摘要
鼓泡塔反应器是一种工业中广泛应用的气-液两相和气-液-固三相接触与反应装置。目前鼓泡塔或浆态床反应器大型化已成为煤化工与石油天然气化工的发展趋势,相关的放大问题和过程强化问题取决于对塔内流体力学规律的了解与把握。现有文献中有关鼓泡塔的流体力学研究大多数集中在低气速(0.03-0.12m/s)、小塔径(<0.5m)、以及无内构件的情况,针对高气速、较大塔径、特别是含密集内构件条件下的湍动鼓泡流情况还研究得很不充分。有鉴于此,本论文针对湍动鼓泡塔充分发展段的流体力学及内构件技术展开研究,采用冷模实验测量与计算流体力学(CFD)模拟两种方法系统地考察空塔与含密集内构件的鼓泡塔流体力学规律,建立各种情况下的鼓泡塔流体力学模型,用于鼓泡反应器的模拟、放大与内构件技术开发。论文主要包括以下几个方面：
1.湍动鼓泡塔流体力学参数的实验测量：使用自制电导探针、Pavlov管和径向测速管在三种不同直径(186、476、760mm)的鼓泡塔冷模实验装置内,实验测定了高空塔气速(0.12-0.62m/s)、高固含率(体积分率10-30%)条件下的平均气含率、鼓泡塔充分发展段的局部气含率、轴向液速、三维脉动均方根速度和湍流动能的径向分布,并考察了不同因素对上述分布的影响规律。
2.湍动鼓泡塔充分发展段的一维流体力学模型：根据气液间的横向升力和湍流扩散力的径向平衡机制建立了描述鼓泡塔或浆态床气含率分布的本构关系,提出了针对无内构件的鼓泡塔充分发展段的一维拟均相k-ε模型。模型计算得到的在不同塔径、空塔气速和固含率条件下的气含率、轴向液速和湍流动能分布与实验测量结果符合良好。应用该模型对无内构件的空塔进行了流体力学放大预测。
3.鼓泡塔纵向列管内构件流动规律的实验研究：在Φ476鼓泡塔内测定了不同列管密度和空塔气速下的气含率与液速径向分布、湍流脉动速度与动能分布。实验揭示列管束的加入显著提高了液相或浆料相的循环速度,速度梯度随着列管布置密度的增大而增加,气含率分布也呈现明显的陡峭化趋势,该现象称为“烟囱效应”。实验考察了气速和列管束密度对流动参数分布的的定量影响,从流动机理方面对“烟囱效应”进行了分析,澄清了文献中对这一问题的不同认识。
4.含列管内构件的鼓泡塔流体力学模型：在实验研究基础上对带列管束的鼓泡塔进行了流体力学建模,将密集列管内构件的作用考虑为连续分布的动量源、动能源、耗散源,摒弃了现有的CFD模型将列管壁面考虑为复杂几何边界的做法,根据力学原理给出了列管束各体积源项的本构关系,添加到一维湍流k-ε方程之中。模型计算的气含率分布、液速分布、湍动动能分布在宽泛的条件下与实验测量值符合良好,能够定量描述“烟囱效应”以及内构件参数对流动的影响。采用该模型对浆态床费托合成反应器进行了流体力学放大预测。
5.带阻尼内构件的鼓泡塔流体力学研究：实验考察了多层阻尼网格、网格+列管、针翅列管三种内构件对鼓泡塔气含率和轴向液速分布的影响。实验表明：阻尼内构件的加入可有效改善塔内液速分布,提高平均气含率,抑制列管束“烟囱效应”,减小塔内返混,其中针翅列管还可强化传热,是一种多功能内构件。根据阻尼内构件对流体作用力的分析,建立了描述该型内构件影响的鼓泡塔流体力学模型。
6.鼓泡塔传热规律研究：使用自制传热探头测定了Φ476鼓泡塔内,列管内构件与针翅内构件的传热系数径向分布。实验表明,列管传热系数随表观气速的增加而增大,且沿径向呈抛物型分布,竖直列管内构件的加入使得传热系数的径向分布更不均匀；针翅管可有效强化传热,与光滑列管相比,传热系数提高了20%以上。基于表面更新理论,提出了计算传热系数的关联式与模型。
Bubble column reactors are widely applied in chemical industry as effective multiphase contactors for gas-liquid or gas-liquid-so lid phase reactions. At present, more and more large scale reactors become the tendency in coal, natural gas and petrochemical industries. Hydrodynamics of bubble column is the key for scale-up and process intensification. However, most of the published literatures were limited to the experimental conditions of low superficial gas velocity range (0.03 to 0.12m/s). small columns (<0.5m), and without internals. Studies on churn turbulent bubbly flow at high superficial gas velocity, in large-scale column, and especially in column with intensive internals are still inadequate. In view of this, a systematic research on hydrodynamics of turbulent bubble column both with and without internals was carried out in this paper. Attention was focused on the well-developed flow region. Both cold-model experiments and CFD simulations were performed to unveil hydrodynamic characteristics of turbulent bubbly flow under various conditions. Novel hydrodynamic models were developed for the reactor simulation, scale-up and development of novel internal technologies. The content of this paper covers following aspects.
1. Measurement of hydrodynamic parameters in column without internals.The average and local gas holdup, axial liquid/slurry velocity,3D root mean square (RMS) liquid fluctuation velocities in the well-developed flow region of different-size bubble columns (186mm,476mm and 760mm). were measured by use of in-house developed conductivity probe. Pavlov tube and radial Pitot tube. Radial profiles of the above hydrodynamic parameters were obtained under high superficial gas velocity (0.12 to 0.62m/s) and high solid holdup (volume fraction of 10 to 30%v/v) conditions. Effects of superficial gas velocities, solid holdup, and column size were investigated.
2. Development of one-dimensional hydrodynamic model for the well-developed flow region. Equations for determination of gas holdup radial distribution were firstly proposed in line with the radial movement balance mechanism between the lateral lift force and turbulent dispersion force imposed on the bubble swarm. Based on it a ID k-εmodel for well-developed flow region of column without internals was presented. The computed profiles of gas holdup, axial liquid velocity and turbulent kinetic energy agree well with experimental data under all investigated conditions. Scale-up predictions in column hydrodynamics were made by use of the model.
3. Experimental investigation on flow characteristics in column with vertical pipe bundles. The profiles of gas holdup, time-average and RMS fluctuate liquid velocities, turbulent kinetic energy were measured in 0476 bubble column with different number of pipes and superficial gas velocities. The results showed that the vertical pipes will remarkably enhance the circulation velocity of liquid or slurry phase. The radial gradients of liquid velocity and gas holdup increase with density of pipe bundles. These phenomena were called "funnel effect". Effects of superficial gas velocity and density of pipe bundles were investigated. Mechnism for the "funnel effect" was analysed, which clarified some disagreed results presented in literatures.
4. CFD modeling for bubble column with pipe bundle internals. The hydrodynamic model for bubble column with pipe bundles was developed on basis of experimental results. The effect of pipe bundles was regarded as continuously distributed volumetric sources of momentum, kinetic energy and dissipation, instead of complex rigid wall boundaries adopted in present literatures. Constitutive relations for these volumetric source terms were deduced in line with mechanic principle, which were added as mass, momentum and turbulent sources in turbulent k-e equations. Radial profiles of gas holdup, liquid velocity and turbulent kinetic energy computed by the model showed good agreements with experimental data. The model provided a powerful tool for the simulation of the "funnel effect" caused by the pipe bundles in bubble column.The model was used to simulate the scale up hydrodynamic behaviors of FT synthesis slurry bubble column reactors.
5. Experiments and modeling on hydrodynamics of resistance internals. Three kinds of resistance internals were considered:multi-layer screens, multi-layer screens plus pipe bundles, spin-fin pipe bundles. The experimental data showed that all these resistance internals can effectively improve liquid velocity distributions, dampen the funnel effect and reduce the back mixing. In addition, the spin-fin pipe can also intensify heat transfer, and is a multifunction internal. Hydrodynamic models for the resistance internals were developed.
6. Heat transfer measurements in bubble columns. Radial distributions of heat transfer coefficients both for bare vertical pipes and spin-fin pipes in 0476 bubble column were measured by in-house developed heat transfer probes. The experiment results showed that the heat transfer coefficients distribution has a parabolic-like curve that similar to velocity and gas holdup profiles, and increase of pipe number leads to more steeper distributions, which is also in line with the pipe bundle "funneling effect". The heat transfer coefficient for the spin-fin pipe is above 20% larger than that of bare pipe, which confirms that the spin-fin pipe can remarkably intensify heat transfer. Correlations based on the surface renewal model for calculation of heat transfer coefficients under various conditions were presented.
引文
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