EVALUATION OF A SUCTION PYROMETER
By analytical heat transfer methods
SEBASTIAN ZETTERSTRÖM
Akademin för ekonomi, samhälle och teknik
Kurs: Examensarbete Handledare: Jan Sandberg Kurskod: ERA403 Examinator: Ioanna Aslanidou Ämne: Energiteknik Uppdragsgivare: Konstantinos Kyprianidis, EST Högskolepoäng: 30 hp Datum: 2017-09-18 Program: Civilingenjörsprogrammet i E-post: energisystem [email protected]
ABSTRACT
Sebastian Zetterström, Master of Science in energy systems, Mälardalens University in Västerås. Abstract of Master’s thesis, submitted 16th of August.
Evaluation of a suction pyrometer by heat and mass transfer methods.
The aim of the thesis is to evaluate the cooling of a specific suction pyrometer which is designed by Jan Skvaril, doctorate at Mälardalens University. First part is explained how the balances and correlations are performed before being implemented in MATLAB, after this a ANSYS Fluent model is constructed and explained, which is used for the comparison of results.
The cooling is performed by using water at an inlet temperature of 10°C and an assumed flue gas temperature of 810°C. Sensitivity analysis are performed to test the stability of the models which yield good results for stability, done by adjusting both flue gas temperature and inlet cooling water temperature which are as well presented for observation. From doing further MATLAB sensitivity analysis which show that the model still performs well and is stable.
The resulting cooling water is heated to approximately 24, 8°C and the flue gas is cooled to 22, 4°C, in ANSYS Fluent the answer differs approximately 2°C and results in 20, 4°C which can be considered by looking at the flue gas inlet temperature of 810°C that this can be deemed an insignificant change and can therefore conclude that the comparison between the two platforms match each other good and that calculations can be considered accurate.
Keywords: Suction pyrometer, cooling, heat transfer, thermal resistance network, MATLAB, ANSYS Fluent, simulation
PREFACE
Before you is the dissertation “Evaluation of a suction pyrometer: By heat and mass transfer methods” which is a thesis about evaluating the cooling possibilities of a newly designed suction pyrometer by using water. It is written as a part of graduating from Master of Science in energy systems at Mälardalens University in Västerås. I started writing and working on this thesis in the beginning of January this year. Chose to work with this topic because the subject of heat and mass transfer optimization is an interesting topic.
The thesis became available as a project after Jan Skvaril made a new design for a suction pyrometer and distributed by Mälardalens University as an internal project. Chose this topic through an available list presented by Konstantinos Kyprianidis.
The research for the thesis was extremely time consuming but has allowed me to gain significant more knowledge of the heat and mass transfer area as well as how CFD simulations are done, and to compare this with results from an analytical model.
1.1 Acknowledgement
This would not have been possible without the support and motivation of my handler Jan Sandberg who has helped me a lot with questions and issues I have had in working on this thesis, who deserves a huge thank you for this help and guidance. Would also like to thank Md Lokman Hosain, a doctorate student at MDH who helped me with ANSYS Fluent simulations and the model construction.
Want to thank Konstatinos Kyprianidis for his support and motivational spirit. A fellow student Kristoffer Hermansson who helped with MATLAB and allowing me for the use of his flue gas radiation function file.
The thesis was made possible by Jan Skvaril who designed the tool and gave his confidence and support in giving me the possibility of working on this thesis, a special thanks to Jan Skvaril.
Västerås, 18th of September 2017
Sebastian Zetterström
CONTENT
1.1 Acknowledgement ...... iii
2 INTRODUCTION ...... 1
2.1 Background ...... 1 2.1.1 Previous research ...... 2
2.2 Problem formulation...... 3
2.3 Research question ...... 3
2.4 Delimitation ...... 3
2.5 Aim and scope ...... 4
3 INTRODUCTION TO PYROMETERS ...... 4
3.1 Examples of pyrometer types ...... 4
3.2 Suction pyrometer design ...... 5 3.2.1 Seebeck effect and thermocouple design ...... 6
3.3 Water cooling ...... 7
3.4 General calculation and validation method for this type of tool ...... 7 3.4.1 ANSYS Fluent ...... 8 3.4.2 MATLAB ...... 8
4 METHODOLOGY ...... 8
4.1 Literature study ...... 9
4.2 Calculation pathway ...... 9 4.2.1 MATLAB ...... 9
4.3 Heat transfer correlations and balances ...... 14 4.3.1 Diameter and radius ...... 15 4.3.2 Thermal resistance network ...... 16 4.3.3 Heat balances ...... 18 4.3.4 Water and flue gas properties ...... 21 4.3.4.1. Created interpolation formulas ...... 22 4.3.5 Equations for properties ...... 24
4.3.6 Pressure loss calculations ...... 25 4.3.7 Flue gas radiation ...... 26
4.4 Utilized MATLAB features ...... 28 4.4.1 Utilized loop methods ...... 28 4.4.2 Function ...... 28 4.4.3 Data import ...... 30
4.5 ANSYS Fluent ...... 32 4.5.1 2D-axisymmetric ...... 33 4.5.2 Geometry ...... 34 4.5.3 Mesh ...... 34 4.5.4 Y-plus(y+) ...... 36 4.5.5 Solver setup ...... 37 4.5.6 Fluent results ...... 38
5 DESCRIPTION OF CURRENT STUDY ...... 38
5.1 Assumed input and properties ...... 38 5.1.1 Fixed constant values ...... 39 5.1.2 Mesh settings ...... 40 5.1.3 ANSYS Fluent boundary conditions ...... 40 5.1.4 Sensitivity analysis settings ...... 42 5.1.5 Fuel content ...... 43
6 RESULTS ...... 43
6.1 MATLAB temperature distribution ...... 44 6.1.1 MATLAB Sensitivity analysis ...... 48 6.1.1.1. 400°C ...... 48 6.1.1.2. 750°C ...... 48 6.1.1.3. 860°C ...... 49 6.1.1.4. 1100°C ...... 49 6.1.1.5. 5°C Water inlet temperature, flue gas inlet = 810°C ...... 50 6.1.1.6. 15°C Water inlet temperature, flue gas inlet = 810°C ...... 50 6.1.2 Pressure loss results ...... 50
6.2 ANSYS Fluent temperature distribution ...... 51 6.2.1 ANSYS Fluent Sensitivity analysis ...... 58 6.2.1.1. 400°C ...... 58 6.2.1.2. 750°C ...... 58 6.2.1.3. 860°C ...... 59 6.2.1.4. 1100°C ...... 59 6.2.1.5. 5°C Water inlet temperature, flue gas inlet = 810°C ...... 59 6.2.1.6. 15°C Water inlet temperature, flue gas inlet = 810°C ...... 60
7 COMPARISON OF MAIN RESULT ...... 60
8 DISCUSSION...... 65
9 CONCLUSION ...... 70
10 PROPOSAL FOR CONTINUED WORK ...... 71
REFERENCE LIST ...... 73
11 APPENDIX 1: MATLAB CODE ...... 2
11.1 Main file code ...... 2
11.2 Function files ...... 8 11.2.1 Specific heat for flue gas ...... 8 11.2.2 Specific heat for water ...... 8 11.2.3 Density for flue gas ...... 9 11.2.4 Density for water ...... 9 11.2.5 Kinematic viscosity for flue gas ...... 9 11.2.6 Kinematic viscosity for water ...... 10 11.2.7 Outer surface function, fsolve ...... 10 11.2.8 Dynamic viscosity for flue gas ...... 11 11.2.9 Dynamic viscosity for water ...... 11 11.2.10 Heat conductivity for water ...... 12 11.2.11 Heat conductivity for steel ...... 12 11.2.12 Convection coefficient for flue gas...... 12 11.2.13 Convection coefficient for water ...... 12
12 APPENDIX 2: FLUE GAS EXCEL SHEET ...... 15
13 APPENDIX 3: ANSYS FLUENT GRAPHS ...... 16
13.1 Flue gas and water velocity profiles ...... 16
14 APPENDIX 4: PREVIOUS FAILED SIMULATIONS ...... 17
15 APPENDIX 5: ANSYS FLUENT MODEL CONSTRUCTION DETAILS ...... 20
15.1 Geometry...... 20
15.2 Mesh ...... 30 15.2.1 Mesh method ...... 30 15.2.2 Boundary layers ...... 32 15.2.4 Solver setup ...... 38 15.2.5 Setting up results and graphs ...... 50
16 APPENDIX 6: FURTHER MATLAB SENSITIVITY ANALYSIS ...... 53
16.1 Different Δx ...... 53
16.2 Change of inlet water velocity ...... 54
FIGURES
Figure 1 Thermocouple measuring circuit with a heat source, cold junction and voltmeter (Wtshymanski, 2011) ...... 7 Figure 2 illustration of a calculation cell ...... 10 Figure 3 Illustration of nodes ...... 10 Figure 4 Side view of the suction pyrometer in a simplified form ...... 12 Figure 5 Front view of the suction pyrometer ...... 13 Figure 6 Overview of how the pipes and energies are setup. Illustrating how the balances are derived ...... 14 Figure 7 Inner and outer diameter of all pipes with their MATLAB designations ...... 15 Figure 8 Thermal resistance network illustration ...... 16 Figure 9 illustrating the radiuses used in the conduction formula ...... 16 Figure 10 Screenshot from Microsoft Excel illustrating the trend curve for heat conductivity of AISI 304 steel. Y-axis is the heat conductivity values with x-axis ranging from 300 – 1500 Kelvin ...... 22 Figure 11 Flue gas input data for partial pressures ...... 27 Figure 12 Partial pressures of the flue gas ...... 27 Figure 13 Syntax for FOR and WHILE loop ...... 28 Figure 14 Example of how to state a function script ...... 29 Figure 15 How to write the syntax for calling the function ...... 29 Figure 16 Example of an function with one output variable which depend on one input variable ...... 29 Figure 17 Example of a function script which return several outputs and depend on several input variables ...... 30 Figure 18 Syntax for data import ...... 31 Figure 19 Example of the layout for a 1D-table ...... 31 Figure 20 Layout of the table used to import the values ...... 31 Figure 21 Ansys fluent project window ...... 33 Figure 22 Geometry layout with designations ...... 34 Figure 23 At the water inlet/outlet location of the suction pyrometer ...... 34 Figure 24 Mesh with refined boundary layers towards the wall ...... 35 Figure 25 Snapshot of the right side of the pyrometer model's Mesh ...... 36 Figure 26 Solver setup window ...... 37 Figure 27 Turbulence specification method for flue gases ...... 41
Figure 28 Turbulence specification method for water ...... 41 Figure 29 flue gas settings, linear interpolation ...... 42 Figure 30 MATLAB Results ...... 44 Figure 31 Sum of the flue gas radiation over the length of the pyrometer ...... 44 Figure 32 Local flue gas pipe energy ...... 44 Figure 33 Flue gas flow temperature ...... 45 Figure 34 Water temperature...... 45 Figure 35 Flue gas flow velocity ...... 46 Figure 36 Water flow velocity ...... 47 Figure 37 Result of a flue gas inlet temperature of 400°C ...... 48 Figure 38 Result of a flue gas inlet temperature of 750°C ...... 48 Figure 39 Result of a flue gas inlet temperature of 860°C ...... 49 Figure 40 Result of a flue gas inlet temperature of 1100°C ...... 49 Figure 41 Result of changing the cooling water inlet temperature to 5°C ...... 50 Figure 42 Result of changing the cooling water inlet temperature to 15°C ...... 50 Figure 43 ANSYS Temperature results ...... 51 Figure 44 ANSYS Fluent calculated properties ...... 52 Figure 45 Mass flows ...... 53 Figure 46 Flue gas flow temperature ...... 53 Figure 47 Water temperature ...... 54 Figure 48 Cut section graph, mid-point at x-coordinate 1, 25 meters ...... 55 Figure 49 Cut section graphs at the end of the pyrometer ...... 56 Figure 50 Simulation Y-plus value ...... 57 Figure 51 Result when adjusting the inlet flue gas temperature in ANSYS Fluent to 400°C .. 58 Figure 52 Result when adjusting the inlet flue gas temperature in ANSYS Fluent to 750°C .. 58 Figure 53 Result when adjusting the inlet flue gas temperature in ANSYS Fluent to 860°C .. 59 Figure 54 Result when adjusting the inlet flue gas temperature in ANSYS Fluent to 1100°C 59 Figure 55 Resulting values when adjusting the cooling water temperature in ANSYS Fluent to 5°C ...... 59 Figure 56 Resulting values when adjusting the cooling water temperature in ANSYS Fluent 60 Figure 57 MATLAB Temperature results ...... 61 Figure 58 ANSYS Fluent temperature results ...... 61 Figure 59 Resulting properties used for linear interpolation in ANSYS Fluent ...... 62 Figure 60 Properties calculated in MATLAB ...... 63 Figure 61 Water outlet velocity profile ...... 16 Figure 62 Flue gas outlet velocity profile ...... 16 Figure 63 y-plus value above 5 of the flue gas pipe ...... 17 Figure 64 y-plus value below 5 of the flue gas pipe ...... 18 Figure 65 Corresponding results to the increased y-plus value ...... 18 Figure 66 Temperature result with increased turbulent Prandtl number ...... 19 Figure 67 Temperature result with faulty heat conductivity ...... 19 Figure 72 Sketching and modeling tab ...... 20 Figure 73 Dimensions in the geometry step ...... 20 Figure 74 Selection of edges/surfaces/edges ...... 21 Figure 75 XY-plane ...... 21
Figure 76 Sketch creation ...... 22 Figure 77 Drawing a geometry ...... 22 Figure 78 Location of the "Generate" button ...... 23 Figure 79 Add frozen ...... 24 Figure 80 Boolean operation ...... 25 Figure 81 Creation of the water bend ...... 26 Figure 82 Wall sketch ...... 27 Figure 83 Water bend sketch ...... 28 Figure 84 Water flow sketch ...... 28 Figure 85 Water bend solid ...... 28 Figure 86 Fluid surface ...... 29 Figure 87 Solid surface ...... 29 Figure 88 Mesh method ...... 30 Figure 89 Edge sizing creation ...... 31 Figure 90 Bias factor and type toolbox ...... 32 Figure 91 Bias type ...... 32 Figure 92 Water boundary layers ...... 33 Figure 93 Water bend boundary layers ...... 33 Figure 94 Boundary layer for the pipes...... 34 Figure 95 Named selections ...... 35 Figure 96 Creating named selection ...... 36 Figure 97 Designating the named selections ...... 36 Figure 98 Edge named selection ...... 37 Figure 99 Surface selection (flow)...... 37 Figure 100 Surface selection (pipe) ...... 37 Figure 101 Solver setup launch window ...... 38 Figure 102 Inside the solver part of ANSYS project...... 39 Figure 103 Chosen turbulence model ...... 40 Figure 104 Materials ...... 41 Figure 105 Flue gas properties ...... 42 Figure 106 Edit of interpolation table ...... 42 Figure 107 Assigning all fluids and solids to their correct material...... 43 Figure 108 Boundary condition of the water inlet ...... 44 Figure 109 Inlet temperature specification for water ...... 45 Figure 110 Outlet condition ...... 45 Figure 111 Wall boundary condition...... 46 Figure 112 Outer pipe external settings...... 46 Figure 113 Symmetry axis settings ...... 47 Figure 114 Solution methods settings ...... 48 Figure 115 Solution initialization ...... 48 Figure 116 Run calculation ...... 49 Figure 117 List of result options ...... 49 Figure 118 How to plot a list of results ...... 50 Figure 119 Creating a graph in ANSYS Fluent ...... 51 Figure 120 Creating a line point ...... 52
Figure 121 Line point options ...... 52 Figure 122 Temperature results from having 2500 steps, with Δx = 0,001 ...... 53 Figure 123 Temperature results from having 25000 steps, with Δx = 0, 0001 ...... 53 Figure 124 Temperature result from having an inlet velocity of 1, 5 m/s ...... 54 Figure 125 Pressure from having an water inlet velocity of 1,5 m/s ...... 54 Figure 126 Temperature from having an inlet water velocity of 2m/s ...... 54 Figure 127 Pressure from having a water inlet velocity of 2m/s ...... 54
NOMENCLATURE
Designation Description Unit