Splitter Erosion CFD Simulation Training using DPM by ANSYS Fluent

$100.00 Student Discount

In this study, using the DPM (Discrete phase material) method, the effect of impurities in the working fluid on the splitter erosion was investigated.

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Description

Splitter Introduction

A splitter is a device for uniformly distributing incoming fluid flow by placing outlets of the same shape and size. Using Splitter, in addition to evenly dividing the initial flow rate, can absorb the impurities with a filter and increase the purity of the outlet gas. The impact of impurities such as sand and oxides of various metals can lead to erosion overtime on the body of various equipment. Therefore, studying the effect of erosion on transmission pipelines and fluid flow distribution will be of particular importance.

Problem Description

In this study, using the DPM (Discrete phase material) method, the effect of impurities in the working fluid on the body gas splitter was investigated. The impurity gas entered vertically at a speed of 5 meters per second and was directed out through 3 outlets. Using Ansys Fluent software, the impurity distribution, concentration, adsorption, and reflection in the installed filters were observed. Different erosion models in the software help correctly predict the erosion effect according to different working conditions.

Splitter

Splitter Geometry & Mesh

The designed geometry specifications include a gas splitter with three nozzles at the outlet. The inlet diameter of the mainstream is 1.6 cm, and the outlet nozzles’ diameter is 0.3 cm. In addition, 2.5 cm long fins are located inside the geometry as a filter (Figure below). (Design Modeler software)

Splitter

For grid generation, unstructured mesh with 2728426 elements in the ANSYS Meshing module was utilized. The curvature and proximity method focused on grid-sensitive areas like close to fins. Also, the boundary layer mesh next to the walls was used to satisfy the turbulence model Y+.  The following figure shows the mesh generation for this problem.

SplitterSplitterSplitter

Solver Setting

ANSYS Fluent software was used to solve the governing equations numerically. The problem is analyzed steady using the pressure-based method, and the gravitational effects were not considered. Also, for solving the above problem, RANS Includes discrete phase particles by integrating the force balance on the particles, which is written in a Lagrangian reference frame. This force balance equates the particle inertia with the forces acting on the particle.

Material Properties

Due to the high-speed internal flow in the computational domain, the natural gas density was assumed to be constant and thermodynamic characteristics such as viscosity and thermal conductivity of gas and impurity density were set.

Boundary Conditions and Solution CFD Methods

Also, The table below shows the characteristics and values of boundary conditions, along with the models and hypotheses.

Material Properties (Erosion)
Natural gas
Amount Fluid properties
0.65 Density (kg/m3)
0.00013 Viscosity (kg/m.s)
Inert-particle (impurities)
Amount Fluid properties
1600 Density (kg/m3)
Discrete phase model (DPM)
Interaction with continuous phase (Erosion) 10 continues phase iteration per DPM
Max step tracking 50000
Step length factor 5
Physical model Erosion/Accretion

Generic model

Finnie

Oka

Accuracy Control 1e-5
Max.Refinement 20
Tracking Scheme Selection: Trapezoidal
Injection type: Surface velocity inlet
Diameter Distribution: uniform
Diameter: 0.15mm
Total flow rate: 0.04627kg/s
Drag law: Spherical
Turbulent Dispersion: Stochastic Tracking

Discrete Random Walk Model

Random Eddy Lifetime

Number of Tries 10

Time Scale Constant 0.3

The number of particles tracked: 24900
The number of particles trapped: 8202
The number of particles that escaped: 16695
Initialize: standard
Boundary Condition (Erosion)
Type Amount (units)
Velocity inlet 5 m/s
pressure outlet (gauge pressure) 0 pa
domain wall
Fin wall trap
External domain wall escape
Cell zone condition
Fluid Natural gas
Turbulence models (Erosion)
K-  viscous model
Realizable K- model
Enhanced-wall treatment Wall function
Solution methods (Erosion)
SIMPLE pressure velocity coupling
Standard pressure spatial discretization
Second-order upwind momentum
First-order upwind turbulent kinetic energy
First-order upwind      turbulent dissipation rate

Splitter Results

In this section, erosion models are first examined. The generic model can be used as an analytical equation for most cases because the material of impurities in this model is sand, which is present in most models. In model Finnie, which, like Oka and Mclaury models, uses an empirical correlation to predict erosion, it is mainly used for malleable materials. The Collision angle and velocity are effective. The model Oka considers the effect of wall hardness and may be more suitable for investigating the erosion of transmission pipes. Model Mclaury is used to study suspended solids in water and was unsuitable for the present case.

According to the above observations, by erosion contours of the splitter wall and examining the appropriate models, it was observed that in all models, the impact of particles on the upper wall due to high fluid velocity causes more erosion compared to other areas. The outlet nozzle walls are then subject to higher erosion. Oka Erosion diagrams have also been monitored during solution solving to better investigate the problem’s convergence.

Results

Splitter

Examination of the contour of the impurity concentration shows that in the output part of the Splitter, due to the high velocity of the downstream flow and the reduction of cross-section, the exit of solid particles were challenging, and the accumulation of particles in that part causes the concentration of impurities to increase. However, due to the placement of filtered fins, can increase the adsorption of impurity particles, which can be seen in the table above by trap and escape particle track.

Reviews

  1. Avatar Of Brandy Armstrong

    Brandy Armstrong

    This training product for splitter erosion using DPM sounds incredibly detailed. I’m curious though, did the study address how different particle sizes might affect erosion patterns and intensities?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In the simulation, a uniform particle diameter of 0.15mm was considered for the discrete phase model (DPM), which assesses impurities interacting with the continuous phase leading to erosion. While the training product might not have directly addressed varying particle sizes, the specified uniform diameter provides insights into erosion patterns and intensities for that particular size. For a comprehensive understanding of erosion with respect to different particle sizes, additional simulations varying particle diameters would be required.

  2. Avatar Of Barbara Emard

    Barbara Emard

    The review lacks clarity regarding the specific erosion models’ suitability for different materials. Could you elaborate on that part?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In the training, various erosion models like Finnie, Oka, and McLaury are discussed. Each model has its suitability for assessing erosion based on different material properties and flow conditions. The Finnie model is typically used for malleable materials where impact angle and velocity are crucial. The Oka model incorporates the hardness of the wall material, making it apt for exploring erosion in pipelines. McLaury’s model, while not applicable here, is commonly used for studying erosion due to suspended solids in water streams.

  3. Avatar Of Yesenia Leannon

    Yesenia Leannon

    Wonderful learning material! The detailed insight into splitter erosion and the usage of DPM in ANSYS Fluent is exceptional. I appreciate the versatility of the erosion models discussed, catering to various materials and conditions. The simulation seems comprehensive, with precise handling of complex flow dynamics, and the result analysis correlates beautifully with the theoretical expectations.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your kind words and appreciation of our training material! It’s wonderful to hear that the details on splitter erosion and the Discrete Phase Model execution could provide you with valuable insights. We strive to create content that captures the complexity of such simulations in accessible ways, and it’s rewarding to know we succeeded. Your feedback motivates us to continue delivering quality educational products. If you ever have more questions or need further assistance, do not hesitate to reach out to us.

  4. Avatar Of Leonie Purdy

    Leonie Purdy

    Fantastic learning experience with the Splitter Erosion CFD Simulation Training! The detailed analysis of erosion models and the insights on particle tracking through DPM in ANSYS Fluent were particularly impressive. It’s clear that a lot of thought went into the design and execution of the simulation. The step-by-step approach made it easy to follow, and I can apply these concepts to my projects.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your kind words! We’re glad to hear that the Splitter Erosion CFD Simulation Training exceeded your expectations and provided you with valuable insights for your work. Our goal is always to deliver comprehensive and practical learning experiences. Your feedback is greatly appreciated, and we look forward to continuing to support your learning journey!

  5. Avatar Of Arnoldo Blick

    Arnoldo Blick

    This training seems pretty comprehensive. Could you explain if temperature effects are also considered in these erosion models, or are these calculations done under isothermal conditions?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In this particular training, the simulations are run focusing on erosion patterns under steady-state conditions without specifying the inclusion of temperature effects. The evaluations are based on the DPM method, impurity interactions, and erosion rates without mentioning thermal dynamics, suggesting that temperature variations are not factored into the models, and the study is likely conducted under isothermal conditions.

  6. Avatar Of Lenna Kreiger V

    Lenna Kreiger V

    I am truly impressed with the results provided by the Splitter Erosion CFD Simulation training. The comprehensive analysis of erosion and choice of models for different materials was very informative. The visualization of particle concentration and the complex motion within the splitter has greatly enhanced my understanding of splitter dynamics. Remarkable work on providing such detailed insights!

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your positive feedback! We are glad to hear that the Splitter Erosion CFD Simulation training has enriched your knowledge about splitter dynamics and erosion analysis. It’s great that you found the visualizations and information comprehensive and insightful. If you have further queries or need more information, feel free to reach out to us.

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