table 1530 mm draft tube crystallizer grid independence verification result
Step three: fluent single-phase analog computation
The method comprises the steps of adopting steady-state simulation based on a pressure solver, adopting a multi-reference-system method, adopting a dynamic reference system in a paddle area, adopting a static reference system in other areas, setting interface.SIMP L E algorithm on connection surfaces of the paddle area and other areas for solving, setting a discrete format to be first-order precision, setting materials to be water, setting an inlet to be a speed inlet, setting an outlet to be a pressure outlet and setting a paddle surface to be a rotating surface, adopting a Navie-Stokes equation and adopting a standard k-equation in a turbulence model to ensure faster convergence rate.
Step four: plotting a cycle rate-power diagram
For each model, the stirring speed is arbitrarily changed for six times to obtain six pairs of circulation volume and power data, a circulation volume-power graph (fig. 3) is drawn, the diameter of the guide cylinder corresponding to the rightmost curve is selected from fig. 3 as the optimal size, and the optimal diameter of the guide cylinder of the DTB crystallizer in this embodiment is 930 mm.
Example two
The method comprises the following steps: DTB crystallizer geometric model establishment
The method comprises the steps of establishing 4 DTB crystallizer geometric models by using Gambit software, taking a z axis as a rotating shaft, enabling the sizes of the 4 DTB crystallizer geometric models except a guide cylinder and a stirring paddle to be completely consistent, enabling the height of the guide cylinder of each DTB crystallizer geometric model to be the same, enabling the diameters to be 630mm, 730mm, 830mm, 930mm and the diameter and the height of a stirring paddle of 630mm to be 600mm and 140mm respectively, and enabling the diameters and the heights of the stirring paddles of the other DTB crystallizer geometric models to be determined by multiplying the diameters of the guide cylinders and the ratio of 630mm respectively by the diameters of the guide.
Step two: simulation model meshing
The geometric model of the whole DTB crystallizer is divided into 2 parts, namely a paddle area and other areas, which are all tetrahedrally meshed, the paddle area is used for encrypting partial meshes of the blades by a pro function, the minimum size is 12, the maximum size is 100, the mesh sizes of the other areas are 100, and the sizes of an inlet and an outlet are 50.
And (3) grid independence verification:
similar to the embodiment, according to the requirement of a calculation task, the velocity field and the circulation volume are used as main monitoring objects, a model with the diameter of the guide shell being 630mm is used as an example, and the independence verification result is shown in table 2, wherein the known grid number is over 52 ten thousand, the calculation accuracy can be ensured, other models are the same as the verification mode, and finally the grid number of all models is determined to be between 50 ten thousand and 55 ten thousand.
Table 2630 mm guide cylinder crystallizer grid independence verification result
Step three: fluent single-phase analog computation
The method comprises the steps of adopting steady-state simulation based on a pressure solver, adopting a multi-reference-system method, adopting a dynamic reference system in a paddle area, adopting a static reference system in other areas, setting interface.SIMP L E algorithm on connection surfaces of the paddle area and other areas for solving, setting a discrete format to be first-order precision, setting materials to be water, setting an inlet to be a speed inlet, setting an outlet to be a pressure outlet and setting a paddle surface to be a rotating surface, adopting a Navie-Stokes equation and adopting a standard k-equation in a turbulence model to ensure faster convergence rate.
Step four: plotting a cycle rate-power diagram
For each model, the stirring speed is arbitrarily changed for six times to obtain six pairs of circulation volume and power data, a circulation volume-power graph (fig. 6) is drawn, the diameter of the guide shell corresponding to the rightmost curve is selected from fig. 6 as the optimal size, and the optimal diameter of the guide shell of the DTB crystallizer in this embodiment is 830 mm.
Example three:
the method comprises the following steps: building a DTB crystallizer geometric model;
the method comprises the steps of establishing 8 DTB crystallizer geometric models by using Gambit software, taking a z axis as a rotating shaft, enabling the sizes of the 8 DTB crystallizer geometric models to be completely consistent except for guide cylinders and stirring paddles, enabling the guide cylinders of the models to be the same in height, enabling the diameters to be 260mm, 360mm, 460mm, 560mm, 660mm, 710mm, 760mm, 860mm and 260mm to be 250mm in diameter and 60mm in height, and enabling the diameters and the heights of the stirring paddles of the models to be determined by multiplying the diameters of the guide cylinders and the ratios of the guide cylinders to the stirring paddles of the models by 250mm and 60mm respectively.
Step two: simulation model meshing
The whole calculation domain model grid is divided into 2 parts, namely a paddle area and other areas, and the tetrahedral grid is divided, the paddle area encrypts part of the grid of the blade by a pro function, the maximum size is 60, the static area encrypts the part of the overflow ring, the maximum size is 60, and the inlet and outlet sizes are 20.
And (3) grid independence verification:
similar to the embodiment, according to the requirement of a calculation task, the velocity field and the circulation volume are used as main monitoring objects, the model with the diameter of the guide cylinder of 260mm is used as an example, and the independence verification result is shown in table 3, wherein the known grid number is over 46 ten thousand, the calculation accuracy can be ensured, other models are the same as the verification mode, and finally, the grid number of all models is about 46 thousand.
Table 3260 mm guide cylinder crystallizer grid independence verification result
Step three: fluent single-phase analog computation
The method comprises the steps of adopting steady-state simulation based on a pressure solver, adopting a multi-reference-system method, adopting a dynamic reference system in a paddle area, adopting a static reference system in other areas, setting interface.SIMP L E algorithm on connection surfaces of the paddle area and other areas for solving, setting a discrete format to be first-order precision, setting materials to be water, setting an inlet to be a speed inlet, setting an outlet to be a pressure outlet and setting a paddle surface to be a rotating surface, adopting a Navie-Stokes equation and adopting a standard k-equation in a turbulence model to ensure faster convergence rate.
Step four: plotting a cycle rate-power diagram
For each model, the stirring speed is changed for six times at will to obtain six pairs of circulation volume and power data, a circulation volume-power graph (figure 9) is drawn, and 660mm, 710mm and 760mm guide shell models can be compared with other models from figure 9 to obtain larger circulation volume at lower power, and the models are all suitable guide shell sizes. Considering that the cost is increased due to the increase of the diameter of the guide cylinder, the 660mm guide cylinder is the optimal condition.
Claims (5)
1. A method for optimizing a guide cylinder of a DTB crystallizer based on Fluent is characterized by comprising the following steps:
the method comprises the following steps of firstly, establishing a plurality of DTB crystallizer geometric models, wherein the sizes of the rest parts in the DTB crystallizer geometric models are completely consistent except the diameter of a guide cylinder, the diameter of a stirring paddle and the height of the stirring paddle;
step two, carrying out grid division on each DTB crystallizer geometric model in the step one by utilizing Gambit preprocessing software to obtain a corresponding DTB crystallizer grid file;
step three, guiding the DTB crystallizer grid files obtained in the step two into computational fluid dynamics software Fluent to carry out single-phase simulation, selecting a mathematical model, setting material properties, solving conditions and boundary conditions, simulating a series of DTB crystallizer flow fields under different stirring rates for the DTB crystallizer with the same geometric structure, generating data files, and completing the flow field simulation of all DTB crystallizer grid files under different stirring rates;
and step four, acquiring the volume circulation flow and the torque of the guide cylinder of different DTB crystallizers at different stirring speeds by applying a report function to the data file obtained in the step three, calculating the stirring power according to the torque, drawing circulation flow-power curves of simulation models of the DTB crystallizers in the same coordinate system, comparing the circulation flow-power curves, and selecting the model corresponding to the rightmost curve as the optimal model of the guide cylinder.
2. The Fluent-based method for optimizing the guide cylinder of the DTB crystallizer as claimed in claim 1, wherein in the second step, after grid division is performed on each geometric model of the DTB crystallizer, grid independence verification is performed.
3. The method for optimizing the guide cylinder of the DTB crystallizer based on Fluent according to claim 2, wherein the specific method for verifying the grid independence is as follows: and (3) encrypting the grids by using the grid self-adaption function of the computational fluid dynamics software Fluent, wherein if the deviation of the grid calculation result is within 1%, the calculation result is irrelevant to the grid quantity, and the grids do not need to be continuously encrypted.
4. The Fluent-based method for optimizing the draft tube of the DTB crystallizer as claimed in claim 1, wherein in the third step, whether the simulated flow field at each stirring speed is reasonable is analyzed, the subsequent steps are performed if the flow field information is reasonable, and the parameters are adjusted if the flow field information is not reasonable to continue simulating the flow field at the stirring speed until the flow field information is reasonable.
5. The method for optimizing the guide cylinder of the DTB crystallizer based on Fluent according to claim 1, wherein in the fourth step, the circulation volume-power curve drawn under the same coordinate system has the rightmost curve with the minimum power under the same circulation volume and the maximum circulation volume under the same power, and the size of the model guide cylinder corresponding to the curve is the optimal value.
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| CN101745612A (en) * | 2009-12-30 | 2010-06-23 | 重庆大学 | Continuous-casting crystallizer simulation method by taking shell thickness and flowing quality balance into consideration and device thereof |
| CN106215454A (en) * | 2016-09-29 | 2016-12-14 | 益盐堂（应城）健康盐制盐有限公司 | A kind of outer circulation DTB fluidized-bed crystallizer |
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| CN101745612A (en) * | 2009-12-30 | 2010-06-23 | 重庆大学 | Continuous-casting crystallizer simulation method by taking shell thickness and flowing quality balance into consideration and device thereof |
| CN106215454A (en) * | 2016-09-29 | 2016-12-14 | 益盐堂（应城）健康盐制盐有限公司 | A kind of outer circulation DTB fluidized-bed crystallizer |
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