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Compressed Air Discharge from a Blowing Unit
G.L. Antinori and M. Spiga*
Abstract: This paper aims at investigating, both through a theoretical and an experimental analysis, the discharging phase
of a blowing unit of compressed air, used for the industrial production of plastic made bottles. The proposed mathematical
model leads to a system of differential equations describing the flow through an open system. The solution was found by
numerical simulations using the software Matlab, determining the gas density, pressure, temperature and mass flow rate,
as functions of time. The pressure loss across the down flow has been tackled with a theoretical investigation, determining
the mechanical loss coefficient and evaluating the effect of these losses on the emptying time of the blowing unit. The
numerical results agree with the real discharging times obtained by experimental tests, and the proposed improvements
allow to reduce loss of pressure and the emptying time of 35% and 20% respectively.
- the improvement of the channel geometry aimed at - the gas is compressible with uniform physical
reducing the discharge phase time. properties;
- the process is adiabatic;
*Address correspondence to this author at the Department of Industrial
Engineering, University of Parma, Viale G.P. Usberti 181/A, 43100 Parma, - the pressure head is described by introducing the
Italy; Tel: +39 521 905855; Fax: +39 521 905705; mechanical loss coefficient [2,3], defined as:
E-mail: marco.spiga@unipr.it
DISCHARGING
PHASE
BOTTLE
EXIT
ROTATING
TABLE STRETCH-BLOWING
PHASE
PRE-SHAPE
INLET
HEATING PHASE
p po W2 W 2 p po V 2 1
2
= (1) = = 2 2
(5)
2 2 2 S
In this model the mechanical losses, both concentrated The pressure and its derivative are then:
and distributed, are located exactly in the exhaust section,
V 2 1
2
which acts, in this way, as the only obstruction to the down
flow. The mechanical loss coefficient , defined in Eq. (1), p=
+ po
2 S 2
connects gas pressure and density just upstream the exhaust (6)
p V 2 2 1
2
section with gas pressure downstream and average velocity
=
2
on the exhaust section. The discharging phase is extremely 2 S 2
2
fast, hence the transformation can be considered adiabatic.
The parameters used in simulating the discharging The time derivative of temperature, for the ideal gas, is:
process from the blowing machine, are [4] = 1.4, R = T 1 p p 1
287.041 J/kgK, cv= 716.4 J/kgK, V = 1.768x10-3 m3, S = = (7)
1.767x10-4 m2, pin= 37 bar, p0= 1.01325 bar, Tin= 10 °C. For 2
R
the ideal gas, the initial density would be in= 45.52 kg/m3. Hence the Eq. (2) reads as:
IDEAL GAS MODEL
–
( )
2 1 1+ + –1 S2
2
– 2 p0 = 0 (8)
In transient conditions, the energy balance equation for
2 2
V
the ideal gas is:
valid if 0. This is a second order differential equation,
W 2
m + cv (T TR ) + RT = not linear and written in a not normal form (that means not
2 (2) singleness of the Cauchy’s problem).
M T
= cv (T TR ) M cv Nevertheless, the solution investigated is not easy to
obtain.
The mass balance equation reads as: The gas density decrease is expected at the initial
moment, in which the tank is opened, hence / 0.
M
M ( ) = ( ) V and =m (3) By defining the new function:
The mean velocity is linked to the mass flow rate: u( ) = (9)
m V 1
W = = (4) the Eq. (8) can be written as:
S S
u C1 2
As a consequence, the gas pressure is linked to the u u = C2 (10)
density, from Eq. (1), as follows: 2
Compressed Air Discharge The Open Mechanical Engineering Journal, 2009, Volume 3 3
where the known constants C1 and C2 are: of the solution, it is suitable resorting to a numerical
analysis.
1 S 2
C1 = +1+ C2 = p (11) The solution to Eq. (8) has been numerically investigated
V2 o
using a dedicated software: Matlab. Matlab collects
The first order differential Eq. (10) requires, to be solved, additional software modules, called “toolboxes”, which
a further definition: perform specific tasks. Many of these toolboxes can be used
to solve differential equations with constant coefficients. In
z(ñ) = u 2 (12) particular, the Runge-Kutta method of second and third class
[6], has been chosen to solve this model. The respective
Hence the first order linear differential equation is solver function of Matlab is “ode23”; it is a one step solver
obtained which solves initial value, moderately stiff problems.
z C1
z = 2 C2 (13) REAL GAS MODEL
Looking at the intensive properties (pressure and
whose solution has the following form: temperature), for both initial state and critical point of air,
2 C2 1C1 the reduced coordinates have been computed and, resorting
z( ) = C1 + K (14) to the Nelson-Obert diagram [2], the compressibility factor
1 C1 has been calculated. It allows quantifying the real gas
deviation from the ideal gas behaviour. Fearing the ideal gas
with K constant of integration calculated by means of the
hypothesis not reliable, a second model of calculation has
initial condition.
been accomplished: the real gas model, according to Van der
Using the Eqs. (10) and (12), the solution (14) can be Waals equation:
written as:
a
1 p + 2 ( v b ) = R T (19)
2 C2 2 v
= ± + K C1 (15)
1 C1
Following the same procedure as for the ideal gas model,
the energy balance equation reads as:
The only solution with physical meaning is the negative
2 1 R + 1
2
{
one, because, when the tank is opened, the density of the gas
is expected to drop.
(1 b ) 2
2
cv
+
The existence domain for the solution to the Eq. (15) is:
R a S2 2
1 + 2 b ] + 2 b 1
+ (20)
2 C2 C1 1 cv V2
(16)
(1 C1 ) K R S2
+1
po } = 0
The steady state is represented by / = 0, which cv V 2
implies: valid if 0.
1
It can be observed that, if a and b were supposed
2 C2 C1 1
*= (17) negligible, the energy balance Eq. (20) would coincide with
(1 C1 ) K the differential Eq. (8) of the ideal gas model.
The density function is monotonically decreasing; it Solving this second order not linear differential equation,
reaches its steady state at the time *, so that the solution to the behaviour the tank discharge can be described. Even in
the problem is the solution to the Eq. (15) for *, the Eq. this case, the computation of the equation has been carried
(17) for *. out numerically using Matlab, in particular the function
solver “ode23”.
Even any small oscillation of , due to pressure waves
spreading along the exhaust duct, can be ruled out by a Some more parameters of the air must be introduced,
qualitative analysis [5] of the differential equation. The exactly: a = 161.9 (m3/kg)2 Pa, b = 1.26x10–3 m3/kg [2].
phenomenon concerning the emptying of the tank ends after The density value at the initial state has been computed,
a * time, just when the first derivative of is zero. being known pressure and temperature values, applying the
Coming back to the Eq. (15) and integrating it, starting Van der Waals equation. It is equal to in=46.98 kg/m3,
from the initial state = 0, we get: slightly different from the value for the ideal gas model
1
(45.52 kg/m3).
2C C
2
50
ρ
45 β = 10
40 β = 30
β = 50
35
30
25
20
15
10
5
0
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 τ 0,90
Fig. (2). Transient air density within the open thermodynamic system.
4,E+06
p
4,E+06 β = 10
β = 30
3,E+06 β = 50
3,E+06
2,E+06
2,E+06
1,E+06
5,E+05
0,E+00
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80
τ 0,90
Fig. (3). Absolute air pressure within the open thermodynamic system.
1,2
m
β = 10
1,0 β = 30
β = 50
0,8
0,6
0,4
0,2
0,0
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90
τ
Fig. (4). Airflow rate from the open thermodynamic system.
Compressed Air Discharge The Open Mechanical Engineering Journal, 2009, Volume 3 5
130
W
120
β = 10
110
β = 30
100
β = 50
90
80
70
60
50
40
30
20
10
0
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90
τ
Fig. (5). Air velocity in the outflow section during the transient.
geometry, and boundary and initial thermodynamic atmospheric value, we are able to know the time needed to
conditions, but also the coefficient of mechanical losses . complete the exhaust phase:
Figs. (2-5) represent a comparison between the time = 0.7695 s Perfect gas model
evolution of density, pressure, flow rate and gas velocity (22)
= 0.7705 s Real gas model
according to ideal gas model for three different values of the
coefficient . As the mechanical losses appeared to be mostly
Introducing into the ideal and real gas models, the value concentrated into the double effect cylinder, a test was
of computed for the blowing machine, and looking at the carried out on the cylinder, using two digital manometers (to
moment in which the gas density derivative becomes zero, measure pressure upstream and downstream), a Pitot tube (to
that is the same in which the air pressure reaches the measure average velocity) and a thermocouple. Following
0,2
0,18 Perfect gas
0,16
0,14
0,12
Mach
0,1
0,08
0,06
0,04
0,02
0
0
0,00 0,10 0,22 0,35 0,50 0,65 0,76
τ
0,990
Z
0,985
0,980
0,975
0,970
0,965
0,960
0,00 0,10 0,22 0,35 0,50 0,65 0,76
τ
Fig. (7). Compressibility factor evolution during the discharge transient.
6 The Open Mechanical Engineering Journal, 2009, Volume 3 Antinori and Spiga
the results of the experimental tests [1], the time required by With the purpose of reducing the time required to carry
the blowing machine, to discharge the quantity of air needed out the complete outflow of the gas (that means to increase
to shape a plastic bottle (1.5 dm3) is about 0.7÷0.8 s. the machine performance) the possibility to decrease the
coefficient of mechanical losses has been investigated.
In Fig. (6) the Mach number is reported in the exit
section, during the discharge transient. It is always less than Paying attention to the geometric components, in particular
the two bushings of the stem set into the double effect
unit. This result let us say the air discharge from a blowing
cylinder, which appeared to be the major obstacles to the air
station happens with a subsonic motion.
flow, and modifying properly their geometry, the coefficient
The comparisons concerning results obtained with ideal has been reduced from 39.93 to 25.95.
gas and real gas models, show a considerable similarity. This
consideration is analytically proven; in fact Fig. (7) shows Introducing the new value of into the ideal and real gas
models, it has been found a reduced time for the discharging
that the compressibility factor, calculated with the equation:
phase:
p
Z= (23) = 0.6207 s Perfect gas model
RT (24)
= 0.6287 s Real gas model
is about a unitary value during the entire transient.
Fig. (8). Section view of the air discharging flow into the stretch-blowing unit, with a zoom view of the stem bushings.
Fig. (9). Section view of the air discharging flow into the stretch-blowing unit, with a zoom view of the stem bushings, after the optimisation
50
ρ
45 Perfect gas
40 Real gas
35
30
25
20
15
10
5
0
0,00 0,08 0,18 0,29 0,41 0,53 τ 0,62
Fig. (10). Air density evolution during discharging phase, after the optimisation of the duct geometry.
Compressed Air Discharge The Open Mechanical Engineering Journal, 2009, Volume 3 7
0,9
τ
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0
20 22 24 26 28 30 32 34 36 38 40 42 44 β
Fig. (11). Time of the discharging phase as a function of the coefficient of mechanical losses.
The stretch-blowing unit is shown in Figs. (8-9), focusing m = gas mass flow rate; kg/s
the stem bushings before and after the optimization,
M = air mass into the tank; kg
respectively.
Ma = Mach number W/Ws
Fig. (10) shows the air density evolution during the
transient. n = number of singularities along the discharging path
Fig. (11) shows the required time for the discharging p = pressure; Pa
phase, as a function of the coefficient of mechanical losses. p0 = atmospheric gas pressure; Pa
CONCLUSIONS R = ideal gas specific constant; J/kg K
In this study, a numerical model has been carried out in S = gas outlet section surface; m2
order to analyze the discharging phase of air from a blowing T = gas temperature; K
machine. The model of simulation is based on the laws of
thermodynamic governing the outflow of a compressible gas TR = conventional temperature corresponding to zero
value of the gas internal energy; K
from an open system.
v = specific gas volume; m3/kg
The mechanical losses, due to each geometrical
singularity of the ducts crossed by the air, have been V = tank volume; m3
estimated. The discharging path has been modified in order W = average gas velocity; m/s
to reduce their relevance. An investigation how the exhaust
phase length is affected by the total coefficient of mechanical Ws = sound velocity in the gas; m/s
losses was carried out. Z = compressibility factor
The geometry optimisation of the discharging path
showed a reduction of the coefficient of 35% and a GREEK SYMBOLS
discharging time reduction of 20% that means to increase the
= mechanical loss coefficient
blowing machine efficiency.
= cp/cv ratio
Another parameter affecting the time reduction is the air
temperature at the beginning of the discharging phase into = gas density; kg/m3
the blowing unit. * = steady state density defined in Eq. (17); kg/m3
The real gas model and the ideal gas model give very
= time; s
similar results, being the compressibility factor Z very close
to unity. Future work will be focussed on the 3-D gas * = instant time corresponding to ()=*
velocity and temperature, obtained through numerical
analysis, slightly simplified by the ideal gas model. SUBSCRIPTS
c = concentrated mechanical losses
GLOSSARY
d = distributed mechanical losses
a = Van der Waals coefficient in Eq. (19); (m3/kg)2 Pa
i = singularity along discharging path
b = real gas covolume; m3 /kg
in = initial time, = 0
C1 = dimensionless coefficient
C2 = constant; kg/m3 s2 ACKNOWLEDGEMENTS
cp = specific heat at constant pressure; J/kg K The contribution of SIG Simonazzi SpA Noceto (Parma,
cv = specific heat at constant volume; J/kg K Italy) is gratefully acknowledged.
Received: March 30, 2008 Revised: May 07, 2008 Accepted: November 14, 2008