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The demand for increasing product diversity in the chemical process industry calls for new production processes that enable greater flexibility. Therefore, plants are needed that produce significant quantities for market supply that can be scaled up to several tons per year. Compared to traditional batch processes, intensified continuous production enables not only flexibility but also the production of compounds that are difficult to produce. Custom-designed small-scale reactors significantly improve heat and mass transfer through micro mixing and can improve safety, e.g. in the case of high grade exothermic or high-pressure reactions, and might play an important role for customized, modular production facilities.1 Combined with optimally designed flow cells, compact NMR instruments currently present promising analytical tools for use in flow chemistry applications.2,3 In recent process monitoring applications, the flow cell and the mixing unit are usually separated parts leading to a severe time delay between mixing and first data acquisition.
In this work, we present a comprehensive workflow for the design of a flow cell−mixer combination based on CFD simulation and other design principles.4 Due to the increasing opportunities in additive manufacturing of ceramics, it was possible to realize an optimized SMX-type mixer with a fully integrated NMR flow cell (cf. Fig. 1).
Validation studies exhibited 1H NMR spectra with a quality comparable to common NMR glass tubes. So far, the mixing performance of the system has been evaluated for different mass flow rates within the intended working range of 5–120 seconds region and compared to ideally mixed samples. Thus, the integrated flow cell−static mixer combination can be used for different purposes such as evaluation of fluid properties, equilibration studies, or reaction monitoring of two instantaneously mixed samples.
The ceramic flow cell was additively manufactured and analyzed through x-ray microtomography revealing surface characteristics due to the manufacturing process (cf. Fig. 2). Furthermore, the working range of the whole system was characterized leading to an operational specification for further applications.
In summary, the role of custom-designed components for modular, chemical production, amongst other essential factors like fast development of reliable evaluation models is discussed.
References
[1] Bornemann-Pfeiffer et al., Chem. Ing. Tech. (2021), 93: 1–10
[2] Kern et al., Anal. Bioanal. Chem. (2018) 410: 3349–3360
[3] Kern et al., Anal. Bioanal. Chem. (2019) 411: 3037–3046
[4] Bornemann et al., Ind. Eng. Chem. Res. (2019), 58: 19562−19570
Air-coupled ultrasonic testing is widely used in the industry for the non-destructive testing of compound materials. It provides a fast and efficient way to inspect large concrete civil infrastructures for damage that might lead to catastrophic failure. Due to the large penetration depths required for concrete structures, the use of traditional piezoelectric transducer requires high power electric systems. In this study, a novel fluidic transducer based on a bistable fluidic amplifier is investigated. Previous experiments have shown that the switching action of the device produces a high-power broadband ultrasonic signal. This study will provide further insight into the switching behaviour of the fluidic switch. Therefore, parametric CFD simulations based on compressible supersonic RANS simulations were performed, varying the inlet pressure and velocity profiles for the control flow. Switching times are analyzed with different methods, and it was found that These are mostly independent of the slope of the velocity profile at the control port. Furthermore, it was found that an inversely proportional relationship exists between flow velocity in the throat and the switching time. The results agree with the theoretical background established by experimental studies that can be found in the literature.
A numerical model for simulation of the steady-state thermal behaviour in keyhole mode welding has been developed. It is based on the equivalent heat source concept and consists of two parts: computational thermo-hydrodynamics and heat conduction. The solution of the thermo-hydrodynamics problem by the finite element method for a bounded domain results in a weld pool interface geometry being the input data for a subsequent heat conduction problem solved for a workpiece by a proposed boundary element method. The main physical phenomena, such as keyhole shape, thermo-capillary and natural convection and temperature-dependent material properties are taken into consideration.
The developed technique is applied to complete-penetration keyhole laser beam welding of a 15 mm thick low-alloyed steel plate at a welding speed of 33 mm/s and a laser power of 18 kW. The fluid flow of the molten metal has a strong influence on the weld pool geometry. The thermo-capillary convection is responsible for an increase of the weld pool size near the plate surfaces and a bulge formation near the plate middle plane. The evaluated and experimental molten pool, cross-sectional weld dimensions and thermal cycles of the heat affected zone are in close agreement.
Mittels Propan-Brennern mit einer Brennerleistung 750 kW wurden in einer U-Bahn-Station Heißgasversuche durchgeführt und die zeitlichen und örtlichen Verteilungen der physikalischen Größen (Stoffkonzentration, Temperatur und Rauchgasdichte) erfasst. Laborversuche sowie die Feldversuche sind Validierungsgrundlage für ANSYS CFX und FDS und die später im Rechenmodell der U-Bahn-Station zur Untersuchung der Grundströmung und Rauchausbreitung verwendeten mathematisch-physikalischen Modelle. Der Aufsatz stellt das Projekt ORPHEUS vor und diskutiert die ersten Ergebnisse.
Nach DIN 18230-1 erfolgt in Deutschland die Brandlastberechnungen unter Anwendung
des Abbrandfaktors m. Der Abbrandfaktor m ist ein dimensionsloser Beiwert mit dem die
Brandlast aus einem Stoff oder Stoffgemisch bewertet wird. Neben dem Brandverhalten
des Stoffes berücksichtigt er das Temperatur-Zeit-Verhalten im Bauteil. Die einzige
Prüfapparatur, mit der Abbrandfaktoren bestimmt wurden, ist jedoch nicht mehr existent.
Ein Wiederaufbau der abgeschafften Prüfapparatur wurde wegen apparateabhängigen
Messunsicherheiten und auch aus wirtschaftlichen Gründen als nicht sinnvoll angesehen.
Die Erarbeitung eines äquivalenten Verfahrens zum Abbrandfaktor m unter Verwendung
der Verbrennungseffektivität und unter Berücksichtigung der Bauteilerwärmung war daher
Gegenstand dieses Forschungsvorhabens. Ziel war es für Brandlastberechnungen
nach DIN 18230-1 die Verbrennungseffektivität anzuwenden. Die Verbrennungseffektivität
beschreibet jedoch nur den verringerten Energieumsatz von Stoffen im Brandraum.
Es wurde daher ein Verfahren erarbeitet, dass ergänzend zur Brandlastberechnung unter
Anwendung der Verbrennungseffektivität das Temperatur-Zeit-Verhalten in einem
brandbelastenden Bauteil berücksichtigt.
The time dependent thermal behavior is analyzed with FLUENT for the fluid as well as the solid region (concrete component) in case of a 100 MW n-heptane fire. To study the effect of parameters in mathematical-physical models several sensitivity studies were carried out to investigate the effect on the fluid flow as well as on the component. The influence of soot was additionally considered. FDS simulations as well as empirical calculations considering underlying assumptions are additionally used to examine the plausibility of results from the FLUENT simulations. This is an appropriate method if no experimental results are available. Recommendations are given for choosing parameters in mathematical-physical models e.g. radiation models. The results of the CFD investigations show that considering the influence of soot provides maximum temperatures which were 200 K lower than without soot.
Heute verfügbare Technik ermöglicht es, die Wärmetransportmechanismen im Brand, an der Bauteiloberfläche und im Bauteil mittels CFD zu koppeln. Die Kopplung von Fluid und Struktur wurde am Beispiel eines 100-MW-Tunnelbrands mit CFD (Computational Fluid Dynamics) untersucht. Die instationären Berechnungen wurden mit dem CFD-Programm ANSYS Fluent durchgeführt. Der infolge eines Lkw-Unfalls verursachte n-Heptan-(C7H16)-Brand wurde mit dem Eddy-Dissipation-Verbrennungsmodell modelliert.
Das Fluid- und Solid-Gebiet wurden durch ein ‚Interface‘ gekoppelt. Die instationäre Wärmeleitung des Bauteils mit einer Höhe von 0,4 m wurde mit der dreidimensionalen Fourier´schen Wärmeleitungsgleichung modelliert und das instationäre thermische Verhalten des quarzhaltigen Betonbauteils analysiert. Temperaturabhängige Stoffkennwerte wurden berücksichtigt.
Dangerous goods are transported as air freight in commercial aircrafts. Using plastic jerrycans or plastic containers, liquids or gases can escape by leakage or permeation effects. Prior research by the German Federal Institute for Materials Research and Testing (BAM) showed that the lower explosion limit can be reached when transporting dangerous goods in sea-freight containers under normal transportation situations. This motivated the presented study of the transportation situation of dangerous goods in cargo compartments of commercial airplanes. The scope of this paper is to present the experimental method used for validating a numerical model for CFD (Computational Fluid Dynamics) simulations. The CFD model will be used in a future study to evaluate the potential risk from transporting dangerous goods.
The objective of this paper is to present the model mock-up of an aircraft cargo compartment and some examples of three dimensional velocity profiles of the air flow in the mock-up. The velocity profiles are calculated using numerical simulations and measured by Laser-Doppler-Anemometry (LDA) experiments. The mock-up is a generic model of a wide-body aircraft lower deck cargo compartment in a 1:10 scale. Geometry, air exchange rates and inlet as well as outlet flow conditions in the cargo compartment are modeled using realistic boundary conditions. The commercial CFD (Computational Fluid Dynamics) code ANSYS CFX 14 is used for numerical flow simulations applying RANS (Reynolds-Averaged-Navier-Stokes) equations and turbulence models. The turbulence models studied are the renormalization group k-ε-model (RNG), the Reynolds-Stress model by Launder, Reece and Rodi (LRR) and the SST-k-ω-model by Menter (SST).
The flow measurement with LDA in the mock-up of a cargo compartment proves to be a feasible method for producing data to validate CFD simulations. Qualitative evaluation of the results shows a good overall agreement between numerical and experimental results. The experimental validation indicates that the implemented CFD model is capable of reproducing the flow situation in the model mock-up.
In the frame of the European harmonization, new European technical standards (Eurocodes) have been developed in recent years. Classical methods, like tables and simplified analytical procedures, as well as general engineering techniques are allowed by the Eurocodes for the fire protection design. The modeling and calculation of fire scenarios with CFD (Computational Fluid Dynamics) numerical methods is one of the general engineering methods. It is nowadays still difficult to check and evaluate the CFD results for their use as technical documents for fire safety design.
Analytical engineering techniques, zone models and CFD-models have been used and compared in the present work for the prediction of the fire development in a building.
To solve the conservation equation for the CFD-model, the CFD-program FDS, with the mixture fraction model, and the CFD-program FLUENT, with the one step reaction model as well as with the volumetric source term model, have been used.
The combustion of polyurethane is modeled in FDS by specifying the heat release rate and the stoichiometry. For the combustion in volumetric source term model, the heat release rate and the smoke release were specified with respect to the stoichiometry. The input parameter for the one step reaction model is the pyrolysis mass flow.
In the one step reaction model, the transport equations for polyurethane, H₂O, N₂, O₂, CO₂, CO and C (soot) are solved and the heat of combustion is determined from the standard formation enthalpy of all the components. In volumetric source term model, the transport equation is solved for air and smoke. FDS solves the transport equation for the mixture fraction.
To model the fire development, and where no literature data was available, the required material characteristics like specific heat capacity, absorption coefficient and heat of combustion were measured.
In all the investigated CFD-models the heat- and species transport equation has been solved and the absorption coefficient of soot has been considered.
Furthermore, the fire development has also been investigated using zone models with the programs CFAST and MRFC.
Results from analytical engineering techniques (plume calculations), which were design criteria in the past, have been used as plausibility checks for the present work. The calculation results from the investigations were compared to measurements in the same building performed by the National Institute for Standards and Technology (NIST).
Thermography (IR) allows global visualization of temperature distribution on surfaces with high accuracy. This potential can be used for visualization of fluid mechanics effects at the intersection of laminar and turbulent flows, where temperature jumps appear due to convection and friction i.e. for the optimization in the design of airplane geometries. In civil engineering too it is the aspiration of the modern engineer of light weight structures to meet singular loads like wind peaks rather by intelligent structures and materials than by massive structures. Therefore the "Institute of Conceptual and Structural Design" of the Technical University of Berlin (TUB) is working on the development of adaptive structures, optimized geometry and intelligent microstructures on surfaces of structural elements. The paper shows the potential of modern computational fluid dynamics (CFD) in combination with thermography (IR) to optimize structures by visualization of laminar-tumultuous border layer currents. Therefore CFD simulations and IR wind tunnel experiments will be presented and discussed. For simulations and experiments - artificial and structural elements of the cable-stayed Strelasund Bridge, Germany, are used.