Chemical and Process Engineering: New Frontiers

The paper presents the results of model studies on the hydrodynamics of the world's first supercritical circulating fluidized bed boiler Lagisza 460 MWe, carried out on a scale model built in a scale of 1/20 while preserving the full geometrical similarity. To reflect the macroscopic pattern of flow in the boiler's combustion chamber, tests were carried out based on two dimensionless flow dynamic similarity criteria, while maintaining a constant Froude number value between the commercial and the scaled-down units. A mix of polydispersion solids with its fractional composition determined by scaling down the particle size distribution of the boiler's inert material was utilised for the tests using a special scaling function. The obtained results show very good agreement with the results of measurements taken on the Lagisza 460 MWe supercritical CFB boiler.

The paper describes the results of various actions and industrial tests conducted in order to decrease the content of unburned carbon in the fly ash of a circulating fluidised bed combustor (CFBC). Several attempts to improve the situation were made and the effects of several parameters on the unburned carbon content in the fly ash were investigated (e.g. bed temperature, cyclone separation efficiency, fuel particle size distribution, boiler hydrodynamics, grid design, and fuel data). Unfortunately, no satisfactory solution to these problems was found. Probably, apart from attrition and char fragmentation, additional factors also contributed to the formation of unburned carbon in the CFBC fly ash.

In this paper starch gelatinisation in Couette-Taylor flow (CTF) apparatus (equipped with a water heat jacket) has been investigated. CTF (characterised by the presence of Taylor vortices) provides good environment for gelatinisation, e.g. effective mixing, fast heat transfer, positive influence on starch rheological properties. During experiments starch gelatinisation degree and starch swelling has been studied. It was accompanied by temperature measurements performed along the apparatus. Additionally, starch gelatinisation was investigated by computer simulation. A complete starch gelatinisation was obtained for the shortest investigated residence time in the apparatus when the temperature in the heat jacket was above 85 °C. Nevertheless, it seems that it is still possible to reduce a residence time value, as well as, the value of Thj, but it may require some acceleration of rotor rotation. The swelling degree of gelatinised starch increased with growing values of residence time, rotor rotation and process temperature. Heat transferred could be affected by the structure of the Taylor vortex flow. No significant destruction of starch granules was observed during the treatment in Couette-Taylor flow apparatus. A quite satisfactory agreement between computer simulation and experiments results was achieved.

The process of carbon dioxide removal from monoethanolamine (MEA) - water solution was investigated on Poly Di Methyl Siloxane (PDMS) hydrophobic tubular membrane with a ceramic support. The effects of feed temperature, liquid flow rate and MEA concentration on CO2 mass transfer and selectivity were examined and found to be with a reasonable deviation (±25%) with predictions based on the multilayer film model. The membrane resistance was evaluated in separate experiments. The measured CO2 mass fluxes (0.17-0.45 kg/(m2h)) were found to be independent of the MEA concentration in the feed.

HY2SEPS was an EU-funded project directed at the reduction of CO2 emissions. The principal objective of the project was to develop a hybrid membrane-adsorptive H2/CO2 separation technique that would form an integral element of the pre-combustion process. Specific tasks included the derivation of simplified mathematical models for the membrane separation of H2/CO2 mixtures.

In the present study one of the developed models is discussed in detail, namely that with the countercurrent plug flow of the feed and the permeate. A number of simulations were carried out concerning the separation of binary mixtures that may appear following steam conversion of methane. The numerical results were then compared with the experimental data obtained by FORTH/ICEHT. The estimated fluxes of pure CO2, H2, CH4 and N2 are shown alongside those measured experimentally as a function of temperature and CO2 partial pressure in Figs 2 - 7. It is concluded that, in general, CO2 flux increases monotonically with both temperature and CO2 partial pressure. It is also found that the fluxes of hydrogen, methane and nitrogen reach a minimum at a temperature slightly above 323 K. Overall, a good agreement was obtained between the simulations and experiments.

Waste disposal is imposed by the European Union under Treaty of Accession concerning waste management order. One of the waste disposal methods is thermal utilisation. The paper presents an investigation of sewage sludge briquettes used as a fuel in combustion process. The research study was carried out on samples taken from the Municipal Wastewater Treatment Plant in Bochnia. Briquettes with lime were formed. The analysis of the elementary chemical composition of municipal sewage sludge, the composition of the ash and thermogravimetric analysis were carried out. The results indicate that the prepared briquettes had sufficient fuel properties.

This paper presents an analysis of the blending characteristics of axial flow high-speed impellers under a turbulent regime of flow of an agitated low viscosity liquid. The conductivity method is used to determine the time course of blending (homogenisation) of miscible liquids in a pilot plant fully baffled mixing vessel, and a torquemeter is used for measuring the impeller power input in the same system. Four-blade and six-blade pitched blade impellers and three high efficiency axial flow impellers are tested for the given degree of homogeneity (98%).

The experimental results and also the results of the authors' previous study, in accordance with the theoretical approach described in the literature, show that there is a universal relationship between the impeller power number and the dimensionless blending time, taking into consideration the impeller-to-vessel diameter ratio, independent of the geometry of the axial flow impeller but dependent on the degree of homogeneity. This relationship is found to be valid on a pilot plant scale under a turbulent flow regime of an agitated liquid.

Experimental investigation of heat transfer during pool boiling of two nanofluids, i.e. water-Al2O3 and water-Cu has been carried out. Nanoparticles were tested at the concentration of 0.01%, 0.1%, and 1% by weight. The horizontal smooth stainless steel tubes having 10 mm OD and 0.6 mm wall thickness formed the test heater. The experiments have been performed to establish the influence of nanofluids concentration on heat transfer characteristics during boiling at different absolute operating pressure values, i.e. 200 kPa, ca. 100 kPa (atmospheric pressure) and 10 kPa. It was established that independent of nanoparticle materials (Al2O3 and Cu) and their concentration, an increase of operating pressure enhances heat transfer. Generally, independent of operating pressure, sub- and atmospheric pressure, and overpressure, an increase of nanoparticle concentration caused heat transfer augmentation.

In many practical situations fluids are normally blended with additives (viscosity index improvers, viscosity thickeners, viscosity thinners) due to which they show pseudoplastic and dilatant nature which can be modelled as cubic stress model (Rabinowitsch model). The cubic stress model for pseudoplastic fluids is adopted because Wada and Hayashi have shown that the theoretical results with this model are in good agreement with the experimental results. The present theoretical analysis is to investigate the pseudoplastic effect along with the effect of rotational inertia on the pressure distribution, frictional torque and fluid flow rate of externally pressurised flow in narrow clearance between two curvilinear surfaces of revolution. The expression for pressure has been derived using energy integral approach. To analyse and discuss the effects of pseudoplasticity and fluid inertia on the pressure distribution, fluid flow rate and frictional torque, the examples of externally pressurised flow in the clearance between parallel disks and concentric spherical surfaces have been considered.

The present work deals with agitation of non-Newtonian fluids in a stirred vessel by Scaba impellers. A commercial CFD package (CFX 12.0) was used to solve the 3D hydrodynamics and to characterise at every point flow patterns especially in the region swept by the impeller. A shear thinning fluid with yield stress was modelled. The influence of agitator speed, impeller location and blade size on the fluid flow and power consumption was investigated. The results obtained are compared with available experimental data and a good agreement is observed. It was found that an increase in blade size is beneficial to enlargement of the well stirred region, but that results in an increased power consumption. A short distance between the impeller and the tank walls limits the flow around the agitator and yields higher power consumption. Thus, the precise middle of the tank is the most appropriate position for this kind of impeller.

Adsorption experiments of nitric oxide in nitrogen carrier gas were held on activated carbon in a fixed bed flow system. Breakthrough curves describing the dependence of exit concentrations of nitric oxide on time were matched with theoretical response curves calculated from the linear driving force model (LDF). The model assumes Langmuir adsorption isotherm for the description of non-linear equilibrium and overall mass transfer coefficient for mass transfer mechanism. Overall mass transfer coefficients were obtained by the method of least squares for fitting numerically modelled breakthrough curves with experimental breakthrough curves. It was found that LDF model fits all the breakthrough curves and it is a useful tool for modelling purposes.

The present work deals with ultrasound assisted crystallisation of lactose from lactose solution. The crystallisation of lactose was completed rapidly by applying the ultrasound waves in the presence of an anti-solvent (n-propanol), at the room temperature (30±3°C). The yield of lactose was found to be more than 85% (w/w) in 4 minutes of sonication. The spread of the crystal size distribution was found to decrease with increase in sonication time.

The article presents the results of laboratory tests carried out on a scaling model of the 966MWth fluidised-bed boiler operating in the Lagisza Power Plant, made on a scale of 1:20 while preserving the geometrical similarity. The tests were carried out for scaled-down material taken from different locations on the circulation contour in the state of full boiler loading. To reflect the hydrodynamic conditions prevailing in the combustion chamber, solids with properly selected density and particle size distribution were used. The obtained results have made it possible to determine the location for taking the most representative granular material sample.

The new efficient method of modeling and thermodynamic analysis of power engineering systems has been presented. With its help a comparison of different structures and investigation of the influence of a particular constituent process onto the whole system efficiency is possible. The shaft work or the exergy is the main thermodynamic quantity taken into account in analyses, and the appropriate dimensionless modeling parameter has been introduced.

The motivation of this work was to define the reburning potential of sewage sludge gasification gas (syngas). Numerical simulation of co-combustion process of syngas in hard coal-fired boiler has been done. All the calculations were performed using the Chemkin program. Plug-Flow Reactor model was used. The calculations were modelled using GRI-Mech 2.11 mechanism. The highest NO conversions are obtained at the temperature of about 1000-1200 K. The highest reduction efficiency was achieved for the molar flow ratio of syngas equal to 15%. The combustion of hard coal with sewage sludge - derived syngas reduces NO emissions and the amount of coal needed to produce electricity and heat. Advanced reburning, which is a more complicated process gives efficiency of up to 80%. The calculations show that the analyzed syngas can yield better results.

This paper presents possibilities for of numerical modelling of biomass combustion in a commercially available boiler. A sample of biomass was tested with respect to its physical and chemical properties. Thermogravimetry studies of biomass were carried out. Computer simulation makes it possible to analyse complex phenomena which are otherwise difficult to observe. The aim of this work was to model biomass combustion to predict the amount of pollutants generated (NOx, CO, SO2) in the exhaust gases coming out from boilers The calculations were made using the CHEMKIN program. Results of calculations were performed taking into account the influence of temperature, pressure and residence time.

Natural gas is a mixture of 21 components and it is widely used in industries and homes. Knowledge of its thermodynamic properties is essential for designing appropriate processes and equipment. This paper presents simple but precise correlations of how to compute important thermodynamic properties of natural gas. As measuring natural gas composition is costly and may not be effective for real time process, the correlations are developed based on measurable real time properties. The real time properties are temperature, pressure and specific gravity of the natural gas. Calculations with these correlations are compared with measured values. The validations show that the average absolute percent deviation (AAPD) for compressibility factor calculations is 0.674%, for density is 2.55%, for Joule-Thomson coefficient is 4.16%. Furthermore, in this work, new correlations are presented for computing thermal properties of natural gas such as enthalpy, internal energy and entropy. Due to the lack of experimental data for these properties, the validation is done for pure methane. The validation shows that AAPD is 1.31%, 1.56% and 0.4% for enthalpy, internal energy and entropy respectively. The comparisons show that the correlations could predict natural gas properties with an error that is acceptable for most engineering applications.

Lean mixture burning leads to a decrease in the temperature of the combustion process and it is one of the methods of limiting nitric oxide emissions. It also increases engine efficiency. An effective method to correct lean mixture combustion can be a two-stage system of stratified mixture combustion in an engine with a prechamber. This article presents the results of laboratory research on an SI engine (spark ignition) with a two-stage combustion system with a cylinder powered by gasoline and a prechamber powered by propane-butane gas LPG (liquefied petroleum gas). The results were compared to the results of research on a conventional engine with a one-stage combustion process. The test engine fuel mixture stratification method, with a two-stage combustion system in the engine with a prechamber, allowed to burn a lean mixture with an average excess air factor equal to 2.0 and thus led to lower emissions of nitrogen oxides in the exhaust of the engine. The test engine with a conventional, single-stage combustion process allowed to properly burn air-fuel mixtures of excess air factors λ not exceeding 1.5. If the value λ > 1.5, the non-repeatability factor COVLi increases, and the engine efficiency decreases, which makes it virtually impossible for the engine to operate. The engine with a two-stage combustion process, working with λ = 2.0, the Qin/Qtot = 2.5%, reduced the NOx content in the exhaust gases to a level of about 1.14 g/kWh. This value is significantly lower than the value obtained in a conventional engine, which worked at λ = 1.3 with comparable non-repeatability of successive cycles (about 3%) and a similar indicated efficiency (about 34%), was characterised by the emissions of NOx in the exhaust equal to 26.26 g/kWh.