3D Swirl Flow Reactor Technology

Laboratory for Chemical Technology, Ghent University
http://www.lct.UGent.be
3D swirl flow reactor technology for
pyrolysis processes:
computational fluid dynamics study
Carl M. Schietekat, Marco M. Van Goethem,
Kevin M. Van Geem, Guy B. Marin
1
Chemreactor-XX, Luxembour, Luxembour, !"#1$#$!1$
0.8
1
1.2
0 0.25 0.5 0.75 1
T
/
T
a
v
g
r/D [-]
0.8
1
1.2
0 0.25 0.5 0.75 1
T
/
T
a
v
g
r/D [-]
Non uniform radial
temperature
Non uniform radial
temperature
Coke layer Coke layer
Coke %ormation &urin 'teamcrackin
$
Chemreactor-XX, Luxembourg, Luxembourg, 05/12/2012
$
3D reactor
technology
Better heat transfer
=
less cokes / more flow
Better heat transfer
=
less cokes / more flow
Higher pressure drop
=
Lower olefins selectivity?
Higher pressure drop
=
Lower olefins selectivity?
More uniform radial
temperature
More uniform radial
temperature
S(irl )lo( *ube &e'in
+
* Veryan Medical Limited: BioMimics 3DTM
Arteries are helically twisted
better crossmixing
Less accumulation of fatty
depositis on artery wall
for tubular chemical reactors: heat transfer, uniform cross-section
for stent design:
patented in 2011 for use in cracking furnaces
helical centerline
,utline
Experimental set-up
Model validation
Swirl decay after SFT
Effect of tube bend
-
.x/erimental 'et-u/
"
compressor
flow meter
manometer
thermocouple
static mixer
thermocouple
test tube
steam jacket
- 3 test tubes:
- 14 pressure experiments (adiabatic)
- 14 temperature experiments (last 2m heated with steam jacket)
SFT-M SFT-M
SFT-H SFT-H
STRAIGHT STRAIGHT
A [m] P [m]
x x
0.0061 286.2
0.0083 217.8
.x/erimental &ata /roce''in
Darcy-Weisbach equation:
]
=
AP J
n
p
2I
A
m
2
Heat transfer to fluid:
ubs
=
m
C
P
I
out
I
n
ubs
= n J
n
I
h
EIC IHI
Nu =

m
C
P
I
out
I
n
n IC I
h
IHI
0
*ube 'ur%ace rouhne''
1
]
co
E
u
, J
, Rc
* N.H. Chen, Ind. Eng. Chem. Fundam., 18 (1979) 296-297297.
min
L
c

],
cxp

],
co
E
u
, J
, Rc
],
cxp
2
4
=1
E
u
= 1S.4pm
o J
, Rc =

]
co
1S.4 1u
-6
, J
, Rc
]
co
u, J
, Rc
,utline
Experimental set-up
Model validation
Effect of tube bend
2
C)3 Mo&el
4
Turbulence:
Reynolds Stress Model
Enhanced wall treatment (Wolfstein)
Material properties:
ideal gas
c
p,
, k temperature polynomials
Computational Fluid Dynamics FLUENT 13.0 Gambit 2.4.6
Extrusion cross
section
T
wall
= 373.15K
P
out
= 101325 Pa
mass flow inlet
Boundary conditions:
>23 10
6
cells
5re''ure &ro/ ex/eriment'
1!
Relative error = 3.2% Relative error = 3.2%
Velocity manitu&e axial /o'ition
11
SFT-M SFT-M
Re = 2 10
4
Re = 2 10
4
Velocity %iel&6 e%%ect o% 7e
1$
Re
[10
3
]
0 m 1m 2m 3m 4m
115
22
SFT-M SFT-M
Velocity %iel&6 e%%ect eometry
1+
0 m 1m 2m 3m 4m
SFT-H SFT-H
SFT-M SFT-M
Re = 2 10
4
Re = 2 10
4
8all 'hear 'tre''
1-
Pa
Pa
SFT-H SFT-H
SFT-M SFT-M
= p
ow
oy
2 turns
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]
Azimuthal coordinate [rad]
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]
8all 'hear 'tre'' alon axial &irection
1"
1 turn
4 turns 10 turns
SFT-M SFT-M
0
*em/erature ex/eriment'
10
Relative error = 12.6% Relative error = 12.6% General overprediction General overprediction
*em/erature %iel&
11
Re
[10
3
]
0 m 0.5m 1m 1.5m 2m
111
22
K
SFT-M SFT-M
Cro'' 'ectional uni%ormity
12
SFT-M SFT-M
SFT-H SFT-H
STRAIGHT STRAIGHT
Re = 6 10
4
Re = 6 10
4
CoI =
_
m,
I
I
ug
N
=1
m,tot
I
ug
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
2.1 2.6 3.1 3.6
C
o
e
f
f
i
c
i
e
n
t

o
f

V
a
r
i
a
t
i
o
n

[
-
]
Axial position in straight tube [m]
STRAIGHT SFT-M SFT-H
more uniform cross sectional temperature profile more uniform cross sectional temperature profile
9eat %lux
14
SFT-M SFT-M
1 helix 2helix 4helix
Azimuthal coordinate [rad] Azimuthal coordinate [rad]
H
e
a
t

f
l
u
x

[
k
W
/
m
]
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]
,utline
Experimental set-up
Model validation
Effect of tube bend
$!
S(irl number
$1
ratio tangential
to axial momentum
S =
]pFWrdA
R]pW
2
dA
ratio tangential
to axial momentum
S =
]pFWrdA
R]pW
2
dA
2m
4m
2m
SFT-M SFT-M
SFT-H SFT-H
S(irl &ecay
$$
0
SFT-M SFT-M
0.0 16.7 m/s
4.00m 4.50m 5.00m 5.50m 6.00m
A
z
i
m
u
t
h
a
l

o
f
f
s
e
t

c
o
s
(
0
)
R
a
d
i
a
l
o
f
f
s
e
t

[
m
]
Axial position [m] Axial position [m]
,utline
Experimental set-up
Model validation
Effect of tube bend
$+
Velocity vector' in ben&
$-
[] 0 90 180
Re = 2 10
4
Re = 2 10
4
SFT-M SFT-M
STRAIGHT STRAIGHT
0
Conclu'ion'
$"
Experimental: SFT enhances heat transfer with limited increase of
the pressure drop
CFD: good agreement for Fanning friction factor.
Nu number slight overprediction
Swirl flow is fully developed after 7-10 pitches. A helical low velocity
and high temperature zone is created near the tube wall
Temperature uniformity in a cross section is improved
Swirl exponential decays at 0.3-0.6 m
-1
depending on Re
Swirl flow is lost after a straight bend for Re < 20 10
3
SFT: promising technology for application in steam crackers
:ckno(le&ment'
FWO-Vlaanderen
The Long Term Structural Methusalem Funding
STEVIN Supercomputer Infrastructure
LCT @ UGent: Amit Mahulkar, David Van Cauwenberge, Georges
Verenghen, Nick Vandewiele, Thomas Dijkmans
$0
Glo''ary
SFT: Swirl Flow Tube, a tube has a helical
centerline. The helix amplitude is smaller than or
equal to the tube radius.
Swirl flow: a whirling or eddying flow of fluid.
Swirl number: ratio of tangential over axial
momentum transfer
Wall shear stress: component of stress coplanar
with the wall. It is the product of the viscosity and
the derivative of axial speed to radial coordinate.
$1
9eat tran'%er /roce''in
$2
9eat tran'%er /roce''in
$4
8all 'hear 'tre'' in S(irl 3ecay
+!
SFT-M SFT-M
Axial coordinate [m]
W
a
l
l

s
h
e
a
r
s
t
r
e
s
s

[
P
a
]

3D Swirl Flow Reactor Technology

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