Ifmg intro

Introduction to iFMg

Industrial Flow Modeling Group

Vivek V. RanadeNational Chemical Laboratory

Pune 411008

Tel: 91 20 589340 Ext. 2170/ 2172

Fax: 91 20 5893260

Email: [email protected]

mailto:[email protected]


NATIONAL CHEMICAL LABORATORY

Located in City of Pune


NATIONAL CHEMICAL LABORATORY

Premier CSIR Laboratory in Chemical Sciences

Catalysis Polymers Organic Chemistry Biotechnology

300 Scientific staff + ~ 200 Ph.D. Students Industrial contract research (GE, DuPont, Unilever, Akzo,

ICI.) > 300 publications, > 100 patents (~ 30 US Patents) per

year

Chemical & Process

Engineering


INDUSTRIAL FLOW MODELING GROUP

Basic Research on Multiphase Fluid Dynamics (DST, CSIR, IFCPAR)

Development of Chemical Reactor Engineering Tools (ReST, TRPro, MoBB, AnTS, RIAT, SPARE, FLUENT, AUTO)

Industrial Applications (DuPont, Indian Oil Corporation Ltd., Reliance Ltd., Herdillia Chemicals Ltd., Thermax Ltd., Fluent India Pvt. Ltd., BEPL, Spellbound, Praj Industries, Bajaj Auto Ltd., GAAC, GDIL)


RECENT iFMg PROJECTS

FCC Regenerator (IOCL) Oxy-hydrochlorination Reactor (Reliance) Thermo-siphon Reactor (Reliance) SAN Co-polymerization reactor (BEPL) PET Finisher (DuPont) Suspension Polymerization Reactor (Thermax) Regeneration of DPO Reactor (Herdillia) Design of Carbonylation Reactor (GAAC, DPG) Chlorination of Acetic Acid (GDIL) Modelling of Stirred Reactors (Praj, Fluent India) Design of Hydrogenation Reactor (Spellbound)


FACILITIES

Computational SGI Origin 200: 2 R12k CPUs, 1 GB RAM SGI Origin 200: 4 R12k CPUs, 2 GB RAM SGI O2, Indy workstations and DEC Alpha workstation 1.4 GHz P4 machines with 1 GB RAM: 2 1 GHz PIII x 2 machines with 1 GB RAM each: 4 Other PIII & older machines: 5

FLUENT, AUTO, MATLAB, ODELIB, Numerical Receipes and other necessary software tools


FACILITIES

Experimental Bubble columns (10 cm, 20 cm and 30 cm diameter); 10 cm

and 20 cm diameter columns may be operated in continuous mode

Stirred vessel facility (5 HP motor, 40 cm diameter vessel, several impellers)

Trickle beds (10 cm and 20 cm diameter) Rectangular bubble column These cold flow facilities are equipped with flow metering

instrumens and provisions to insert different probes (pressure sensors, conductivity probes, torque sensors and so on)


FACILITIES

Experimental: Measurement Techniques Wall pressure sensors Voidage probes Torque sensors High speed camera (500 frames/s) Tied-up with BARC for carrying out radio-active tracer

experiments for RTD and hold-up

All of these measurement techniques use compueterized data acquisition systems. Except the camera, two laptops with independent PCMCIA cards are used. Camera is used with standard desktop PIII computer.


REACTOR ENGINEERING

Optimize the Business of Transformations to Maximize Productivity

What transformations are expected to occur? Chemistry/ Thermodynamics

How fast these changes will occur? Reaction kinetics Transport processes (mixing, heat transfer, mass transfer)

What is the best way to carry out these transformations? Hardware configuration / design/ operating protocols

Raw Materials

Value Added Products

Chemical or Physical

Transformations


iFMg MODELING APPROACH

Evolve Detailed Wish List

Occams Razor: It is futile to do with more, what can be done with less Simple/ conventional models may provide adequate solution Conventional models must be used prior to CFD models

One should always try to make things as simple as possible BUT NOT simpler Throwing baby with the bath water Match complexity of the problem with the analysis tool


BASIC RESEARCH: Main Contributions

Multi-environment model for mixing sensitive reactions in turbulent flows

Models to simulate influence of drag reducing polymers on turbulent reacting flows

Computational snapshot approach to simulate impeller rotation in a steady framework without any adjustable parameters: extendable to multiphase flows

Phenomenological and CFD models to simulate dynamics of dispersed gas-liquid flows

CFD models to simulate hydrodynamics of trickle bed reactors


iFMg Reactor Engineering Tools

ReST: Reactor Simulation Tool for fluid-fluid reactors TRPro: Tool for Regeneration Protocols for fixed bed

reactors MoBB: Model for Bubbling fluidized Beds AnTS: Analysis of non-linear Time Series RIAT: Reactions in Agitated Tanks (mixing sensitive) SPARE: Sparged Reactors, general purpose multi-

fluid CFD code FLUENT: Commercial CFD code of Fluent Inc., USA AUTO: Freeware tool for bifurcation analysis


SUMMARY of CONTRIBUTIONS

1 Book, Academic Press, September 2001 42 Papers in Journals (published/ accepted) 36 papers in Conferences 7 Workshops (Mixing, CFM) 8 Industrial contract research/ consultancy projects 5 Basic research projects Established state of the art computing facilities (capable of

carrying out million node simulations) Established multiphase reactor laboratory with computerized

data acquisition systems Established international collaborations (France, USA) 4 Major awards > Rs. 1.2 Crore external funding (received/ approved)


CURRENT ACTIVITIES

Dispersed Gas-liquid Flows Cavities behind impellers Dynamics of bubble columns Development of measurement techniques

Pressure probes Voidage probes High speed camera Radio active tracres CARPT

Entrainment prediction/ reduction Coalescence-breakup models Snapshot approach for reactive mixing


CURRENT ACTIVITIES

Gas-liquid Flow in Trickle Bed Reactors Eulerian models Inter-phase coupling terms Capillary forces

Degree of wetting

Liquid mal-distribution

Development of experimental techniques RTD Visualizations

Microscopic flow around pellets


CURRENT ACTIVITIES

Gas-solid Fluidized Bed Reactors

FCC riser reactor CFD model Reactor model

Mixing cell model of complete FCCU

Mixing cell model of poly-propylene reactor


CURRENT ACTIVITIES

Collaborations:

Professor Bertrand, ENSIGC, Toulouse, France Gas-liquid stirred reactors PIV/ LDV data

Professor Dudukovic, CREL, Washington University, ST. Louis, USA Mixing in opaque multiphase systems CARPT/ CT data

BARC Isotope Group Development of tracer techniques for multiphase reactors

Fluent Inc., USA

Education

Ifmg intro