Table Of ContentStefan Heinrich Editor
Dynamic
Flowsheet
Simulation
of Solids
Processes
Dynamic Flowsheet Simulation of Solids Processes
Stefan Heinrich
Editor
Dynamic Flowsheet
Simulation of Solids
Processes
123
Editor
StefanHeinrich
Institute of Solids ProcessEngineering
andParticle Technology
Hamburg University of Technology
Hamburg,Germany
ISBN978-3-030-45167-7 ISBN978-3-030-45168-4 (eBook)
https://doi.org/10.1007/978-3-030-45168-4
©SpringerNatureSwitzerlandAG2020
Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart
of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission
orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar
methodologynowknownorhereafterdeveloped.
The use of general descriptive names, registered names, trademarks, service marks, etc. in this
publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom
therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse.
The publisher, the authors and the editors are safe to assume that the advice and information in this
book are believed to be true and accurate at the date of publication. Neither the publisher nor the
authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor
for any errors or omissions that may have been made. The publisher remains neutral with regard to
jurisdictionalclaimsinpublishedmapsandinstitutionalaffiliations.
ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG
Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland
Preface
Processes of material and energy conversion often consist of multiple individual
sub-processesthat are interconnected by material, energy and information streams.
The cross-links between the individual sub-processes have a significant impact on
the dynamic behaviour and the stability of such processes. For the design and
optimization, particularly in view of the conservation of energy and raw material
resources, not only the individual components should be simulated, but also the
dynamic behaviour of the whole process. This is the state of the art for fluid
processes and different tools for dynamic flowsheet simulation are commercially
available. In contrast, such program systems and process models which are gen-
erally applicable to a wide range of applications are missing for solids processes.
This is due to the complex description of solids with their multivariate disperse
properties and the associated processes for the conversion of solids.
The flowsheet modelling allows for an investigation of complex processes
consisting of several interconnected apparatuses and sub-processes on longtime
scales.Forthesolidsprocessengineering,themultidimensionalityoftheproperties
of granular materials significantly complicates the solution of various problems,
such as design or optimization of production processes. As most solids processing
systemsincludeunitoperationsthathaveastrongimpactonthetransientbehaviour
of the whole process, like conveyors or bunkers, the ability to simulate the beha-
viourofdynamicsystemsiscrucialforapplyingflowsheetmodelsforoptimization
or control purposes in the area of solids processing technology.
Available flowsheet simulation programs deal with the challenge of solids
processsimulation.However,noneofthetoolsoffertheoptionofdynamicprocess
simulationofsolidsprocesseswiththeinherentdescriptionofthemultidimensional
distributed parameters of the granular material.
The German Research Foundation (Deutsche Forschungsgemeinschaft, DFG)
hassupportedaresearchprogramintheformofthePriorityProgram(SPP1679)on
“Dynamicsimulationofinterconnectedsolidsprocesses(DYNSIM-FP)”from2013
to 2020. The goal was to study the dynamics of different processes in the area of
solidsprocessengineeringandtogainabetterunderstandingofthephenomenathat
arise when combining various of such sub-processes into a single interconnected
v
vi Preface
system. The central aim was to provide numerical tools for dynamic simulation of
interconnectedsolidsprocesses.Forthis,dynamicmodelsofvariousequipmentand
machinery for solids processing are to be formulated and implemented.
Furthermore,methodsforthenumericaltreatmentofsuchsystemsandnewmodels
for the description of solids properties shall be developed.
TheresearchwithinSPP1679wasclassifiedintothreeresearchareasconsisting
of 27 research projects from universities and research institutes from Germany:
(a), (b) models for the description of solids properties, (c) algorithms and process
simulation.Additionally, a separateCentral Project (Z-project) was established. Its
goal was to develop a flowsheet modelling system, which should serve as a plat-
form for combining the results of all these individual groups into a single frame-
work. To allow for mostly independent model development and research, the
flowsheet simulation framework must provide high flexibility, extensible libraries
and stable interfaces. The resulting open-source modular modelling system
Dyssol—an acronym for “Dynamic simulation of solids processes”—offers these
features through its high degree of modularity, open and standardized interfaces,
efficient algorithms and a clear user interface.
This book summarizes the research results of this joint research project. The
research program SPP 1679 DYNSIM-FP has been steered by a committee, where
Prof. Stefan Heinrich, Hamburg, took over the coordination (spokesperson) and
was supported by Prof. Arno Kwade, Braunschweig (vice-spokesperson); Prof.
Heiko Briesen (vice-spokesperson), München; Prof. Wolfgang Peukert, Erlangen;
Prof. Matthias Kind, Karlsruhe; and Prof. Achim Kienle, Magdeburg. We want to
thank andgreatly appreciate theDFG forfinancialsupport,andespeciallyDr.-Ing.
BerndGiernoth,Dr.-Ing.GeorgBechtold,Dr.SimonJörresandMs.AnjaKleefuß
fortheirexcellentcoordinationandcontinued supportoftheresearch activities. Of
course,thegreatsuccessoftheSPP1679wouldnothavebeenpossiblewithoutthe
enthusiasm of all involved Ph.D. students and researchers and their excellent
contributions.Numerousworkshops,mostheldinHamburg,weretheclampofthe
intensive cooperation within the several projects.
Hamburg, Germany Stefan Heinrich
February 2020
Contents
Part I New Dynamic Process Models
1 Process Modeling for Dynamic Disperse Particle Separation
and Deposition Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sören Sander, Lizoel Buss, and Udo Fritsching
2 Dynamic Modelling of Reactive Fluidized Bed Systems
Using the Example of the Chemical Looping Combustion
Process for Solid Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lennard Lindmüller, Johannes Haus, Ernst-Ulrich Hartge,
and Stefan Heinrich
3 Dynamics of Spray Granulation in Continuously Operated
Horizontal Fluidized Beds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
C. Neugebauer, E. Diez, L. Mielke, S. Palis, A. Bück, E. Tsotsas,
A. Kienle, and S. Heinrich
4 Dynamic Simulation of Technical Precipitation Processes. . . . . . . . 109
Hendrik Rehage and Matthias Kind
5 Development of a Dynamic-Physical Process Model for Sieving . . . 141
Darius Markauskas and Harald Kruggel-Emden
6 Dynamic Process Models for Fine Grinding and Dispersing. . . . . . 199
Greta Fragnière, Ann-Christin Böttcher, Christoph Thon,
Carsten Schilde, and Arno Kwade
7 Dynamic Simulation of Mechanical Fluid Separation
in Solid Bowl Centrifuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Marco Gleiss and Hermann Nirschl
8 Flowsheet Simulation of Integrated Precipitation Processes . . . . . . 269
Mark Michaud, Michael Haderlein, Doris Segets,
and Wolfgang Peukert
vii
viii Contents
9 Impact Comminution in Jet Mills. . . . . . . . . . . . . . . . . . . . . . . . . . 305
Alexander Strobel, Benedikt Köninger, Stefan Romeis,
Karl-Ernst Wirth, and Wolfgang Peukert
10 Dynamics of Separation Characteristics of Sieving and Flow
Classification Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
MartinWeers,AnnettWollmann,UlrichTeipel,andAlfredP.Weber
11 Experimental Study and Modelling of Particle Behaviour
in a Multi-stage Zigzag Air Classifier . . . . . . . . . . . . . . . . . . . . . . . 391
Eduard Lukas, Christoph Roloff, Hannes Mann, Kristin Kerst,
Thomas Hagemeier, Berend van Wachem, Dominique Thévenin,
and Jürgen Tomas
Part II Material Parameters in Solids Process Engineering
12 Property Function to Compute the Dustiness of Powders. . . . . . . . 413
Kai Vaupel, Tim Londershausen, and Eberhard Schmidt
Part III Algorithms and Process Simulation
13 Morphological Modelling and Simulation of Crystallization
Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Simon Schiele, Tijana Kovačević, and Heiko Briesen
14 Numerical Methods for Coupled Population Balance
Systems Applied to the Dynamical Simulation
of Crystallization Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Robin Ahrens, Zahra Lakdawala, Andreas Voigt,
Viktoria Wiedmeyer, Volker John, Sabine Le Borne,
and Kai Sundmacher
15 Compartmental Population Balances by Means
of Monte Carlo Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Gregor Kotalczyk and Frank Einar Kruis
16 Modeling, Simulation and Optimization of Process Chains. . . . . . . 549
Michele Spinola, Alexander Keimer, Doris Segets, Lukas Pflug,
and Günter Leugering
Part IV Development of a Dynamic Simulation System
for Interconnected Solids Processes
17 A Framework for Dynamic Simulation of Interconnected
Solids Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
Vasyl Skorych, Moritz Buchholz, Maksym Dosta,
and Stefan Heinrich
Part I
New Dynamic Process Models
Chapter 1
Process Modeling for Dynamic Disperse
Particle Separation and Deposition
Processes
SörenSander,LizoelBuss,andUdoFritsching
1 Introduction
Dynamic particulate process models are to be derived within the framework of
dynamicflowsheetmodelingandsimulation(FSS).InthecontributionFSSisdevel-
opedfortheseparationprocessesofsolidparticlesfromafluidresp.gas.Potential
applications of the dynamic simulation environment of particle separation are for
instanceintheanalysisanddesignofthedynamicprocessbehaviorinthepurifica-
tionofexhaustgases(forexampletoreduceemissionsfromcombustionprocesses)
butalsointheproductionofparticlelayerswithdefinedproperties,asoccurinthe
powdercoatingofsurfaces.
A specific focus of the derivation is on analysis of gas cleaning of a particle-
laden air stream through a plate-wire electrostatic precipitator. In this process, the
intensificationofthedegreeofseparationisachievedbytheapplicationofelectric
field forces. The result is a coupled multiphase flow system in which interactions
betweentheelectricfield,thefluidphaseandtheparticlesonseveralscalesleadto
acomplexrelationshipbetweenthedegreeofprecipitationandtheconditionsinthe
process.
Thepropertiesoftheparticulatematerial,thefeedstreamparametersaswellas
the specific process control directly influence the output stream conditions as for
instancetheparticlesizedistributionanddustconcentration,thustheprecipitation
efficiencyoftheprocess.Thespecificspatialdistributionoftheparticlesandtheir
charges may cause temporal changes in the deposition behavior in the apparatus.
Thelocallyvaryingthicknessofthedepositedparticlelayerincreasinglyinfluences
the re-dispersion and re-entrainment of already deposited particles back into the
flowfield.Thissuccessivegrowingparticlelayerstructureplaysasignificantrole,
especiallyduringthetransientstartupphaseoftheprocess.Forheavyloadchanges,
B
S.Sander·L.Buss·U.Fritsching( )
Leibniz-InstituteforMaterialsEngineeringIWT,ParticlesandProcessEngineering,
UniversityofBremen,BadgasteinerStrasse3,28359Bremen,Germany
e-mail:ufri@iwt.uni-bremen.de
©SpringerNatureSwitzerlandAG2020 3
S.Heinrich(ed.),DynamicFlowsheetSimulationofSolidsProcesses,
https://doi.org/10.1007/978-3-030-45168-4_1
