直流电弧等离子体炬的数值模拟
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摘要
电弧热等离子体被广泛应用于切割、焊接、喷涂、冶金、材料、化工和废物处理等工业领域。对电弧热等离子体的数值模拟有助于更好的理解热等离子体的物理过程和优化等离子体发生器的设计。本文首先比较了五种湍流模型,即:雷诺应力模型(RSM)、标准ｋ-ε模型、重整化群(RNG)ｋ-ε模型、考虑低雷诺数的重整化群ｋ-ε模型以及可实现化ｋ-ε模型。发现雷诺应力模型和考虑低雷诺数的重整化群ｋ-ε模型所得到的流场温度、速度、压强非常相近;不但这两种湍流模型所得的压强、温度沿轴线上的分布与实验十分一致;而且由这两种模型计算出的弧电压也和实验值相当吻合。然而,其他三种模型所得到的等离子体射流部分的温度和实验值相差很远,其中标准ｋ-ε模型以及可实现化ｋ-ε模型所得到的轴线上的温度值在某些区域和实验值相差超过10000 K。这三种湍流模型所计算的弧电压值也和实验值差别很大。
等离子体切割是利用电弧的高能量熔化金属,再利用等离子体射流的高动量将熔化金属吹走。目前,使用氧气作为等离子体气体的精细切割已在工业上广泛应用。本文利用考虑低雷诺数的重整化群ｋ-ε模型对等离子体切割弧进行了系统的模拟,研究结果如下:(一)在研究旋转气流时发现,增加旋气度会增加弧室的压强并改变弧室内的压强分布,从而收缩电弧。旋气对切割炬喷嘴小孔内部和射流区域的温度影响很小,但会使喷口外等离子体得到更高的速度和更强的激波。旋气会通过改变阴极附近的气流方向和增加阴极附近的压强加速阴极的烧损。(二)在参数研究中发现,切割炬喷嘴小孔长度增加会使射流的最大速度增加,弧室压强增大,激波后的高速射流区域半径增大。减小喷嘴小孔半径,会使弧室的压强升高,激波强度增加,激波后的速度、能流密度径向分布的最大值偏离轴线。这会有利于电弧与切割工件的能量与动量交换,从而提升切割的速度。气流量会影响等离子体的速度和温度分布,强气流由于冷却效应强,会收缩电弧,增加弧电压和功率,从而增加射流的速度、温度和能量通量。弧电流对等离子体的速度场和温度场都有非常重要的影响。在等离子体射流中的能流密度几乎与弧电流成正比。(三)通过比较两种不同结构切割炬所产生的等离子体流场,发现保护气对等离子体的温度和速度分布影响很小。垂直保护气在切割炬喷口形成阻碍作用,造成切割炬内的压强有所升高,但是变化不大。两种结构保护气对切割弧的影响只是在炬喷口外的激波附近。加入保护气后激波的强度会减弱。相对于没有保护气的情况,保护气增加冷却作用,弧电压会略有升高。当改变保护气的成分时,发现弧柱区的氧气含量不受影响,所以保护气成分的改变不会影响到弧电压。计算发现轴线处氧气和周围气体的混和很少,在喷口下游10 mm处,氧气的摩尔分数仍在90%以上。
大功率氢等离子体炬(5MW-10MW)是煤裂解制乙炔的核心设备。我们在四CPU工作站上使用FLUENT对V型炬的一半进行并行模拟。由于计算区域较大,我们使用雷诺应力模型考虑湍流。计算所得到的各电极电压分布与实验值基本吻合。数值模拟发现由于电极半径逐渐增大,进气量逐渐增多,所以在等离子体炬内,存在一系列的加速,减速过程。模拟还研究了旋转气流对等离子体流场的影响,发现旋气度对大功率等离子体炬内的流场影响不大;而增加气流量使弧电压值有很大提高,且电极壁面的热量损失显著降低。
Electrical arcs and, more generally thermal plasmas, are widely used in many industrial applications) such as cutting, welding, spraying, metallurgy, ultrafine particles synthesis and waste treatment. The understanding or the improvement of the corresponding processes or systems often requires precise modelling of the plasma. The thermal plasmas characteristics are first investigated with different turbulence models, i.e. the Reynolds Stress Model (RSM), the k-εmodel and its variants, the ReNor-malization Group (RNG) k-εmodel, the RNG k-εmodel taking into account the low Reynolds number effect and the realizable k-εmodel. The results of the RSM and the RNG k-εmodel taking into account the low Reynolds number effect are in reasonable agreement with the experiment. They both predict very close voltage, shock wave location and temperature variation along the axis to experiment. On the other hand, the other three models overestimate the turbulence effects and predict much lower velocity and temperature, especially the standard k-εmodel, which predicts the temperature is about 10000 K lower than the experiment in certain plasma jet regions.
After comparing the turbulence model, we use the RNG k-εmodel taking into account the low Reynolds number effect to investigate the plasma cutting arc. The effects of plasma-gas swirl flow, the process parameters, torch geometry and the shielding gas on the plasma cutting arc are investigated. When the inlet gas swirl number increases, the maximum pressure location moves to the plenum chamber edge due to centrifugal force, the minimum pressure location moves much closer to the axis. The difference between the maximum and minimum pressure increases with swirl number. This will constricts the arc and leads to large current density and Ohm heating near the axis, and causes much higher temperature near the cathode. It is indicated that the swirl gas accelerates cathode erosion for two reasons: increasing plenum chamber pressure and changing the flow patterns in the vicinity of cathode. It is also found that, the gas with large swirl number leads swirl velocity component to be larger at cutting location according to angular momentum conservation. It has been suggested that this causes the different bevel angles for the left and right edges of the cutting kerf. In the parameters study, it is shown that gas flow rate, arc current, nozzle bore length and radius have essential effects on plasma arc characteristics. Long nozzle torch can provide high velocity plasma jet with high heat flux. Both arc voltage and chamber pressure increase with the nozzle length. Small radius nozzle torch increases the plenum chamber pressure and providing off-axis maximum velocity after shock wave. High arc current increases plasma velocity and temperature, enhances heat flux and augments chamber pressure and thus, the shock wave. Strong mass flow has pinch effect on plasma arc inside the torch, enhances the arc voltage and power, therefore increases plasma velocity, temperature and heat flux. After comparing two different torch geometries, it is found that the shielding flow has no significant effects on plasma velocity and temperature except the shock wave region. The shielding flow decreases the shock wave, and increases the arc voltage due to cooling effect. In the impinging geometry, shielding flow will crash the plasma jet after the nozzle exit and slightly increases the pressure in the torch. It is shown that the component of shielding gas has no significant effect on plasma cutting arc. The mole fraction of oxygen decreases very slowly along the axis and is still more than 90% at 10 mm downstream the nozzle exit.
High-power hydrogen plasma torch (5 MW-10 MW) is of great importance in coal pyrolysis for producing acetylene and other industrial applications. Considering the large computational domain, the RSM is used to investigate high-power plasma torch. The calculated arc voltage and the electric potential distribution at electrodes are very close to the experimental data. It is found the swirl number has no significant effect on the plasma characteristics except the first two electrodes region. Both the arc voltage and energy-efficiency increase with the mass flow rate. It is shown that large mass flow will constrict the plasma arc, and therefore enhance the maximal temperature and velocity at the torch outlet.
等离子体切割是利用电弧的高能量熔化金属,再利用等离子体射流的高动量将熔化金属吹走。目前,使用氧气作为等离子体气体的精细切割已在工业上广泛应用。本文利用考虑低雷诺数的重整化群ｋ-ε模型对等离子体切割弧进行了系统的模拟,研究结果如下:(一)在研究旋转气流时发现,增加旋气度会增加弧室的压强并改变弧室内的压强分布,从而收缩电弧。旋气对切割炬喷嘴小孔内部和射流区域的温度影响很小,但会使喷口外等离子体得到更高的速度和更强的激波。旋气会通过改变阴极附近的气流方向和增加阴极附近的压强加速阴极的烧损。(二)在参数研究中发现,切割炬喷嘴小孔长度增加会使射流的最大速度增加,弧室压强增大,激波后的高速射流区域半径增大。减小喷嘴小孔半径,会使弧室的压强升高,激波强度增加,激波后的速度、能流密度径向分布的最大值偏离轴线。这会有利于电弧与切割工件的能量与动量交换,从而提升切割的速度。气流量会影响等离子体的速度和温度分布,强气流由于冷却效应强,会收缩电弧,增加弧电压和功率,从而增加射流的速度、温度和能量通量。弧电流对等离子体的速度场和温度场都有非常重要的影响。在等离子体射流中的能流密度几乎与弧电流成正比。(三)通过比较两种不同结构切割炬所产生的等离子体流场,发现保护气对等离子体的温度和速度分布影响很小。垂直保护气在切割炬喷口形成阻碍作用,造成切割炬内的压强有所升高,但是变化不大。两种结构保护气对切割弧的影响只是在炬喷口外的激波附近。加入保护气后激波的强度会减弱。相对于没有保护气的情况,保护气增加冷却作用,弧电压会略有升高。当改变保护气的成分时,发现弧柱区的氧气含量不受影响,所以保护气成分的改变不会影响到弧电压。计算发现轴线处氧气和周围气体的混和很少,在喷口下游10 mm处,氧气的摩尔分数仍在90%以上。
大功率氢等离子体炬(5MW-10MW)是煤裂解制乙炔的核心设备。我们在四CPU工作站上使用FLUENT对V型炬的一半进行并行模拟。由于计算区域较大,我们使用雷诺应力模型考虑湍流。计算所得到的各电极电压分布与实验值基本吻合。数值模拟发现由于电极半径逐渐增大,进气量逐渐增多,所以在等离子体炬内,存在一系列的加速,减速过程。模拟还研究了旋转气流对等离子体流场的影响,发现旋气度对大功率等离子体炬内的流场影响不大;而增加气流量使弧电压值有很大提高,且电极壁面的热量损失显著降低。
Electrical arcs and, more generally thermal plasmas, are widely used in many industrial applications) such as cutting, welding, spraying, metallurgy, ultrafine particles synthesis and waste treatment. The understanding or the improvement of the corresponding processes or systems often requires precise modelling of the plasma. The thermal plasmas characteristics are first investigated with different turbulence models, i.e. the Reynolds Stress Model (RSM), the k-εmodel and its variants, the ReNor-malization Group (RNG) k-εmodel, the RNG k-εmodel taking into account the low Reynolds number effect and the realizable k-εmodel. The results of the RSM and the RNG k-εmodel taking into account the low Reynolds number effect are in reasonable agreement with the experiment. They both predict very close voltage, shock wave location and temperature variation along the axis to experiment. On the other hand, the other three models overestimate the turbulence effects and predict much lower velocity and temperature, especially the standard k-εmodel, which predicts the temperature is about 10000 K lower than the experiment in certain plasma jet regions.
After comparing the turbulence model, we use the RNG k-εmodel taking into account the low Reynolds number effect to investigate the plasma cutting arc. The effects of plasma-gas swirl flow, the process parameters, torch geometry and the shielding gas on the plasma cutting arc are investigated. When the inlet gas swirl number increases, the maximum pressure location moves to the plenum chamber edge due to centrifugal force, the minimum pressure location moves much closer to the axis. The difference between the maximum and minimum pressure increases with swirl number. This will constricts the arc and leads to large current density and Ohm heating near the axis, and causes much higher temperature near the cathode. It is indicated that the swirl gas accelerates cathode erosion for two reasons: increasing plenum chamber pressure and changing the flow patterns in the vicinity of cathode. It is also found that, the gas with large swirl number leads swirl velocity component to be larger at cutting location according to angular momentum conservation. It has been suggested that this causes the different bevel angles for the left and right edges of the cutting kerf. In the parameters study, it is shown that gas flow rate, arc current, nozzle bore length and radius have essential effects on plasma arc characteristics. Long nozzle torch can provide high velocity plasma jet with high heat flux. Both arc voltage and chamber pressure increase with the nozzle length. Small radius nozzle torch increases the plenum chamber pressure and providing off-axis maximum velocity after shock wave. High arc current increases plasma velocity and temperature, enhances heat flux and augments chamber pressure and thus, the shock wave. Strong mass flow has pinch effect on plasma arc inside the torch, enhances the arc voltage and power, therefore increases plasma velocity, temperature and heat flux. After comparing two different torch geometries, it is found that the shielding flow has no significant effects on plasma velocity and temperature except the shock wave region. The shielding flow decreases the shock wave, and increases the arc voltage due to cooling effect. In the impinging geometry, shielding flow will crash the plasma jet after the nozzle exit and slightly increases the pressure in the torch. It is shown that the component of shielding gas has no significant effect on plasma cutting arc. The mole fraction of oxygen decreases very slowly along the axis and is still more than 90% at 10 mm downstream the nozzle exit.
High-power hydrogen plasma torch (5 MW-10 MW) is of great importance in coal pyrolysis for producing acetylene and other industrial applications. Considering the large computational domain, the RSM is used to investigate high-power plasma torch. The calculated arc voltage and the electric potential distribution at electrodes are very close to the experimental data. It is found the swirl number has no significant effect on the plasma characteristics except the first two electrodes region. Both the arc voltage and energy-efficiency increase with the mass flow rate. It is shown that large mass flow will constrict the plasma arc, and therefore enhance the maximal temperature and velocity at the torch outlet.
引文
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