气固两相流对旋风分离器壁面磨损机理的研究
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摘要
旋风分离器由于结构简单,耐高温、高压,维护方便等优点,在众多领域得到了广泛的应用。然而,在实际运行过程中也逐渐暴露出了一些问题,其中旋风分离器壁面的磨损,已成为严重制约其应用与发展的首要问题。目前,从国内外已有的研究工作来看,对旋风分离器壁面的磨损还缺乏足够的认识,仅有的结论也多源于现场经验,对于分离器壁面的磨损机理更是欠缺系统的分析。本文正是针对旋风分离器壁面存在的严重磨损问题,采用理论分析和数值试验相结合的研究方法,借助先进的计算流体力学技术,深入研究了气固两相流对旋风分离器壁面的磨损情况,探讨了壁面磨损的机理。
首先对基于CFD的壁面磨损预测模型的基础理论进行了介绍,该模型主要包括内部流场计算、颗粒运行轨迹追踪和运用磨损方程计算磨损值三个部分。在此基础上,运用该方法计算了气固两相流对旋风分离器壁面的磨损情况。通过计算得知:分离器壁面以局部磨损为主,壁面严重磨损的区域有环形空间顶板附近区域、从入口方向看到的环形空间筒体壁面区域、分离空间筒体区域的螺旋磨损槽以及锥体末端区域。环形空间壁面磨损率在周向上呈先增加后降低的趋势;在分离空间筒体段磨损率沿轴向呈“波形”状变化,有明显的波峰和波谷出现;在分离空间锥体壁面,磨损率随着轴向位置的增加而增大,且在锥体末端附近出现磨损峰值,但随后又明显降低。
其次研究了不同结构参数(排气管直径比、排尘口直径比、入口面积比)、不同入口结构型式、不同操作参数(入口速度、操作温度)以及颗粒粒径变化对旋风分离器壁面磨损的影响规律。研究结果表明:这些参数对旋风分离器壁面磨损的部位以及磨损率的大小都有不同程度的影响,为进一步完善和改进设计、优化结构尺寸以提高设备工艺性能奠定基础。
最后结合实验室和工业现场应用旋风分离器的实际磨损情况,对壁面局部磨损部位的宏观形貌和微观形貌进行了观察分析,研究其失效行为,建立壁面磨损的模型,探讨了旋风分离器不同区域壁面磨损的产生机制,同时研究了固体颗粒对壁面局部区域磨损的微观机理。研究结果显示:旋风分离器壁面磨损的失效不是固体颗粒作用造成的大面积均匀的磨损,而是受到颗粒严重冲蚀的局部区域磨损。局部磨损区域发生了明显的塑性变形,有犁沟状冲蚀磨损形貌存在,基体表面布满均匀的条状磨痕,磨痕方向大体一致;局部区域伴随有带方向的凹坑出现,在凹坑的前方有明显的塑性变形和材料挤出的现象。就气固两相流体的流动特性而论,颗粒对壁面的磨损有三种主要机理:固体颗粒与壁面的直接碰撞磨损、湍流运动中固体颗粒与壁面的随机碰撞磨损和滑移颗粒与壁面之间的摩擦磨损。而旋风分离器壁面局部磨损的微观机制为冲刷—切削—撞击—冲刷—剥落,即以颗粒相对壁面碰撞角度较小的微观切削为主,以碰撞角度较大颗粒的撞击剥落为辅。
Cyclone separator has obvious advantages of simple structure, high temperature resistant, high pressure resistant and convenient maintenance. These make cyclone separator share a wide range of applications in many industries. However, some problems have revealed in the actual operation, especially the erosion of cyclone separator’s surface wall, which seriously restricts the cyclone’s development and application. At present, previous researches don’t have an adequate understanding of the wall erosion mechanism of cyclone separator. Most of existing conclusions are obtained from field experience rather than systemic theoretical analysis. In this paper, theoretical analysis and numerical simulation were adopted to study the serious erosion problem of cyclone separator. The advanced computational fluid dynamics was applied to investigate wall erosion of cyclone separator caused by gas-solid two-phase flow and discuss the erosion mechanism further.
Firstly, the theories of CFD-based erosion prediction model were introduced in this paper. Usually this model consists of three main sections: internal flow field modeling, particle trajectory tracking, and erosion computing modeling. On this basis, using this method compute the erosion of cyclone separator’s surface wall caused by gas-solid two-phase flow. Through calculation find that the eroded surface wall of cyclone separator is mainly local erosion. Several severe erosion regions are the annular space near the roof, the cyclone barrel which is in the direct line-of-sight of the inlet, the helical-shaped grooves in separated barrel space and the lower cone. Erosion rate of annular space increases first and then decreases along circumferential direction. At separated barrel space, the trend of erosion rate distribution along the axial direction is“wave”shape; there are clear sharp crests and troughs appearance. At separated cone space, erosion increases rather strongly with axial distance down the cone section and reaches its maximum value in the lower or lowermost section of the cone and then lower apparently.
Secondly, in this paper the erosion law of cyclone separator’s surface wall was studied under different structure parameters (vortex finder diameter ratio, dust exit diameter ratio, and inlet area ratio), different inlet structure, different operation parameters (inlet velocity and operation temperature) and different particle diameter. The results show that these parameters have varying degrees influence on the erosion location and erosion rate of cyclone separator’s wall.
Finally, based on the laboratory and industrial field application of cyclone separator, observe macro and micro morphology of local wear parts wall, study its failure analysis and establish wall erosion model. At the same time, the erosion mechanisms of different parts of cyclone separator and micro mechanisms of severe local erosion zone caused by particles impingent are also studied in this section. Research results show that the failure of cyclone separator’s wall is not the uniform erosion of surface wall, but the local erosion caused by particles seriously impact. The local eroded regions have obviously plastic deformation and appear plough troughs. Grinding strips are uniform on the surface wall, grinding mark cardinally identical direction. There are pits appear accompanied with the local eroded regions. Plastic deformation and extrusion is observed at the tip of the leading edge of the large trough. In terms of gas-solid two-phase flow characteristics, there are three main mechanisms: the directional impingement of solid particles, the random impingement of particles in turbulent motion, and the friction of a sliding bed pressing onto the wall. The micro mechanism of local erosion on surface wall of cyclone separator’s is scousr-cutting-impingement-scousr-exfoliation. That is to say, micro-cutting arises primarily from the small collision angle of particle and surface, while collision exfoliation arises from the bigger collision angle.
首先对基于CFD的壁面磨损预测模型的基础理论进行了介绍,该模型主要包括内部流场计算、颗粒运行轨迹追踪和运用磨损方程计算磨损值三个部分。在此基础上,运用该方法计算了气固两相流对旋风分离器壁面的磨损情况。通过计算得知:分离器壁面以局部磨损为主,壁面严重磨损的区域有环形空间顶板附近区域、从入口方向看到的环形空间筒体壁面区域、分离空间筒体区域的螺旋磨损槽以及锥体末端区域。环形空间壁面磨损率在周向上呈先增加后降低的趋势;在分离空间筒体段磨损率沿轴向呈“波形”状变化,有明显的波峰和波谷出现;在分离空间锥体壁面,磨损率随着轴向位置的增加而增大,且在锥体末端附近出现磨损峰值,但随后又明显降低。
其次研究了不同结构参数(排气管直径比、排尘口直径比、入口面积比)、不同入口结构型式、不同操作参数(入口速度、操作温度)以及颗粒粒径变化对旋风分离器壁面磨损的影响规律。研究结果表明:这些参数对旋风分离器壁面磨损的部位以及磨损率的大小都有不同程度的影响,为进一步完善和改进设计、优化结构尺寸以提高设备工艺性能奠定基础。
最后结合实验室和工业现场应用旋风分离器的实际磨损情况,对壁面局部磨损部位的宏观形貌和微观形貌进行了观察分析,研究其失效行为,建立壁面磨损的模型,探讨了旋风分离器不同区域壁面磨损的产生机制,同时研究了固体颗粒对壁面局部区域磨损的微观机理。研究结果显示:旋风分离器壁面磨损的失效不是固体颗粒作用造成的大面积均匀的磨损,而是受到颗粒严重冲蚀的局部区域磨损。局部磨损区域发生了明显的塑性变形,有犁沟状冲蚀磨损形貌存在,基体表面布满均匀的条状磨痕,磨痕方向大体一致;局部区域伴随有带方向的凹坑出现,在凹坑的前方有明显的塑性变形和材料挤出的现象。就气固两相流体的流动特性而论,颗粒对壁面的磨损有三种主要机理:固体颗粒与壁面的直接碰撞磨损、湍流运动中固体颗粒与壁面的随机碰撞磨损和滑移颗粒与壁面之间的摩擦磨损。而旋风分离器壁面局部磨损的微观机制为冲刷—切削—撞击—冲刷—剥落,即以颗粒相对壁面碰撞角度较小的微观切削为主,以碰撞角度较大颗粒的撞击剥落为辅。
Cyclone separator has obvious advantages of simple structure, high temperature resistant, high pressure resistant and convenient maintenance. These make cyclone separator share a wide range of applications in many industries. However, some problems have revealed in the actual operation, especially the erosion of cyclone separator’s surface wall, which seriously restricts the cyclone’s development and application. At present, previous researches don’t have an adequate understanding of the wall erosion mechanism of cyclone separator. Most of existing conclusions are obtained from field experience rather than systemic theoretical analysis. In this paper, theoretical analysis and numerical simulation were adopted to study the serious erosion problem of cyclone separator. The advanced computational fluid dynamics was applied to investigate wall erosion of cyclone separator caused by gas-solid two-phase flow and discuss the erosion mechanism further.
Firstly, the theories of CFD-based erosion prediction model were introduced in this paper. Usually this model consists of three main sections: internal flow field modeling, particle trajectory tracking, and erosion computing modeling. On this basis, using this method compute the erosion of cyclone separator’s surface wall caused by gas-solid two-phase flow. Through calculation find that the eroded surface wall of cyclone separator is mainly local erosion. Several severe erosion regions are the annular space near the roof, the cyclone barrel which is in the direct line-of-sight of the inlet, the helical-shaped grooves in separated barrel space and the lower cone. Erosion rate of annular space increases first and then decreases along circumferential direction. At separated barrel space, the trend of erosion rate distribution along the axial direction is“wave”shape; there are clear sharp crests and troughs appearance. At separated cone space, erosion increases rather strongly with axial distance down the cone section and reaches its maximum value in the lower or lowermost section of the cone and then lower apparently.
Secondly, in this paper the erosion law of cyclone separator’s surface wall was studied under different structure parameters (vortex finder diameter ratio, dust exit diameter ratio, and inlet area ratio), different inlet structure, different operation parameters (inlet velocity and operation temperature) and different particle diameter. The results show that these parameters have varying degrees influence on the erosion location and erosion rate of cyclone separator’s wall.
Finally, based on the laboratory and industrial field application of cyclone separator, observe macro and micro morphology of local wear parts wall, study its failure analysis and establish wall erosion model. At the same time, the erosion mechanisms of different parts of cyclone separator and micro mechanisms of severe local erosion zone caused by particles impingent are also studied in this section. Research results show that the failure of cyclone separator’s wall is not the uniform erosion of surface wall, but the local erosion caused by particles seriously impact. The local eroded regions have obviously plastic deformation and appear plough troughs. Grinding strips are uniform on the surface wall, grinding mark cardinally identical direction. There are pits appear accompanied with the local eroded regions. Plastic deformation and extrusion is observed at the tip of the leading edge of the large trough. In terms of gas-solid two-phase flow characteristics, there are three main mechanisms: the directional impingement of solid particles, the random impingement of particles in turbulent motion, and the friction of a sliding bed pressing onto the wall. The micro mechanism of local erosion on surface wall of cyclone separator’s is scousr-cutting-impingement-scousr-exfoliation. That is to say, micro-cutting arises primarily from the small collision angle of particle and surface, while collision exfoliation arises from the bigger collision angle.
引文
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