Numerical Simulation of Fluid Flow and Mixing Dynamics inside Planetary Roller Extruders

In this contribution, the fluid flow and mixing dynamics inside planetary roller extruders are simulated using the finite element method (FEM) and the mesh superposition technique (MST). Three-dimensional configurations with planetary spindles of varying number and geometry of planetary spindles were created to analyse the influence of the spindle configuration and the rotational speed on the process behavior. Therefore, pressure gradients, flow velocities and directions, shear rates, the mixing index and residence time distributions were evaluated. The distributive and dispersive mixing efficiencies varied depending on the planetary spindle configuration, and these configurations thus suit different processing tasks. In comparison to the standard planetary spindles, the TT3 spindles, with their incomplete toothing, and the knob spindles, with their double transversal helical toothing, showed intense axial and radial mixing. In general, the mixing performance of the planetary roller extruder is explained by a high rate of extensional flow and frequent changes in flow type. The reported numerical approach allows, for the first time, a comprehensive observation of the process behavior of planetary roller extruders.

The use of flow diagnostics to rank model ensembles

Ensembles of geomodels provide an opportunity to investigate a range of parameters and possible operational outcomes for a reservoir. Full-featured dynamic modelling of all ensemble members is often computationally unfeasible, however some form of modelling, allowing us to discriminate between ensemble members based on their flow characteristics, is required. Flow diagnostics (based on a single-phase, steady-state simulation) can provide tools for analysing flow patterns in reservoir models but can be calculated in a much shorter time than a full-physics simulation. Heterogeneity measures derived from flow diagnostics can be used as proxies for oil recovery. More advanced flow diagnostic techniques can also be used to estimate recovery. With these tools we can rank ensemble members and choose a subset of models, representing a range of possible outcomes, which can then be simulated further. We demonstrate two types of flow diagnostics. The first are based on volume-averaged travel times, calculated on a cell by cell basis from a given flow field. The second use residence time distributions, which take longer to calculate but are more accurate and allow for direct estimation of recovery volumes. Additionally we have developed new metrics which work better for situations where we have a non-uniform initial saturation, e.g., a reservoir with an oil cap. Three different ensembles are analysed: Egg, Norne, and Brugge. Very good correlation, in terms of model ranking and recovery estimates, is found between flow diagnostics and full simulations for all three ensembles using both the cell-averaged and residence time based diagnostics.

Particle Lagrangian CFD Simulation and Experimental Characterization of the Rounding of Polymer Particles in a Downer Reactor with Direct Heating

Polypropylene (PP) powders are rounded at different conditions in a downer reactor with direct heating. The particles are fed through a single central tube, while the preheated sheath gas is fed coaxially surrounding the central aerosol jet. The influence of the process parameters on the quality of the powder product in terms of particle shape and size is analyzed by correlating the experimental results with the flow pattern, residence time distribution of the particles and temperature distribution predicted by computational fluid dynamics (CFD) simulations. An Eulerian–Lagrangian numerical approach is used to capture the effect of the particle size distribution on the particle dynamics and the degree of rounding. The simulation results reveal that inlet effects lead to inhomogeneous particle radial distributions along the total length of the downer. The configuration of particle/gas injection also leads to fast dispersion of the particles in direction of the wall and to particle segregation by size. Broad particle residence time distributions are obtained due to broad particle size distribution of the powders and the particles dispersion towards the wall. Lower mass flow ratios of aerosol to sheath gas are useful to reduce the particle dispersion and produce more homogenous residence time distributions. The particles’ residence time at temperatures above the polymer’s melting onset is determined from the simulations. This time accounts for the effective treatment (rounding) time of the particles. Clear correlations are observed between the numerically determined effective rounding time distributions and the progress of shape modification on the particles determined experimentally.