Search Results (143)

Meso-scale combustors face persistent challenges in sustaining stable combustion and efficient heat transfer due to high surface-to-volume ratios and attendant heat losses. In contrast, larger outlet diameters exhibit weaker recirculation and more diffused temperature zones, resulting in reduced combustion efficiency and thermal confinement. The behavior of non-premixed flames in meso-scale combustor has been investigated through a comprehensive numerical study, utilizing computational fluid dynamics (CFD) under stoichiometric natural gas (methane)–air conditions; three outlet configurations (6 mm, 8 mm, and 10 mm) were analysed to evaluate their impact on temperature behaviour, vortex flow, swirl intensity, and central recirculation zone (CRZ) formation. Among the tested geometries, the 6 mm outlet produced the most robust central recirculation, intensifying reactant entrainment and mixing and yielding a sharply localised high-temperature core approaching 1880 K. The study highlights the critical role of geometric parameters in governing heat release distribution, with the 6 mm configuration achieving the highest exhaust temperature (920 K) and peak wall temperature (1020 K), making it particularly suitable for thermoelectric generator (TEG) integration. These findings underscore the interplay between combustor geometry, flow dynamics, and heat transfer mechanisms in meso-scale systems, providing valuable insights for optimizing portable power generation devices. Full article

The entrainment behavior of solid particles from the top liquid surface into molten steel exerts a crucial influence on rapid slagging and efficient desulfurization during the refining process. A Euler–Euler mathematical model was established to describe the multiphase flow field and the entrainment behavior of solid particles in a bottom-blown ladle. This model was validated by comparison with water model experiments. The effects of bottom-blowing tuyere number, gas flow rate, and solid particle size on the flow field and particle entrainment behavior were investigated. It was found that increasing the gas flow rate enhances the participation of particles in the ladle; however, the entrainment effect changes minimally when the gas flow rate exceeds 192 Nm³/h. Increasing the number of tuyeres adversely affects particle entrainment and mixing efficiency, while simultaneously expanding the size of the “open eyes”. The particle size of the refining slag has a significant impact on the entrainment effect: when the particle size exceeds 10 mm, the particles are hardly entrained in the ladle. Reducing the particle size is more conducive to increasing the entrainment amount, but excessively small particles will significantly enlarge the size of the “open eyes”. Full article

Near-nozzle atomization characteristics in air-assisted spraying were investigated through a novel 3D transient model integrating Volume-of-Fluid and Large Eddy Simulation (VOF-DPM) methods, with experimental validation of droplet distributions (Malvern analyzer) and coating thickness profiles. Key findings reveal that (1) the spray field stabilizes within 30 mm downstream, achieving 80% atomization efficiency (droplets ≤ 100 μm) at 27.5 mm axial distance; (2) radial momentum originates dually from fan-shaped airflow (max 595 m/s) and transverse motion induced by central atomizing air entrainment—a previously unreported mechanism; (3) paint loading delays flow stabilization to 2.5 ms (vs. 0.7 ms for gas-only flow) while reducing peak axial velocity by 18%–22% due to gas–liquid momentum exchange; (4) auxiliary and fan airflows synergistically constrain dispersion, forming elliptical sprays with characteristic cone angles of 61.7° (short axis) and 99.1° (long axis). Significantly, surface tension plays a dual role in inhibiting droplet atomization while promoting ligament pinch-off at 8.1 mm breakup length. These results provide the first quantitative characterization of gas–liquid interactions in near-nozzle regions, enabling precise parameter control for enhanced coating uniformity on complex surfaces. Full article

A computational fluid dynamics (CFD) numerical simulation methodology was implemented to model transient heating processes in steel industry reheating furnaces, targeting combustion efficiency optimization and carbon emission reduction. The effects of oxygen concentration (O₂%) and different fuel types on the flow and heat transfer characteristics were investigated under both oxygen-enriched combustion and MILD oxy-fuel combustion. The results indicate that MILD oxy-fuel combustion promotes flue gas entrainment via high-velocity oxygen jets, leading to a substantial improvement in the uniformity of the furnace temperature field. The effect is most obvious at O₂% = 31%. MILD oxy-fuel combustion significantly reduces NOx emissions, achieving levels that are one to two orders of magnitude lower than those under oxygen-enriched combustion. Under MILD conditions, the oxygen mass fraction in flue gas remains below 0.001 when O₂% ≤ 81%, indicating effective dilution. In contrast, oxygen-enriched combustion leads to a sharp rise in flame temperature with an increasing oxygen concentration, resulting in a significant increase in NOx emissions. Elevating the oxygen concentration enhances both thermal efficiency and the energy-saving rate for both combustion modes; however, the rate of improvement diminishes when O₂% exceeds 51%. Based on these findings, MILD oxy-fuel combustion using mixed gas or natural gas is recommended for reheating furnaces operating at O₂% = 51–71%, while coke oven gas is not. Full article

The Shenfu Gas Field faces challenges with uneven wellhead pressures, where low-pressure wells lose discharge capacity and high-pressure wells require throttling, leading to significant energy waste. Ejectors offer potential for energy recovery by utilizing high-pressure gas to boost low-pressure production. A computational fluid dynamics (CFD) model was developed using simulation software to simulate ejector performance. Parametric studies analyzed key structural parameters (mixing chamber length L_m, diameter D_m, nozzle spacing L_c, diffuser length L_d) and operational variables (compression ratio, working/entrained fluid pressures). Model validity was confirmed via grid independence tests and experimental comparisons (error < 10%). Network-level efficacy was verified using pipeline simulation software. Entrainment ratio (ε) and isentropic efficiency (η) exhibited non-linear relationships with structural parameters, with distinct optima depending on compression ratio. D_m had the strongest influence on ε. Higher compression ratios reduced ε, while increasing working fluid pressure or entrained fluid pressure improved ε. Optimal configurations were identified. Network simulations confirmed functional effectiveness, though efficiency diminished over production time. Ejector efficiency is highly sensitive to specific structural and operational parameters. Deployment in gas gathering networks is viable but most beneficial in early production stages. Full article

To commercialize supersonic and hypersonic passenger aircraft and reusable spaceplanes, we are developing a small-scale supersonic flight experiment vehicle as a flying testbed for technical demonstrations in high-speed flight environments. This experiment vehicle is equipped with a fuel tank and an oxidizer tank, and the propellants inside the tanks slosh due to changes in acceleration during flight. In this situation, there is a risk of gas entrainment during liquid discharge, which could potentially cause an engine malfunction. To avoid such a situation, we considered installing a propellant management device (PMD) inside the tank to suppress the gas entrainment. In this study, a capillary type PMD with a screen channel structure, commonly used in satellites featuring no moving parts, was adopted due to its applicability to a wide acceleration range. The PMD was designed with a structure featuring cylindrical mesh screen nozzles installed at the top and bottom of a cylindrical tank. A one-dimensional flow analysis model was developed taking into account factors such as the pressure loss across the mesh screens and the flow loss within the mesh screen nozzles, which enabled the identification of conditions under which gas entrainment occurred. In this analytical model, separate formulations were developed using Hartwig’s and Ingmanson’s formulas for evaluating the flow losses through the mesh screens. Furthermore, by applying the flow analysis model, the specifications of the mesh screens as key parameters of the PMD, together with the nozzle diameter and nozzle length, were selected. Moreover, we fabricated prototype PMDs with each nozzle and conducted visualization tests using a transparent tank. The tests were conducted under static conditions, where a gravitational acceleration acted downward, and the effects of the cylindrical mesh screen length and discharge flow rate on the free surface height at which gas entrainment occurred were investigated. This experiment demonstrated the effectiveness of the propellant acquisition mechanism of the present PMD. The height of the free surface was also compared with the experimental and analytical results, and it was shown that the results obtained by using Ingmanson’s formula for pressure loss through the screen mesh were closer to the experimental results. These findings demonstrated the validity of the one-dimensional flow analysis model. Full article

With the rapid growth of the global population, increasing per capita energy demands, and waste generation, the need for innovative strategies to mitigate greenhouse gas emissions and effective waste management has become paramount. Pyrolysis, a thermochemical conversion process, facilitates the transformation of diverse biomass feedstocks, including agricultural biomass, forestry waste, and other carbonaceous wastes, into valuable biofuels such as bio-oil, biochar, and producer gas. The article reviews the benefits of pyrolysis as an effective and scalable technique for biofuel production from waste biomass. The review describes the different types of pyrolysis processes, such as slow, intermediate, fast, and catalytic, focusing on the effects of process parameters like temperature, heating rate, and residence time on biofuel yields and properties. The review also highlights the configurations and operating principles of different reactors used for pyrolysis, such as fixed bed, fluidized bed, entrained flow, plasma system, and microwaves. The review examines the factors affecting reactor performance, including energy consumption and feedstock attributes while highlighting the necessity of optimizing these systems to improve sustainability and economic feasibility in pyrolysis processes. The diverse value-added applications of biochar, bio-oil, and producer gas obtained from biomass pyrolysis are also discussed. Full article

During the drainage process of coalbed methane (CBM) horizontal wells, wellbore fluctuations exert a significant influence on gas–liquid–solid three-phase flow behavior and coal particle migration. This study investigates the effects of wellbore inclination, gas–liquid flow rates, and coal particle sizes on migration characteristics through laboratory-scale experiments, based on an initial analysis of coal particle physical properties. A critical velocity model accounting for wellbore fluctuations is developed and refined. The migration states of coal particles under various operational conditions are examined, and the corresponding critical velocities and movement patterns are analyzed. The results show that coal particle migration is predominantly governed by the liquid phase, while the presence of particles has limited impact on the overall gas–liquid flow regime. Under different wellbore inclinations, the critical velocity increases with particle size; however, the influence of inclination is more pronounced than that of particle size. Coal particle entrainment follows three distinct stages: hopping, rolling, and suspension. The velocity during the rolling stage is identified as the critical velocity. At steeper inclination angles, particles are more easily entrained by the flow, and the associated critical velocity is higher. Based on the fitted experimental data, the model is revised to improve its predictive capability for coal particle transport in CBM wells. Finally, the model is validated using field data from a CBM well in the Ordos Basin. The results confirm the model’s ability to predict coal particle accumulation trends within the wellbore. This study provides new insights into coal particle migration mechanisms under fluctuating wellbore conditions, offering both experimental and theoretical support for understanding gas–liquid–solid flow behavior. It also presents technical guidance for optimizing drainage performance, controlling particle deposition, and formulating wellbore cleaning strategies. Full article

Fermentation at high temperatures may be a viable alternative for ethanol production, especially in tropical climate regions. This work describes the evaluation of ethanol production through extractive fermentation at high temperatures using thermotolerant Kluyveromyces marxianus. An experimental design was applied to assess the effect of temperature on the ethanol removal process by CO₂ stripping. Subsequently, kinetic modeling of conventional batch ethanol fermentation at high temperatures was performed, and the hybrid Andrews−Levenspiel model was found to be suitable for describing the kinetics of this process. Experiments were conducted to evaluate ethanol production at high temperatures using thermotolerant yeast, specifically evaluating the effects of different specific CO₂ flow rates (ϕ = 1.0, 1.5, and 2.0 vvm) on ethanol stripping. The results indicated that in all the extractive fermentations conducted with K. marxianus, there was faster substrate uptake and earlier substrate exhaustion compared to conventional fermentation. Significant ethanol removal by stripping was achieved using a CO₂ flow rate of 1.0 vvm (EF_HT1), and complete substrate consumption was observed by the end of 12 h of fermentation. This result highlights the positive effect of temperature on ethanol entrainment. In addition, integrating the CO₂ stripping technique with high-temperature fermentation (T = 40 °C) improves process efficiency with a lower gas flow rate. This is advantageous, especially for industrial-scale applications, as it can reduce equipment costs associated with the CO₂ feed. Full article

This study presents a novel unresolved SPH-DEM coupling framework to investigate the complex interactions between rising gas bubbles and sinking solid particles in multiphase systems. Traditional numerical methods often struggle with large deformations, multiphase interfaces, and computational efficiency when simulating dense particle-laden flows. To address these challenges, the proposed model leverages SPH’s Lagrangian nature to resolve fluid motion and bubble dynamics, while the DEM captures particle–particle and particle–bubble interactions. An unresolved coupling strategy is introduced to bridge the scales between fluid and particle phases, enabling efficient simulations of large-scale systems with discrete bubbles/particles. The model is validated against benchmark cases, including single bubbles rising and single particle’s sedimentation. Simulation studies reveal the effects of particle/bubble number and initial distance on phase interaction patterns and clustering behaviors. Results further illustrate the model’s capability to capture complex phenomena such as particle entrainment by bubble wakes and hindered settling in dense suspensions. The framework offers a robust and efficient tool for optimizing industrial processes like mineral flotation, where bubble–particle dynamics play a critical role. Full article

This study aims to reduce pores, cracks, and other defects on the surface of laser powder bed fusion (LPBF)-fabricated 18Ni300 steel and improve its surface quality. Remelting was carried out on the surface with an argon arc as the heat source. Then, the surface layer was characterized using SEM, EDS, XRD, EBSD, and hardness testing. The results showed the following: When the pulse current $I$ increased from 16 A to 20 A, the surface hardness of LPBF 18Ni300 increased due to a decrease in defects and an increase in the martensite phase. The driving forces of convection in the molten pool (such as buoyancy, Lorentz magnetic force, surface tension, and plasma flow force) rose with an increase in current. When the current $I$ exceeded 20 A, the convection became more intense, making it easier for gas to be entrained into the melt pool, forming pores and introducing new defects, resulting in a decrease in surface hardness. The primary factors affecting the hardness of LPBF 18Ni300 after surface argon arc remelting were pore (defect) weakening and phase transformation strengthening, while the secondary factors included grain refinement strengthening and texture strengthening. The solidification mode of the remelted layer was: L → A → M + A′. The phase transition mode of the heat-affected zone was: M + A′ → A_reverse → M_temper. Compared with the base material and heat-affected zone, the grains in the remelted layer formed a stronger <001> texture with a larger average size (2.51 μm) and a lower misorientation angle. The content of the residual austenite A′ was relatively high in the remelted layer. It was distributed in the form of strips along grain boundaries, and it always maintained a shear–coherent relationship with martensite. Full article

Recent advancements in computational and experimental techniques have deepened the understanding of ejector dynamics. Working maps, which depict the relationship between operating conditions and the performance metrics of entrainment and pressure, are commonly used in defining the ejectors’ performances and designs and enhancing their operational flexibility. This paper investigates the sensitivity of a jet ejector to variations in the inlet temperatures, with a focus on how changes in these temperatures affect its performance and Mach number distribution. Using high resolution CFD (computational fluid dynamics) simulations, this study maps ejector behavior by using the ideal gas approximation, marks Mach number scene responses to those changes, and is aimed at optimizing it to work with refrigeration systems using commercial fluid R1234yf/2,3,3,3-Tetrafluoropropene. The findings provide valuable insight into operational conditions for jet ejectors. The analysis revealed little dependence on the changes in inlet temperatures, therefore expanding the design working conditions by at least +20% of the temperature at each of the inlets. This study also analyzes the small deviations in ejector behavior due to temperature variations at the inlets. It contributes to the development of sustainable refrigeration systems, as it broadens the operational temperature range and enhances practical applications in this field, as this information is difficult to find in commercial databases. Full article

The most common type of well in the Fuling shale gas field is the long horizontal section well. Once the energy attenuates, it is difficult to discharge the accumulated liquid. So, it is particularly important to determine the time of accumulation. Through indoor experiments, it was observed that droplets in the gas core flowing under critical conditions and the liquid film adhering to the tube wall cannot be ignored. It was also discovered that the liquid phase on the tube wall can form fluctuations due to the shear effect of the gas phase. Based on the observed distribution of gas–liquid phases in experiments, a critical liquid-carrying velocity calculation method considering the coexistence of droplets and liquid films, as well as the frictional resistance coefficient at the gas–liquid interface under wave morphology, was established. Integrating production data from 106 wells at home and abroad, as well as testing data from the Fuling example well, the new model was validated. The results showed that the new model can accurately diagnose fluid accumulation in different gas fields, with an accuracy rate of 86.8%, and it can provide an accurate diagnosis for fluid accumulation in gas wells in different water-producing gas fields. Full article

China has abundant biomass and renewable energy resources suitable for producing green methanol via biomass thermochemical conversion. Given China’s increasing demand for sustainable fuel alternatives and the urgency to reduce carbon emissions, optimizing biomass utilization through gasification is critical. Research has highlighted the potential of integrating biomass gasification with water electrolysis to enhance efficiency in green methanol production, leveraging China’s vast biomass reserves to establish a cleaner energy pathway. Four main biomass gasification technologies—fixed-bed, fluidized-bed, pressurized fluidized-bed, and entrained-flow—have been investigated. Fixed-bed and bubbling fluidized-bed gasification face low gas yield and scaling issues; whereas, circulating fluidized-bed gasification (CFB) offers better gas yield, carbon efficiency, and scalability, though it exhibits high tar and methane in syngas. Pressurized fluidized-bed gasification improves gasification intensity, reaction rate, and equipment footprint, yet stable feedstock delivery under pressure remains challenging. Entrained-flow gasification achieves high carbon conversion and low tar but requires finely crushed biomass, restricted by biomass’ low combustion temperature and fibrous nature. Current industrially promising routes include oxygen-enriched and steam-based CFB gasification with tar cracking, which reduces tar but requires significant energy and investment; oxygen-enriched combustion to produce CO₂ for methanol synthesis, though oxygen in flue gas can poison catalysts; and a new high oxygen equivalence ratio CFB gasification technology proposed here, which lowers tar formation and effectively removes oxygen from syngas, thereby enabling efficient green methanol production. Overcoming feedstock challenges, optimizing operating conditions, and controlling tar and catalyst poisoning remain key hurdles for large-scale commercialization. Full article

In the cold chamber high pressure die casting process (CC-HPDC) for light alloys, the piston lubricants play a key role in protecting the piston tip from wearing and ensure adequate seal with the shot sleeve. However, during the production process, the pouring of overheated aluminum alloy melt into the shot sleeve would lead to evaporation and burning of the lubricants once in contact with the piston tip. The burning products, however, would form gas and non-metallic inclusions in the melt which would be transported and injected into the die area and finally trapped in the castings, all of which would affect the mechanical properties of the as-cast samples and deteriorate the product quality. To further investigate this issue, a pilot scale HPDC machine is used and the lubricant burning issue is studied based on material characterization and numerical modelling. The chemical composition, size, and morphology of the burned products are observed using scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). In order to better explore the issue of lubricant combustion discovered in the experiment, a finite element model describing the entire HPDC process is established and the burning, motion, and trapping of the lubricant are calculated. The final distribution of the burned products such as gas and non-metallic inclusions are predicted and their influence on final solidification quality of the as-cast products under various process parameters are analyzed qualitatively. Finally, a slow shot velocity range of 0.4–0.6 m/s and an acceleration profile that ramps up to 0.3 m/s over 0–370 mm of the shot sleeve proved to be the most effective in reducing air entrainment and oxide inclusions to alleviate the burning of lubricant on final product quality. Full article