CFD simulation and experimental validation of multiphase flow in industrial cyclone preheaters

• Published in: Chemical engineering journal (Lausanne, Switzerland : 1996) Switzerland : 1996), 2023-06, Vol.465, p.142757, Article 142757
• Main Authors: Mirzaei, Mohamadali, Clausen, Sønnik, Wu, Hao, Zakrzewski, Sam, Nakhaei, Mohammadhadi, Zhou, Haosheng, Martin Jønck, Kasper, Arendt Jensen, Peter, Lin, Weigang
• Format: Article
• Language: English
• Subjects: Dense Discrete Phase Model (DDPM); Dense dispersed gas–solid flow; Gas-particle heat transfer; Industrial-scale cyclone preheater
• ISSN: 1385-8947; 1873-3212
• DOI: 10.1016/j.cej.2023.142757

[Display omitted] •Dense Discrete Phase Model was employed to simulate an industrial cyclone preheater.•The model was validated against overall and local measurements.•Overall measurements for validation include pressure drop and heat transfer rate.•Local measurements for validation include LDA and temperature profile measurements.•The model reflects the trends observed in the measurements. A hybrid multiphase model (Dense Discrete Phase Model, DDPM) coupled with a k-ω sst turbulence model, which includes gas–solid heat exchange was developed for the simulation of industrial-scale cyclone preheaters operating under high solid loadings. The model results are validated by experimental measurements from an industrial cyclone preheater with a diameter of 1.6 m, with respect to the pressure drop, gas and particle exit temperature, local gas velocity profiles, measured using the LDA, and gas temperature profiles, measured using thermocouple and FTIR. Reasonable agreement between the data from experiments and simulations was obtained. In addition, the major trends, such as changes in the pressure drop, overall heat transfer rate, and flow pattern, caused by the changes in the operating parameters can be captured accurately by the model.