Search Results (30)

Stirred tanks are widely used in polymerization processes, where the residence time distribution (RTD) significantly affects monomer conversion and polymer quality. In this study, the RTD in the stirred tank with both constant and variable viscosity fluids was investigated numerically. To account for the viscosity evolution during polymerization, a model relating fluid viscosity to the mean age of the fluid was developed. After verifying mesh and time step independence, the effects of impeller speed, fluid space time, and viscosity varying on RTD were examined in both single-tank and two-tank configurations. Compared to the constant-viscosity fluids, the variable-viscosity fluid shows different flow behaviors such as dead zones and short-circuiting. Analysis based on the number of tanks in series showed that increasing impeller speed and extending space time can enhance mixing efficiency, where the improved mixing in the second stage of the two-tank configuration eliminated the concentration fluctuations caused by recirculating flow in the first tank, which may result in a more uniform RTD curves. Full article

Background/Objectives: In the twin-screw wet granulation (TSWG) process, accurate measurement of residence time distribution (RTD) is critical, as it characterizes material transport kinetics and mixing behavior. It plays a critical role in evaluating the homogeneity and stability of the granulation process and optimizing process parameters. It is necessary to overcome the limitations arising from the complex and time-consuming procedures of conventional RTD determination methods. Methods: This study proposes a new RTD detection method based on image processing. It uses black dye as a tracer to obtain RTD curve data, and the effects of process parameters such as tracer dosage, screw speed, and feeding rate on the RTD were investigated. Results: The results show that the established method can accurately determine RTD and that the tracer dosage has no significant effect on the detection results. Further analysis revealed that the screw speed is negatively correlated with the mean residence time (MRT). As the speed increases, not only does the MRT shorten, but its distribution also decreases. Similarly, an increase in the feeding rate also leads to a decrease in the MRT and distribution, but it is worth noting that lower feeding rates are beneficial for achieving a state close to mixed flow, while excessively high feeding rates are not conducive to sufficient mixing of materials in the extruder. Conclusions: The RTD detection method provides a reliable parameter basis and theoretical guidance for the in-depth study of the TSWG process and the development of quality control strategies. Full article

The behavior of molten steel within a tundish plays a crucial role in achieving uniform temperature and chemical composition, enhancing the removal efficiency of non-metallic inclusions, and reducing the wear of refractory linings. These aspects are key for ensuring the production of steel with superior quality. In multi-strand delta-type tundishes, such as the six-strand configuration, flow dynamics become particularly challenging. Key considerations include strand-specific residence times, the uniform distribution of steel flow, and the mitigation of refractory degradation. This paper presents a detailed numerical analysis aimed at designing an optimally shaped impact pad. The effectiveness of each proposed design was assessed through a tracer-based visualization of flow behavior and the evaluation of residence time distribution (RTD) curves. RTD curves were created in isothermal conditions, while the calculations of the temperature fields of steel in the tundish were made in non-isothermal conditions. The results of the simulations were verified by a real plant trial test and indicate that the use of the “SPHERIC-K4” impact pad can greatly enhance the flow characteristics of liquid steel during the continuous casting process. These improvements include preventing the erosion of the tundish refractory lining, improving the distribution of residence times between individual casting strands, and adjusting the proportions of the mixing zones. Full article

Casting AISI 52100 steel represents a challenge, particularly at the start of the casting sequence, due to its low melting point. The steel spilling over the tundish bottom cools down rapidly and freezes in the stopper rods, obliging the closure of a strand. Therefore, an additional function of turbulence inhibitors is to induce steel masses at a slow cooling rate. This paper deals with the physical and mathematical modeling of unsteady state-flows using two turbulence inhibitors (TIs) during the sequence start. One of the TIs makes steel spill forming thin layers of liquid on the tundish bottom, while the other forms a thicker layer. Based on the Flow of Volume Model, the mathematical simulation was satisfactorily replicated in the water model. Full article

The study focuses on the four-strand tundish as the research object, aiming at the phenomenon of fewer strand casting (stable blockage) and sudden blockage of the tundish in industrial production. Numerical simulation methods are employed to compare the velocity vectors, flow fields, residence time distribution (RTD) curves, and outflow percentage curves under stable blockage and sudden blockage of the tundishes with a double-weir structure, U-shaped weir structure, and U-shaped weir structure with holes in the front. The results indicate that, after sudden blockage of the tundish strands, the flow field transitions from an unstable four-strand flow field to a stable three-strand flow field. Both the double-weir tundish and the U-shaped weir tundish reach a stable state after 200 s, while the U-shaped weir tundish with holes in the front reaches stability after 150 s. Additionally, compared to other structures, the tundish strands of the U-shaped weir with holes in the front are less affected by blockage, showing better consistency among strands and better adaptability under non-standard casting conditions. Full article

The quality of the bloom will be impacted by the non-metallic impurities in the molten steel in the tundish, which will reduce the plasticity and fatigue life of the steel. In this research, a mathematical model of a six-flow double-channel T-shaped induction heating tundish was established, the effects of induction heating conditions on the removal of inclusions in the tundish were investigated, and the impact of various inclusion particle sizes on the removal effect of inclusions under induction heating was explored. The results show that the Residence Time Distribution (RTD) curve produced through numerical simulation and physical simulation is in good agreement. The reduction of inclusion particles in the channel is made affordable by the dual-channel induction heating technique. As the diameter of inclusion particles increases from 10 μm to 50 μm, the probability of inclusion particles being removed from the channel gradually decreases from 70.9% to 56.1%. Full article

A transient inline spiking system is a promising tool for evaluating the performance of a virus filter in continuous operation. For better implementation of the system, we performed a systematic analysis to understand the residence time distribution (RTD) of inert tracers in the system. We aimed to understand the RTD of a salt spike, not retained onto or within the membrane pore, to focus on its mixing and spreading within the processing units. A concentrated NaCl solution was spiked into a feed stream as the spiking duration ($t_{spike}$) was varied from 1 to 40 min. A static mixer was employed to mix the salt spike with the feed stream, which then passed through a single-layered nylon membrane inserted in a filter holder. The RTD curve was obtained by measuring the conductivity of the collected samples. An analytical model, the PFR-2CSTR model, was employed to predict the outlet concentration from the system. The slope and peak of the RTD curves were well-aligned with the experimental findings when ${\tau }_{PFR}$ = 4.3 min, ${\tau }_{CSTR1}$ = 4.1 min, and ${\tau }_{CSTR2}$ = 1.0 min. CFD simulations were performed to describe the flow and transport of the inert tracers through the static mixer and the membrane filter. The RTD curve spanned more than 30 min, much longer than $t_{spike}$, since solutes were dispersed within processing units. The flow characteristics in each processing unit correlated with the RTD curves. Our detailed analysis of the transient inline spiking system would be helpful for implementing this protocol in continuous bioprocessing. Full article

The solute transport in the fractured rock is dominated by a single fracture. The geometric characteristics of single rough-walled fractures considerably influence their solute transport behavior. According to the self-affinity of the rough fractures, the fractal model of single fractures is established based on the fractional Brownian motion and the successive random accumulation method. The Navier–Stokes equation and solute transport convective-dispersion equation are employed to analyze the effect of fractal dimension and standard deviation of aperture on the solute transport characteristics. The results show that the concentration front and streamline distribution are inhomogeneous, and the residence time distribution (RTD) curves have obvious tailing. For the larger fractal dimension and the standard deviation of aperture, the fracture surface becomes rougher, aperture distribution becomes more scattered, and the average flow velocity becomes slower. As a result, the average time of solute transport is a power function of the fractal dimension, while the time variance and the time skewness present a negative linear correlation with the fractal dimension. For the standard deviation of aperture, the average time exhibits a linearly decreasing trend, the time variance is increased by a power function, and the skewness is increased logarithmically. Full article

With the increase in the penetration rate of renewable energy sources, a machine-learning-based forecasting system has been introduced to the grid sector to improve the participation rate in the electricity market and reduce energy losses. In these studies, correlation analysis of mechanical and environmental variables, including geographical figures, is considered a crucial point to increase the prediction’s accuracy. Various models have been applied in terms of accuracy, speed calculation, and amount of data based on a mathematical model that can calculate the wake; however, it can be difficult to derive variables such as air density, roughness length, and the effect of turbulence on the structural characteristics of wind turbines. Furthermore, wake accuracy could decrease due to the excessive variables that come from the wake effect parameters. In this paper, we intend to conduct research to improve prediction accuracy by considering the wake effect of wind turbines using supervisory control and data acquisition (SCADA) data from the Dongbok wind farm. The wake divides the wind direction into four parts and then recognizes and predicts the affected wind turbine. The predicted result is the wake wind speed and its conversion to power generation by applying a power curve. We try to show the efficiency of machine learning by comparing the wake wind speed and the power generation in the wake model. This result shows the error rate using evaluation metrics of regression, such as mean squared error (MSE), root mean squared error (RMSE), and weighted absolute percentage error (WAPE), and attempts to verify power system impact and efficiency through a real-time digital simulator (RTDS). Full article

This study aims to compare the limb symmetry index (LSI) of the rate of torque development (RTD) of the quadriceps with that of the peak torque after anterior cruciate ligament reconstruction (ACLR) using semitendinosus and gracilis tendon (STG) autografts and to investigate the associations of the LSI of torque parameters with patient-reported knee function. The participants included 23 female athletes after ACLR with STG grafts. Isometric quadriceps tests were performed using an isokinetic dynamometer. The peak torque, RTD₁₀₀ (0 to 100 ms) and RTD₂₀₀ (100 to 200 ms) were determined using torque-time curves. Comparisons of the LSI of torque parameters was performed by ANOVA. Univariate regression analysis was used to examine the relationship between the LSI of torque parameters and the patient-reported knee function. The LSIs of the peak torque and RTD₂₀₀ were significantly lower than that of the RTD₁₀₀ (p = 0.049, p = 0.039, respectively). Regression analysis showed that the LSI of the peak torque was associated with the patient-reported knee function (R² = 0.40, p = 0.001). It would be useful to evaluate the peak torque in young female athletes under the age of 18 and at 8–10 months after ACLR with STG grafts. Full article

The continuous casting tundish is a very important metallurgical reactor in continuous casting production. The flow characteristics of tundishes are usually evaluated by residence time distribution (RTD) curves. At present, the analysis model of RTD curves still has limitations. In this study, we reviewed RTD curve analysis models of the single flow and multi-flow tundish. We compared the mixing model and modified combination model for RTD curves of single flow tundish. At the same time, multi-strand tundish flow characteristics analysis models for RTD curves were analyzed. Based on the RTD curves obtained from a tundish water experiment, the applicability of various models is discussed, providing a reference for the selection of RTD analysis models. Finally, we proposed a flow characteristics analysis of multi-strand tundish based on a cumulative time distribution curve (F-curve). The F-curve and intensity curve can be used to analyze and compare the flow characteristics of multi-strand tundishes. The modified dead zone calculation method is also more reasonable. This method provides a new perspective for the study of multi-strand tundishes or other reactor flow characteristics analysis models. Full article

Rational function approximation is commonly used to fit the transmission line impedance over a wide frequency range. Nevertheless, it is computationally costly and challenging to implement in practical applications due to the high number of approximations required to fit the impedance curve for the high-frequency range. Therefore, a novel fitting method of multiconductor transmission line (MTL) based on the analytical impedance equation of a transmission line using the impedance frequency response measurement is presented in this paper. The proposed fitting method is a function of the transmission line length since it is based on the analytical impedance equation of a finite transmission line. Furthermore, the proposed model uses a constant set of equations and calculated parameters to fit the impedance frequency response for a wide range of frequencies. Moreover, the proposed model parameters are calculated using derived resonance equations and the impedance frequency response measurement. In addition, an algorithm is developed to further fit the proposed model to the impedance frequency response measurement of the transmission line. MTL impedance frequency response is measured using a real-time digital simulator (RTDS). To ensure the accuracy of the proposed model, a comparison between the proposed model and vector fitting (VF) is presented. Full article

The mechanical energy resulting from cutting processes is turned almost completely in thermal energy, which encourages thermal procedures, such as diffusion, leading to higher wear in the cutting tool and thus to higher temperatures. Furthermore, high temperatures influence the properties of the marginal zones in the workpiece. In this presented work, the in-process temperature of a cutting insert during single-lip deep hole drilling (SLD) is investigated. Therefore, a sensor-integrated tool with resistance temperature detectors (RTD) placed beneath the cutting insert is developed. First, the thermal properties of the cutting insert are adjusted to fit the assembled tool. Afterwards, a CEL-Simulation is obtained to examine the temperature distribution at the cutting edge of the SLD-tool. The temperatures calculated by simulation can be compared to the in-process temperatures of the sensor integrated tool. Because of the usage of a cooling lubricant, simulated temperatures can be varied with a factor to fit the experimentally measured temperature curves. The highest temperature during the process appears at the outer edge of the cutting insert. By knowing the thermal properties, the maximum process temperatures for the deep hole drilling operation are to be calculated. The results represent a contribution to an interdisciplinary research project “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG). Full article

The solute transport process in porous media is central to understanding many geophysical processes and determines the success of engineered applications. However, fundamental understanding of solute transport in heterogeneous porous media remains challenging especially when inertial effects are significant. To address this challenge, we employed direct numerical simulations in a variety of intrapore geometries at a high Reynolds number (Re = 10) flow regime, where recirculation zones (RZs) are present with significant inertial effects. We find that the volume of RZs depends on pore geometries. Moreover, RZs serve as an immobile domain that can trap and release solutes that lead to non-Fickian transport, characterized by the early arrival and heavy tailing of breakthrough curves and bimodal residence time distributions (RTDs). Lastly, the late time portion of RTDs is fitted to the power law function with determined exponent n, where n depends on the pore geometries and consequently the volume of RZs. Our study sheds light on the mechanisms of an immobile zone on the solute transport, especially improving our understanding of late time transport tailing in pressurized heterogeneous porous media. Full article

Cracking con-rod is an advanced high-precision connecting structure based on brittle expansion, breaking and reconnection of steel, to solve the problem of assembly circle missing. High carbon micro-alloyed steel C70S6, as a dominant material for the production of cracking con-rod, has extremely strict requirements on non-metallic inclusions in steel and microstructure stability. Continuous casting tundish plays an important role in removing large-sized inclusions and stabilizing casting quality. Aiming at the inconsistent casting quality of C70S6 steel produced by a three-strand asymmetric tundish and the frequent occurrence of slag entrapment problems in Xining Special Steel, the tundish structure was optimized by means of physical modelling combined with numerical simulation, and the quality of the bloom castings and subsequent hot-rolled products before and after optimization were compared based on volume production. The results show that a new flow control design to the tundish can effectively improve the consistency of its metallurgical effect for each of the three strands and the following overall product quality, in which the flow field and temperature field in the tundish are more uniform. This is due to the adoption of a vortex inhibitor and an optimized wall structure according to the measured RTD curve, ink trajectory and numerical simulation on the 3-D streamline contours and temperature distribution in the tundish. The peak concentration of outlet 1 is decreased from 6.5 before optimization to less than 2.0 after optimization, which means the elimination or alleviation of the local short-circuit flow. The maximum temperature difference of C70S6 molten steel measured at the outlets of the tundish three strands is decreased from 2–5 °C to 1–3 °C, which is in good agreement with the numerical simulation results. The difference in columnar crystal ratio of the corresponding bloom castings is decreased from 2.27–3.17% to 1.26–1.85%, and the consistency of central carbon segregation index is also significantly improved. In addition, the difference in oxygen content among the three strand blooms is decreased from 1.7–3.5 ppm to 0.8–1.9 ppm. As a result, the overall mechanical properties and microstructure stability of the hot-rolled products are improved statistically, in which the hardness fluctuation is decreased from 84 HBW to 60 HBW, the inclusion grade of types B + C + D + Ds is reduced to 1.105, and the occurrence rate of Ds dropped to 0.118%. Accordingly, the failure rate of the cracking con-rod is controlled stably within 4‰, and the fracture is generally smoother than that before tundish optimization. In summary, the flow field optimization to a multi-strand asymmetric tundish has a clear effect on improving the overall quality of its bloom castings and rolled products, which should be paid more attention industrially. Meanwhile, the present study provides a reliable theoretical and experimental reference for the improvement of metallurgical effects of an asymmetric-typed tundish commonly used in special steel production. Full article