CN110427693B - Fluid simulation calculation method in industrial reactor with spray gun - Google Patents
Fluid simulation calculation method in industrial reactor with spray gun Download PDFInfo
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Abstract
The disclosure relates to the technical field of industrial reactors, in particular to a method for simulating and calculating fluid in an industrial reactor with a spray gun. The simulation calculation method comprises the following steps: modeling a closed curved surface of the industrial reactor to form a geometric model of the industrial reactor; carrying out mesh division on the geometric model; establishing a mathematical model of the fluid in the industrial reactor; defining boundary conditions of the mathematical model; and calculating to obtain the to-be-measured parameters of the fluid based on the boundary conditions so as to obtain the flow field characteristics in the industrial reactor. The simulation calculation method can obtain the flow characteristics of the fluid in the industrial reactor, so that the industrial reactor is designed in a targeted manner.
Description
Technical Field
The disclosure relates to the technical field of industrial reactors, in particular to a method for simulating and calculating fluid in an industrial reactor with a spray gun.
Background
The industrial reactor is a reaction device for realizing a liquid phase single phase reaction process or a gas-liquid, liquid-solid, gas-liquid-solid and other multi-phase reaction processes, and is widely applied to the fields of chemical industry, oil refining, metallurgy and the like. The industrial reactors such as the iron-making blast furnace, the steel-making converter and the nonferrous metallurgical furnace are provided with spray guns for providing reactants for the reactors, and the chemical reaction and heat transfer conditions in the industrial reactor with the spray guns are complex, so that the design scheme of the industrial reactor needs to be verified in the design stage, and the flow field characteristics in the industrial reactor need to be analyzed in the operation stage.
At present, the flow field characteristics of an industrial reactor with a spray gun are generally analyzed in a test mode, and the test research includes a water model test, a pilot test and an industrial test, wherein: the water model in the water model test generally adopts a reduced-scale model, has a large size difference with an actual reactor, is difficult to consider the physical characteristics of the viscosity, the density and the like of fluid in the reactor, and the flow characteristics of the fluid need to be measured by expensive equipment; the pilot test and the industrial test generally need to consume a large amount of manpower and material resources, the detection means is less, the data collection is difficult, and the industrial test can influence the normal operation of the reactor, so that the normal production activity is influenced.
The above information disclosed in the background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not constitute prior art that is known to a person of ordinary skill in the art.
Disclosure of Invention
The purpose of the present disclosure is to provide a simulation calculation method for fluids in an industrial reactor with a spray gun, which can obtain the flow characteristics of the fluids in the industrial reactor, and particularly can observe the local flow field characteristics of the spray gun, so as to design the industrial reactor in a targeted manner.
In order to achieve the purpose, the technical scheme adopted by the disclosure is as follows:
according to one aspect of the present disclosure, there is provided a method of simulation calculation of fluid in an industrial reactor with a lance, the method comprising:
modeling the industrial reactor with a closed surface to form a geometric model of the industrial reactor;
meshing the geometric model of the industrial reactor;
establishing a mathematical model of the fluid within the industrial reactor;
defining boundary conditions for the mathematical model;
and solving the parameter to be measured of the fluid based on the boundary condition so as to obtain the flow field characteristics in the industrial reactor.
In an exemplary embodiment of the present disclosure, the lance is provided to a reactor body of the industrial reactor for charging gas into the reactor body; the geometric model of the lance is a simplified model.
In an exemplary embodiment of the present disclosure, the grid is a structured grid.
In an exemplary embodiment of the present disclosure, a mesh size of the lance is smaller than a mesh size of the reactor body.
In an exemplary embodiment of the present disclosure, the establishing a mathematical model of the fluid within the industrial reactor comprises:
defining a reaction equation for the fluid;
selecting a phase flow model of the fluid and a turbulence model of the gas;
and determining the type of the parameter to be measured.
In an exemplary embodiment of the present disclosure, the reaction equation includes reactant, product, and heat parameters.
In an exemplary embodiment of the present disclosure, the phase flow model is a VOF multiphase flow model.
In an exemplary embodiment of the present disclosure, the turbulence model is a standard k-epsilon model.
In an exemplary embodiment of the present disclosure, the reactor body is provided with an exhaust port for exhausting flue gas;
the boundary conditions include inlet conditions of the gas, outlet conditions of the flue gas, and wall boundary conditions of the reactor body.
In an exemplary embodiment of the present disclosure, the parameter to be measured includes a temperature field.
The method comprises the following steps of firstly, carrying out closed surface modeling on the industrial reactor in three-dimensional modeling software to form a geometric model of the industrial reactor; secondly, importing the geometric model into meshing software, and meshing the geometric model; and finally, introducing the model divided with the grids into fluid analysis software, establishing a mathematical model of the fluid, defining boundary conditions of the mathematical model, and solving parameters to be measured of the fluid based on the boundary conditions so as to obtain the smooth characteristics in the industrial reactor. The simulation calculation method can obtain the flow characteristics of the fluid in the industrial reactor, particularly can observe the local flow field characteristics of the spray gun, and accordingly designs the industrial reactor in a targeted manner.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and together with the description, serve to explain the principles of the disclosure. It is to be understood that the drawings in the following description are merely exemplary of the disclosure, and that other drawings may be derived from those drawings by one of ordinary skill in the art without the exercise of inventive faculty.
FIG. 1 is a flow chart of a method for fluid simulation calculations in an industrial reactor with a lance in an embodiment of the present disclosure.
Fig. 2 is a schematic view of the actual structure of a spray gun according to an embodiment of the present disclosure.
FIG. 3 is a simplified schematic diagram of a spray gun according to an embodiment of the present disclosure.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and thus their detailed description will be omitted.
Although relative terms, such as "upper" and "lower," may be used in this specification to describe one element of an icon relative to another, these terms are used in this specification for convenience only, e.g., in accordance with the orientation of the examples described in the figures. It will be appreciated that if the device of the icon were turned upside down, the element described as "upper" would become the element "lower". When a structure is "on" another structure, it may mean that the structure is integrally formed with the other structure, or that the structure is "directly" disposed on the other structure, or that the structure is "indirectly" disposed on the other structure via another structure.
The terms "a," "an," "the," "said" are used to indicate the presence of one or more elements/components/etc.; the terms "comprising" and "having" are intended to be inclusive and mean that there may be additional elements/components/etc. other than the listed elements/components/etc.
The disclosed embodiment provides a simulation calculation method for fluid in an industrial reactor with a spray gun, and as shown in fig. 1, the simulation calculation method can comprise the following steps:
step S110, carrying out closed surface modeling on the industrial reactor to form a geometric model of the industrial reactor;
step S120, carrying out mesh division on the geometric model;
step S130, establishing a mathematical model of the fluid in the industrial reactor;
step S140, defining the boundary condition of the mathematical model;
and step S150, solving parameters to be measured of the fluid based on the boundary conditions so as to obtain the flow field characteristics in the industrial reactor.
The method comprises the following steps of firstly, carrying out closed surface modeling on the industrial reactor in three-dimensional modeling software to form a geometric model of the industrial reactor; secondly, importing the geometric model into meshing software, and meshing the geometric model; and finally, introducing the model divided with the grids into fluid analysis software, establishing a mathematical model of the fluid, defining boundary conditions of the mathematical model, and solving parameters to be measured of the fluid based on the boundary conditions so as to obtain the smooth characteristics in the industrial reactor. The simulation calculation method can obtain the flow characteristics of the fluid in the industrial reactor, particularly can observe the local flow field characteristics of the spray gun, and accordingly designs the industrial reactor in a targeted manner.
The following describes the simulation calculation method provided by the embodiments of the present disclosure in detail with reference to the accompanying drawings:
in step S110, the industrial reactor can be modeled as a closed surface by using three-dimensional modeling software such as SolidWorks, pro/E and the like so as to form a geometric model of the industrial reactor.
For example, an industrial reactor may include a reactor body, a feed inlet, a discharge outlet, a spray gun, and an exhaust outlet, wherein: the reactor body is a place for reaction and can be in the shape of a cylinder, a cube or the like; the feed inlet and the discharge outlet can be positioned on the reactor body, reactants can enter the reactor body through the feed inlet, and products after reaction can be discharged out of the reactor body through the discharge outlet; the spray gun is used for filling gas or liquid reactants into the reactor body, can be arranged at the bottom of the reactor body, and can also be arranged at the top or the side of the reactor body, and the spray gun is not particularly limited; the exhaust port may be disposed at the top of the reactor body for exhausting the exhaust gas generated by the reaction.
It should be noted that, because the actual structure of the lance (as shown in fig. 2) is complex, in order to reduce the calculation amount of the simulation analysis and improve the calculation efficiency, and combine the distance of the lance extending into the reactor body and the actual number of structural layers of the lance, the structure of the lance can be simplified, and the simplified result is shown in fig. 3, that is, the geometric model of the lance is a simplified model.
And step S120, carrying out Meshing on the geometric model by utilizing Meshing software such as Meshing, ICEM-CFD, gambit and the like.
The category of mesh includes structured mesh and unstructured mesh, where: a structured grid refers to all interior points within a grid area having the same contiguous cells, while an unstructured grid refers to interior points within a grid area not having the same contiguous cells. Because the structured grid has the advantages of high grid generation speed, good grid quality, simple data structure and the like, the boundary fitting of the region can be easily realized, and the method is suitable for the calculation in the aspects of fluid and surface stress concentration and the like, the grid of the industrial reactor can be set into a quadrilateral or hexahedral structured grid. In particular, the structured mesh may be a hexahedral mesh, so that the calculation process is more easily converged and also more accurate.
It should be noted that the size (accuracy) of the grid affects the calculation, and the grid size of the lance may be made smaller than the grid size of the reactor body in order to more accurately determine the local flow characteristics at the lance.
Step S130, a mathematical model of the fluid in the industrial reactor is established to simulate the flow characteristics of the fluid in the industrial reactor. Specifically, step S130 may include the steps of:
step S1301, defining a reaction equation of the fluid;
step S1302, selecting a fluid phase flow model and a gas turbulence model;
step S1303, determining the type of the parameter to be measured.
For example, the industrial reactor in the present application may be a copper smelting furnace for producing copper, which is charged with oxygen-enriched air and nitrogen gas via a lance, wherein: the oxygen-enriched air is used for providing oxygen and can be filled into the copper smelting furnace through the inner ring of the spray gun; the nitrogen is used for cooling the copper smelting furnace to prevent the copper smelting furnace from being overheated, and can be filled into the copper smelting furnace through the outermost ring of the spray gun. The flow rates of the nitrogen and oxygen-enriched air can be determined according to the size of the copper smelting furnace and the reaction formula in the furnace, and are not described in detail herein.
The copper smelting process can be divided into two stages of smelting and converting, wherein the two stages are respectively carried out in two similar copper smelting furnaces, and taking the converting period as an example, the reaction formula generated in the copper smelting furnace is as follows:
2FeS(l)+3O 2 (g)+SiO 2 (s)＝2FeO·SiO 2 (l)+2SO 2 (g)+1028.28kJ
Cu 2 S(l)+O 2 (g)＝2Cu(l)+SO 2 (g)+217.4kJ
as can be seen from the reaction formula, the reactants in the copper smelting furnace include FeS and Cu 2 S and SiO 2 The product has FeO. SiO 2 Copper liquid Cu and SO 2 The copper smelting furnace has two forms of substances, namely gas and liquid, namely, the phase flow type of the fluid in the copper smelting furnace is multiphase flow, so that a VOF multiphase flow model can be selected to reduce the flow characteristics of the gas and the liquid in the furnace.
At this time, the flow rate of nitrogen gas may be 5600Nm 3 The flow rate of the oxygen-enriched air can be 14220Nm 3 H is used as the reference value. It should be noted that heat is generated during the reaction process, and therefore, the reaction equation also includes heat parameters to make the simulation process more realistic.
For the VOF multi-phase flow model, an explicit volume fraction parameter equation and an implicit inertia force equation can be selected, the calculation adopts unsteady calculation and self-adaptive step length, the Kuronn number can be 5.0, a pressure-speed coupling mode can adopt a SIMPLE format, pressure discretization can adopt a PRESTO format, momentum can adopt a second-order windward format, the volume rate can adopt a Compressive format, the other modes can adopt a first-order windward format, and all convergence residual errors can be set as 1 x 10- 3 By definition of mathematical models
In addition, the mixed gas (nitrogen and oxygen-enriched air) injected by the spray gun arranged at the bottom of the copper smelting furnace enters in the form of jet flow, and the flow behavior is a strong turbulent flow process. Thus, a standard k-epsilon turbulence model can be used as a turbulence model for mixed gases, and is a semi-empirical formula, based primarily on turbulence kinetic energy and diffusivity, where: the k equation is an exact equation and the ε equation is an equation derived from an empirical formula, as follows:
in the formula: ρ represents a density; v represents a velocity; mu.s T,m Means the turbulent viscosity, mu T,m ＝ρC μ k 2 /ε，C μ The empirical constant is taken as 0.9; g k,m Representing turbulent kinetic energy due to the mean laminar velocity gradient; g b,m Representing the turbulent kinetic energy generated by buoyancy; sigma k 、σ ε Respectively, the turbulent prandtl numbers of k and epsilon. The turbulence empirical constant in the model usually takes the value of C 1 ＝1.44，C 2 ＝1.92，C 3 ＝1.0，σ k ＝1.0，σ ε ＝1.3。
Of course, realizable k-epsilon model or DNG k-epsilon model can also be used as the turbulent flow model of the mixed gas, and is not particularly limited herein
Accordingly, the parameter to be measured may include a temperature field, a concentration field, a density field, etc. of each phase fluid, which are not listed here. Taking the temperature field as an example, the parameters to be measured can comprise the temperature of the molten copper Cu, the temperature of the flue gas SO2 and the temperature of the converting slag FeO & SiO 2.
In step S140, boundary conditions of the mathematical model are defined.
As can be seen from the foregoing, the top of the reactor body is provided with an exhaust port for exhausting the exhaust gas (flue gas), and the boundary conditions may include gas inlet conditions, flue gas outlet conditions, and wall boundary conditions of the reactor body.
Taking the copper smelting furnace as an example, the inlet of the spray gun is a mass flow boundary condition, the working medium at the inlet is a mixed gas consisting of nitrogen and oxygen-enriched air, the turbulence intensity of the mixed gas can be 4.9%, the flow of the nitrogen can be 5600Nm3/h, and the flow of the oxygen-enriched air can be 14220Nm3/h; the outlet condition of the flue gas is a pressure outlet boundary condition, and the outlet pressure can be set to be-72 Pa; for the wall boundary condition of the reactor body, the wall of the reactor body may be treated as an adiabatic wall irrespective of heat radiation of the wall, and at this time, it is considered that the fluid velocity at the wall is 0, i.e., there is no slip wall boundary condition, and the near wall region is treated with a standard wall function.
And step S150, substituting the boundary conditions into the mathematical model to solve the to-be-detected parameters of the fluid so as to obtain the flow field characteristics in the industrial reactor.
Taking the copper smelting furnace as an example, the temperature of molten copper Cu is 1260 ℃, and the flue gas SO is obtained 2 At a temperature of 1235 ℃ and blowing slag FeO & SiO 2 The temperature of (2) is 1250 ℃.
Further, other physical properties during the blowing period are shown in the following table:
it should be noted that after the flow characteristics of the fluid in the industrial reactor are obtained, the local flow field characteristics of the lance can be observed correspondingly, and the heating condition of the lance and the erosion condition based on the heating condition can be further calculated. At the moment, if the simulation result shows that the corrosion condition of the spray gun is serious, the high-temperature resistant material can be paved on the position of the reactor body where the spray gun is arranged, so that the spray gun is prevented from being burnt, and the service life of the spray gun is prolonged.
Of course, in order to verify whether the simulation result is accurate, it may be compared whether the actual erosion result of the lance is consistent with the simulation result: if not, readjusting the simulation parameters until the results are consistent; and if the results are consistent, the simulation method is accurate. After the simulation method is correct, the industrial reactor is designed with pertinence by utilizing the simulation result.
Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
Claims (8)
1. A simulation calculation method for fluid in an industrial reactor with a spray gun is characterized in that the spray gun is arranged in a reactor body of the industrial reactor and is used for filling gas into the reactor body, the reactor body is provided with an exhaust port for exhausting flue gas, and the simulation calculation method comprises the following steps:
modeling the industrial reactor with a closed surface to form a geometric model of the industrial reactor;
meshing the geometric model of the industrial reactor;
establishing a mathematical model of the fluid within the industrial reactor;
defining boundary conditions for the mathematical model, the boundary conditions including an inlet condition for the gas, an outlet condition for the flue gas, and a wall boundary condition for the reactor body;
solving parameters to be measured of the fluid based on the boundary conditions to obtain flow field characteristics in the industrial reactor;
wherein the content of the first and second substances,
the establishing a mathematical model of the fluid within the industrial reactor comprises:
defining a reaction equation for the fluid;
selecting a phase flow model of the fluid and a turbulence model of the gas;
and determining the type of the parameter to be measured.
2. The simulation calculation method of claim 1, wherein the geometric model of the lance is a simplified model.
3. The method of simulated computation of claim 2, wherein the grid is a structured grid.
4. The simulation calculation method of claim 3, wherein the mesh size of the lance is smaller than the mesh size of the reactor body.
5. The simulation calculation method of claim 1, wherein the reaction equation comprises reactant, product and thermal parameters.
6. The simulation calculation method of claim 1, wherein the phase flow model is a VOF multi-phase flow model.
7. The method of simulation computation of claim 1, wherein the turbulence model is a standard k-epsilon model.
8. The simulation calculation method of claim 1, wherein the parameter to be measured comprises a temperature field.
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