Fludizied Reactor Bed Optimization 1

Fluidized Reactor Bed
Optimization by
Computational Fluid Dynamics
Curtin University & BHPB
Chemical Engineering Research Project
Project Manager & Author

Genghis Erkan
Principle Process Engineer
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Fluidized Reactor Optimization – Genghis Erkan
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Executive Summery
The aim of this Research Project is to simulate the fluidised bed interaction between iron ore
and Reducing Gases (H2 and CO) using Computational Fluid Dynamics.
The velocity of the fluidising Reducing Gas is accelerated by passing through over 500
nozzles. Avoid blockages of these nozzles and insufficient fluidisation during normal
operation necessary to optimize the nozzle size and their arrangement on the grid.
Optimization is possible through the simulation on the CFD programs Gambit and Fluent.
In Gambit the structure of the reactor is created, meshed and its Boundary conditions
specified. This structure is then exported to Fluent where fluid flow conditions are initialised
 Exp A: Two Dimensional-Simplified Reactor Simulation. This is the simplest experiment

as it is in 2D and has no nozzles or separate chambers.
 Exp B: Three Dimensional-Simplified Reactor Simulation. Follows on from Exp A and is
more complex in that the reactor is this time in 3D and has six nozzles that separate the
Above Grid Chamber and the Below Grid Chamber.
 Exp C: Three Dimensional-Replica Scale 1:1 Reactor Simulation. Advances the concepts
learnt from Exp B. Using detailed mechanical drawings to create a scale replica of HBI
plant Reactor 1.
Each experiment is the final product of several trials using Gambit and Fluent. It should be
noted that these experiments are only single phase. In a sense iron ore solids have yet to be
added to the simulation.
The Results of fluid simulation for A and Exp B were as expected and followed the Velocity,
Pressure and Turbulence basic principles of single phase flow. Exp C is a scale replica of
Reactor 1 and thus its complexity (incorporating 548 nozzles) has produced difficulties in
meshing in the Gambit.
This issue will be addressed in the next and final report, along with these future objectives
 Patching Iron oxide onto the fluidising grid (two phase)
 Optimization of nozzle sizes and grid arrangement.
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Table of Contents
Acknowledgements
Executive Summary
Table of Contents
1.0 Introduction
2.0 Process Description

2.1 Reactor Train
2.2 Reactor 1
2.2.1 Nozzle Fluidisation
2.2.2 Material Lines Input and Output
2.2.3 Cyclone Separation
3.0 Reactor 1 Process Overview
4.0 Research Project Objective

4.1 Main Objective
4.2 Report Objective
5.0 Literature Review

5.1 Computational Fluid Dynamics
5.2 Gambit: Geometry Modelling
5.3 Fluent: Fluid Simulation
6.0 CFD Trials and Experiments
7.0 Basic Principles in Fluid Mechanics
8.0 Experiment A: Two Dimensional-Simplified Reactor Simulation

8.1 Gambit Method
8.2 Fluent Simulation
8.2.1 Fluent Method
8.2.2 Contours of Velocity Magnitude (Results and Discussion)
8.2.3 Contour of Total Pressure (Results and Discussion)
8.2.4 Contours of Turbulence Intensity % (Results and Discussion)
8.2.5 Velocity Vectors (Results and Discussion)
9.0 Experiment B: Three Dimensional Simplified Reactor Simulation

9.1 Gambit Method
9.2.1 Fluent Method
9.2.2 Contour of Velocity Magnitude (Results and Discussion)
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10.0 Experiment C: Three Dimensional Scale 1:1 Reactor Simulation
10.1 Gambit Method
11.0 Conclusion
12.0 Problems and Recommendations
13.0 Objectives Yet to be Completed
Appendices
Appendix A: Exp A Gambit Procedure
Appendix B: Reactor 1 Mechanical Drawing
Appendix C: Grid Plate and Nozzel Mechanical Drawings
Appendix D: Exp C Radial Face
Appendix E: Exp A Gambit Journal File
Appendix F: Exp B Gambit Journal File
Appendix G: Exp C Gambit Journal File
List of Figures
Fig. 1: Boodarie at night
Fig. 2: Reactor Train
Fig. 3: Reactor 1 Process Overview (section 3.0)
Fig. 4: Meshed Two Dimensional Simplified Reactor
Fig. 5: Exp. A Fluent residuals converged
Fig. 6: Exp. A Contours of Velocity Magnitude
Fig. 7: Exp. A Contours of Total Pressure
Fig. 8: Exp. A Contours of Turbulence Intensity
Fig. 9: Exp. A Velocity Vectors
Fig. 10: Exp. B Radial face of Simplified Reactor
Fig. 11: Exp. B Simplified 3D reactor with six nozzles in the grid plate
Fig. 12: Exp. B Tetrahedral mesh of Unified volumes
Fig. 13: Exp. B Boundary Types
Fig. 14: Exp. B Fluent Residual Iteration
Fig. 15: Exp. B Contours of Velocity Magnitude
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Fig. 16: Exp. B Contours of Total Pressure
Fig. 17a: Exp. B Velocity Vectors (Scale2, Skip5)

Fig. 17b: Exp. B Velocity Vectors (Scale5, Skip50)
Fig. 18: Exp. C Reactor Replica: Radial faces.
Fig. 19: Exp. C 360 Rotation of Reactor Replica faces
Fig. 20: Exp. C Quarter Grid of 137 Nozzles
Fig. 21: Exp. C Full Grid of 548 Nozzles
Fig A2: Simplified R1 vertices
Fig A3: Node Distribution
Fig A4: Meshed 2D Simplified Reactor
Fig D1:Exp C Radial Face
List of Tables
Table 1 : Exp C Reactor 1 overview of Dimensions
Table A1: Exp A Grid Dimensions
Table A2: Exp A Coordinates of Vertices
Table A3: Exp A Node Distribution
Table A4: Exp A R1 Boundary types
Table D1: Exp C Vertex coordinates
N.B.
Each experiment is unique and thus has differing methodology and results. The method of
each experiment lies within the Gambit Construction Procedure and Fluent Initialization.
Whereas the results and discussion of each experiment is in the contour display of Velocity,
Pressure, Turbulence and Velocity Vectors.
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1.0 Introduction: HBI - Boodarie Iron
Boodarie Iron is located in Port Hedland WA and operated by BHP Billiton. Most plants in the
world use blast furnaces and coke to reduce iron ore, however there are two plants in the world
(Fior, Venezuela and Port Hedland, Australia) that utilizes the unique FINMET process (FINes
METalised). In Port Hedland, Boodarie Iron reduces iron ore fines by exposing it to hydrogen
and carbon monoxide gases at 835°C in a fluidised bed reactor. This changes the ore's chemical
composition by stripping away the oxygen molecules, chemically reducing it from hematite ore
(Fe2O3) with a 68% iron content to metallic iron granules (Fe) with over 90% iron content. [1]
Fig. 1: HBI Plant Port Hedland WA
2.0 Process Description

2.1 Reactor Train
The Reactors section of the Boodarie plant consist of four trains, each with four reactor vessels
(total of 16 reactor vessels). Each reactor is a vertical cylindrical vessel (20m high and 6m in
diameter). The four reactor vessels in all trains are in series.
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(BFB)
R4
Riser
R3
R2
R1
Furnace
Fig 2: Reactor Train
Reducing Gas enters through the bottom of Reactor 1, exits from the top of R1 into the bottom
of R2. (See Fig 1 above for illustration) The Reducing Gas stream eventually exits through
the top of R4. Iron ore is gravity fed into R4 and “flows” down into each reactor before exiting
R1 (92% Fe metal). [2]
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2.2 Reactor 1
2.2.1 Nozzle Fluidisation

DRI is feed into R1 via the Solid Inlet standpipe and is held in place by the Grid Plate.
Reducing gas enters the base of R1 and travels up through the nozzles of the porous Grid Plate
and fluidises the DRI. Fluidisation of the DRI is achieved because the Reducing Gas is at
temperature of 800C and pressure of 13bar. [2]
2.2.2 Material Lines Input and Output (see Section 3.0) [2], [3], [4] & [5]
 Solid Inlet: The solid inlet feed from R2 enters R1 already as 80% Direct Reduced
Iron (DRI). The DRI is gravity fed into the R1 via standpipes.
 Solid Outlet (the Riser). The DRI exits R1 as 92% metallised iron via Riser into the
Briquetter Feed Bin (BFB). The large P between R1 (13 bar) and the BFB (2.0 bar)
results in the solid DRI particles being conveyed to the BFB were it is undergoes
further value adding.
 Reducing Gas (RG) Inlet: Reducing gas from the furnace enters R1 via pipe 2007-
RP. The active gases are H2 and CO and reduces iron ore
Fe2O3 + 3H2  2Fe + 3H2O
Fe2O3 + 3CO  2Fe + 3H2O
 2008-RP Reducing Gas Outlet: The reducing gas exiting R1 is then piped into the RG
inlet of R2. There is drop in pressure and temperature.
2.2.3 Cyclone Separation

Reducing Gas emerging through the fluidised bed still contains particles of DRI (entrainment).
Four cyclones separate the entrained DRI from the Reducing Gas. DRI falls back down into the
bed via Cyclone Dipleg whilst the RG is flows out into the RG Outlet Line.
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3.0 Reactor 1 Process Overview
Reducing Gas Outlet
Press: 13.0 bar
Temp: 785C
Flow: 140660 Nm3/h
54% H2, 23%CH4, 8.0%CO
Grid Nozzles on
the Grid Plate
Solid Inlet
Metalisation: 80%
Feed Rate: 89tonnes/h
Solid Outlet
Metalisation: 92%
Feed Rate: 82 tonnes/h
Reducing Gas Inlet

Press: 13.6 bar
Temp: 835C
Flow: 138560 Nm3/h [2]
60% H2, 24%CH4, 6.5%CO
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4.0 Research Honours Project Objective
4.1 Main Objective [2]
Successful fluidisation in Reactor 1 is important in order to ensure the best possible contact
between solids and gas, as well as good transfer into and out of the reactor.
Critical fluidisation variables for optimization include

 Nozzle exit velocity
 Nozzle diameter
 Number of nozzles
 Nozzle configuration
 RG temp and pressure
For any given particle size distribution, there will be an optimum nozzle size and configuration
that will provide an ideal fluidisation state.
The fluidisation of Reactor 1 (the last reactor in series) is particularly important, since it
operates at the highest temperature and pressure, and this is traditionally where the majority of
transfer problems occur. Further optimisation may yet be possible however, to minimise the
process risk, tests first need to be done on an experimental basis.
Report Objective
The Main Objective of this Research Honours Project as the Title suggest is to optimise the
Fluidized bed Reactor at Boodarie Iron using CFD.
The nature of a fluidised bed not only depends on the nature of flow (velocity, temp) but also
the physical geometry of the reactor (nozzle diameter and configuration, and the number of
nozzles. The CFD pre-processor Gambit is to be used to conduct a series of trials and
experiments in modelling simplified and replica scale models of HBI Reactor1.
The Models are then exported to Fluent where Fluid flow is initialised. The success of these
models depend on wether they can simulate single phase fluid flow whilst obeying the Basic
Principals of Fluid Mechanics
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5.0 Literature Review [6]
As this is a progressive project, the concept and principals of Fluidisation are not used in this
report which only deals with single phase flow. However as this project develops in the future
and iron oxide is introduced in the Fluent simulation, a Literature Review on the Fluidised Bed
will be written. This is report focuses entirely on CFD…more precisely Gambit and Fluent.
5.1 Computational Fluid Dynamics

Computational fluid dynamics (CFD) is the use of computer models to calculate and predict
the properties of flowing materials—gas, liquid, solid or combinations. In fluidized bed
processes, solid particles are suspended by a gas, with the suspended mass taking on many
properties similar to liquids.
CFD software allows the chemical engineer to analyse fluid flow problems in detail, faster
than testing, at an earlier stage in the design cycle, for less money and with lower risk. CFD
predicts fluid flow, heat and mass transfer, chemical reaction and related phenomena.
By solving the fundamental equations governing fluid flow processes, CFD provides
information on important flow characteristics such as pressure loss, flow distribution and
mixing rates. CFD analysis complements traditional testing and experimentation. Fluent Inc.
has two CFD programmes titled Gambit and Fluent.
5.2 Gambit: Geometry Modelling

Gambit is the Pre-processor for Fluent. It models the geometry by the construction of vertices,
lines, faces and volumes. High quality Meshing are crucial to successful use of CFD
GAMBIT has a single interface for geometry creation and meshing that brings together all of
Fluent's pre-processing technologies in one environment. Once Meshed, Boundary Conditions
and Continuity Types are specified before the final model is saved and exported for Fluent
Simulation.
5.3 Fluent: Fluid Simulation

The structure modelled in Gambit has fluid flow characteristics initialised on Fluent. Some of
these characteristics include; number of phases, viscous model, material selection, fluid
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temperature, pressure, mass flow etc. Once initialised Fluent can visually predict fluid flow
(velocity, pressure, turbulence temperature etc) and thus optimise process operating conditions.
6.0 CFD Trails and Experiments

Trails in Gambit and Fluent were necessary because
a) The time consuming procedures of creating the structure in Gambit.
b) The equally time consuming initializing and iteration in Fluent.
The novice users of Gambit and Fluent (my self included) would find that both programmes
are highly prone to user input error. If the result of a trial was not as expected or if
Gambit/Fluent identified an error, then steps a) and or b) will have had to be revisited to correct
the error or be entirely redone. Thus there would be little chance of success if not a waste of
time in creating and simulating a scale 1:1
Three Dimensional Reactor, but to only find unexpected results or errors. Thus three
experiments were designed for simulation.
Exp A: Two Dimensional-Simplified Reactor Simulation

Exp B: Three Dimensional-Simplified Reactor Simulation
Exp C: Three Dimensional-Replica Scale 1:1 Reactor Simulation
Each experiment is unique and thus has differing methodology and results. The method of
each experiment lies within the Gambit Construction Procedure and Fluent Initialization.
Where as the results and discussion of each experiment is in the contour display of Velocity,
Pressure, Turbulence and Velocity Vectors.
7.0 Basic Principles in Fluid Mechanics

The resulting counter displays for each experiment are tested against the basic principals of
fluid mechanics:
 Fluid Velocity increases through a nozzle (or when the volume decreases). Continuity
equation (Area1 Vel2 = Area2 Vel2)
 Fluid Velocity approaches zero nearer the wall
 Fluid Pressure decrease when Fluid Velocity increases
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 Turbulence Intensity decrease radially away from walls or protrusions (less friction
between fluid and walls).
The success of any trial or experiment is determined by these basic principals
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8.0 Experiment A: Two Dimensional-Simplified Reactor Simulation
8.1 Gambit Method

Before the fluidised bed in R1 can be optimised, there were a series of CFD “trials” that
were conducted on a simplified two dimensional Reactor 1 geometry. The simplification of the
Reactor vessel has meant that the following internals are absent for this simulation
Solid Inlet and Outlet Standpipes
Discharge, Dump and Solid Sampling Lines (see Section 3.0)
Cyclone and Cyclone Diplegs
Plenum
Below grid Plate Plenum
The Two Dimensional-Simplified Reactor structure constructed on Gambit is essentially a

swaged vertical pipe consisting of
 Grid Plate Gas inlet at the bottom
 Gas outlet nozzle at the top
 Two swaged walls to the left and right
Creating Gambit geometry can be summed up by the following steps:

Create Vertices  Create Lines from Vertices  Create Face from joined Lines  Mesh
(decompose) Face  Specify Boundary Type (wall, inlet, outlet)  Export to Fluent
Appendix A has a more comprehensive description on the methodology of creating the Two
Dimensional-Simplified Reactor structure on Gambit.
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Fig 4: Meshed Two Dimensional Simplified Reactor
8.2.1 Fluent Method
Just like the simplified 2D structure created in Gambit, the process flow simulation conducted
on Fluent was also simplified. The process flow in the vessel only involves the Reducing Gases
(single phase). Thus the iron/iron oxide mixture was omitted for simplification but will be
added in the future as this Research Project progresses.
The file Gambit file final2.MSH is exported to Fluent (see Appendix E for Gambit Journal
File). The following steps illustrate the initialized parameters and conditions that were set
prior to iteration.
Initialization
 Multiphase  off (single phase)
 Viscous Model  k-epsilon
 Materials  CO, H2, CH4 , CO2 , N2, H2O , H2S
 Wall Boundary Conditions  default
 Fluid Boundary Conditions  H2
 Mass Flow Inlet  Grid inlet
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8.2.2 Contours of Velocity Magnitude (Results and Discussion)
DISPLAY  COUNTOURS  FILLED 

COUNTOURS OF : VELOCITY 
VELOCITY MAGITUDE  DISPLAY
Fig. 6: Exp.A Contours of Velocity Magnitude
Fig 6: Shows the velocity distribution of the Reactor. The lowest velocity occurs at the reactor
walls (dark blue) and at the Grid mass flow inlet (light green). There is also as expected a
decrease in velocity (turquoise) due to the swagged shape (increase in volume) of the top half
of the reactor. The highest velocity (red) occurs at the nozzle shaped RG outlet.
DISPLAY  COUNTOURS  FILLED

 COUNTOURS OF : PRESSURE 
TOTAL PRESSURE  DISPLAY
Fig. 7: Exp.A Contours of Total Pressure

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Fig 7: Shows the pressure distribution of the Reactor. The lowest total pressure (dark blue)
occurs at the walls of the RG outlet.. The highest pressure (red) occurs thorough out the
reactor.
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8.2.4 Contours of Turbulence Intensity % (Results and Discussion)
DISPLAY  COUNTOURS  FILLED

 COUNTOURS OF : TURBULANCE 
TURBULENCE INTENSITY DISPLAY
Fig. 8: Exp.A Contours of Turbulence Intensity
Fig 8: Shows the turbulence intensity distribution of the Reactor. The greatest turbulence
occurs at the Grid mass flow inlet (red & yellow). Turbulence decreases in a radial fashion
away from the wall, mass inlet and outlet (green to light blue to dark blue lowest velocity
occurs at the reactor walls (dark blue) and at the Grid mass flow inlet (light green)
DISPLAY  VECTORS 
COUNTOURS OF : VELOSITY 
VELOCITY MAGNITUDE
DISPLAY
Fig. 9: Exp.A Velocity Vectors

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Fig 9: Shows velocity path lines of gas flow in the Reactor. As expected the greatest velocity
(red arrows) occurs at the nozzle shaped.
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9.0 Experiment B: Three Dimensional Simplified Reactor Simulation
9.1 Gambit method

The Gambit program provides several options in creating a 3D structure. Since the Reactor 1 at
Boodarie is radially symmetrical, a face representing the radius of the reactor is all that’s
required to create a 3D image. A crude and simplified reactor face is shown in Fig 10 below.
The Blue section in the centre represents the Grid Plate, whilst the Red and Green sections are
the Above Grid Chamber and Below Grid Chamber respectively.
Fig 10 : Radial face of simplified Reactor.
The three coloured sections that make up the Radial face are Rotated 360 about their common
axis. A cylindrical is Created, Copied five times and Translated onto the grid plate as shown
below in Fig 11.
.
Fig 11: Simplified 3D reactor with six nozzles in the grid plate
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These six cylinders are crude representations of the grid nozzles illustrated in Fig 2. The Grid
Plate Volume was then subtracted. The remaining volumes (Above Grid Chamber, Below Grid
Chamber and the six nozzles were United to form a single volume. The unified volume was
Meshed using the Tetrahedral mesh option (Interval size = 0.2). Fig 12 below shows the
meshed product.
Fig 12: Tetrahedral mesh of Unified

volumes.
The Boundary Types for the open-ended nozzles were appropriately defined as Walls along the
above and Below Grid Chambers. The mass flow inlet (blue) and outlet (red) faces were also
defined accordingly as illustrated in Fig 13 below. Finally the Continuum Type was specified
for the Unified volume as Fluid. See Appendix F for Gambit Journal File
Fig. 13: Exp. B Boundary Types
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9.2.1 Fluent Method
The Fluent initialization parameters and conditions that were used for 2D Exp A was also used
for the 3D Exp B.
Initialization
 Multiphase  off (single phase)
 Viscous Model  k-epsilon
 Materials  CO, H2, CH4 , CO2 , N2, H2O , H2S
 Wall Boundary Conditions  default
 Fluid Boundary Conditions  H2
 Mass Flow Inlet  Grid inlet
 Mass Flow  500kg/s
 Total Temp  1108 K (835C)
 Gauge Pressure  500 kPa
Iterate
Number of Iterations set  100
Fig. 14: Exp. B Fluent Residual Iteration
The iterations did not converge after 100 iterations. Further iterations (1000) did not converge
the residuals to the default value (1x10-3). The residuals did however plateau out to
approximately 4x10-3. Similarly the continuity residual also plateaus at 2x10-2. Thus any
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further iteration would have been unnecessary. Contours of pressure and velocity were then
created.
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9.2.2 Contour of Velocity Magnitude m/s (Results and Discussion)
Fig. 15: Exp. B Contours of Velocity Magnitude
Fig 15 above shows the Contour of Velocity Magnitude for the Simplified 3D reactor. Note
that this Figure can only show the velocity of the Reactor walls. If this was however viewed in
Fluent, the difference in velocity away from the wall can be appreciated.
As expected the lowest velocity (dark blue) occurs at the chamber walls, this is due to the Fluid
Mechanics fundamentals (fluid velocity approaches zero along the wall).
Note the nozzle walls have a greater velocity (light green) than either chamber this is of course
due to the fact that the velocity is greatly increased in accordance with the smaller nozzle
volume.
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9.2.3 Contour of Total Pressure (Pa) (Results and Discussion)
Fig. 16: Exp. B Contours of Total Pressure
Fix 16 Above illustrates the Contours of Total Pressure. As expected the bottom chamber
where Gas enters will have the greatest pressure (orange). As the gas flows up through the
nozzles, there is a significant decrease in pressure (green) due to the increased velocity of gases
passing through the smaller volume nozzles.
The top chamber where upon the gas exits has the lowest pressure (blue), corresponding to the
high velocity produced at the nozzle and the increased volume in this chamber.
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Fig 17a: 3D Simplified 3D Reactor Fig 17b: 3D Simplified 3D Reactor

Velocity Vectors (Scale2, Skip5) Velocity Vectors (Scale5, Skip50)
This two figures illustrate the velocity magnitude of the gas and the direction it is travelling in
(hence the term vector). The differences between the two figures are the Scale of each vector and
the Skip or spacing between each vector.
Fig 17b clearly shows medium speed (green) gas vectors entering the lower chamber. Minor
turbulence (blue) is present in the lower chamber as gas vectors that do not enter the nozzles swirl
around this chamber.
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The velocity of swirling vectors is greater in the upper chamber where the high velocity gases
emanating from the nozzles increase the turbulence.
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Fig 17a: illustrates more clearly the effect that nozzles would have on a fluidised bed. The nozzles
increase the velocity of the gases entering the upper chamber much like a jet spray. This is where
and number of nozzles, their diameter and arrangement can be optimised and fluidised bed flow can
be simulated.
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10.0 Experiment C: Three Dimensional Scale 1:1 Reactor Simulation
10.1 Gambit Method

The previous Experiments A and B were preliminary experiments that build on the
understanding of creating the reactor on Gambit and simulating flow in Fluent. However to
fully appreciate the effect of real simulation, a Scale 1:1 replica of Reactor 1 from Boodarie
must be created in Gambit. An exact scale replica of R1 required detailed mechanical
dimensions that were used to construct the Gambit structure.
Mechanical Drawings of R1, Nozzles and Grid nozzle arrangements were used (see Appendix B
and C) to create the radial faces.
Table 1 below gives brief overviews of the dimensions of the R1 are
Table 1: Reactor 1 overview of Dimensions
Above Grid Chamber Height 18.89m Largest Diameter 6.90m

Grid Thickness 5cm Grid Plate Diameter 4.12m
Below Grid Chamber Height 3.11m Number of Nozzles 548 (: 3cm)
Overall Height 22.05m Grid Nozzle square pitch
Configuration (18 x 18 cm)
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Just like in Exp 2, the radial face is created from the vertices and lines. (See Appendix D for the
coordinates on each vertex created). Fig 18 illustrates radial face. And again the three radial
faces are the ; Grid plate (blue), Above Grid Chamber (green) and Below Grid Chamber (red).
Fig 18: Reactor Replica: Radial faces
The three radial faces are again rotated by 360 to form three corresponding volumes; Grid
Plate Volume (blue), Above Grid Volume (green) and Below Grid Volume (red). As illustrated
in Fig 19 below.
Fig 19: 360 Rotation of Reactor Replica

faces
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The next step in the replicating of R1 onto Gambit was to Create and Translate a nozzle
(orange, diameter3mm, height7mm) to the Grid Plate. This solitary nozzle was copied 136
times and Translated on the grid plate in a square pitch arrangement (x-coordinate: 18mm, and
z-coordinate: 18mm). These 137 nozzles occupied a quarter of the grid plate as shown in Fig 20
below.
Fig 20: Quarter Grid of 137 Nozzles
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The 137 nozzles were copied and reflected about the z axis. Thus creating another 137 nozzles
(137x2 = 274nozzels) and a half grid full of nozzles. Finally the half grid of 274 nozzles were
once again copied and reflected about the x-axis. Fig 21 below shows the full grid containing
274x2 = 548nozzels.
Fig 21: Full Grid of 548 Nozzles
As usual the next step required after creating all the volumes would be to mesh them.
Unfortunately problems were encountered when meshing such a large structure and complex
structure. Thus Experiment C is as yet uncompleted. (See Appendix G for Gambit Journal File)
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11.0 Conclusion
Each experiment had several trials. Over 20 trials were attempted on Gambit and about 10 on
Fluent. A majority of these trials ended in a user input error (Gambit) and unexpected fluid
flow patterns (eg: velocity vector flow through a predefined wall in Fluent). However each trial
(even failed trials) builds on the understanding and the extension for the next trial. Thus there
was an “evolution” of several trials that leads to the conception of the three final trials: Exp A,
B and C.
The progress of the project is documented in terms three experiments.

Exp A: Two Dimensional-Simplified Reactor Simulation
Exp B: Three Dimensional-Simplified Reactor Simulation
Exp C: Three Dimensional-Replica Scale 1:1 Reactor Simulation
Experiment B proved to be more challenging when creating the structure on Gambit. The now
3D structure also incorporated six nozzles that separated an Above Grid Chamber and Below
Grid Chamber. This structure now crudely resembles Boodarie’s Reactor 1. During Fluent
iteration, residuals did not converge at the default value of 1x10-3 but instead plateau at 4x10-3.
Nevertheless contours of Velocity and Pressure were displayed. Again as expected further
success resulted since both the Velocity and Pressure contours of this reactor obeyed the Basic
Principals of Fluid Mechanics.
The Results of fluid simulation for Exp A and Exp B were as expected and followed the
Velocity, Pressure and Turbulence basic principles of single phase flow. Exp C is a scale
replica of Reactor 1 and thus its complexity (incorporating 548 nozzles) has produced
difficulties in meshing in the Gambit.
As you are well aware this is the second report of an ongoing Research Honours Project. The
project title :Fluidised Bed Optimization of Boodarie Iron’s Reactor 1 by CFD is yet to be
undertaken. However the skills developed and knowledge gained from the three experiments
are essential in order to optimize the fluidised bed of R1 using CFD.
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12.0 Problems and Recommendations
The trails and experiments proved to be very time consuming. This was of course expected
when meshing complex 3D structures in Gambit and when waiting for Residuals to converge
during fluent iterations.
A recommendation to combat the time consuming nature of CFD simulation is to run several
trials/experiments on several computers. I personally had just recently been implementing this
recommendation on five computers when attempting to mesh the complex 3D Gambit structure
of Exp C. This was however all but to avail since I always encounter the same problem of
“computer hang”. However the concept of multi-computer simulation will continue.
Another problem that was encountered during the meshing of Exp. C was insufficient
computer memory. This not only occurred during meshing, but also when rotating or resizing
the view of a complex structure on Gambit.
13.0 Objectives Yet to be Completed

The ongoing nature of this Research Honours Project means the following objectives are yet to
be competed:
 Meshing of 3D Replica Scale Reactor (Exp C continued).
 Patching Iron oxide onto the fluidising grid (two phase)
 Optimization of nozzle sizes and grid arrangement.
 Addition of Cyclone separators, diplegs, and plenum (time permitting)
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Mass Flow  500kg/s
Total Temp  1108 K (835C)
Gauge Pressure  500 kPa
Iterate
Number of Iterations set  100
Fig. 5: Exp. A Fluent Residuals Converged
After 38 iterations, all of the Residuals converged to below 1x10-3. This is value is the default
value set by Fluent where upon the differences from all iterations are acceptable low values (i.e.:
1x10-3).
Appendix A: Exp.A Gambit Procedure
Reactor internals are absent in this simulation:

 Grid Plate
 Solid Inlet and Outlet Standpipes
 Discharge, Dump and Solid Sampling Lines see Figure 3
 Cyclone and Cyclone Diplegs
 Plenum
36
Vertices and Edges
TOOLS  COORDINATE SYSTEM  DISPLAY GRID

A square grid was created so as to assist in drawing the vertices of the 2-dimensional reactor.
The grid had the following ranges on its x and y-axis
37
Table A1: Grid Dimensions
Min Max Increment
x-axis -32 32 1
y-axis -32 32 1
Thus this Grid had dimensions of 64x64.

GEOMETRY  VERTEX  CREATE REAL VERTEX
As stated before the current Geometry created on Gambit is a simplification….and thus is only
the approximate shape of the reactor. Future alterations on the Geometry will be made so as to
take into account the specific measurements of the reactor. However the swaged vertical
cylinder was created with the following vertices.
Table A2: Coordinates of Vertices Fig A2: Simplified R1 vertices

x-axis y-axis
-4 26
4 26
4 23
11 21
-10 21
-4 23
Vertex
-13 15
13 15
-13 7
13 7
-11 -12
11 -12
-11 -31
11 -31
GEOMETRY  VERTEX  CREATE STRAIGHT EDGE

GEOMETRY  VERTEX  CREATE REAL ARC
The Create Straight Edge command allows you to create one or more straight edges between
any two or more existing vertices. The Create Real Circular Arc command allows you to
38
create a real edge in the shape of a circular arc. The vertices were then connected by creating
straight edges and arcs as illustrated in Fig A2 above.
39
Face and Meshing
GEOMETRY  FACE  CREATE FACE FROM WIREFRAME

This command allows you to create a face from three or more existing edges. A face was then
created from all 12 edges.
MESH  EDGES  MESH EDGES

The grid density on the edges of the geometry is defined by selecting each edge and assigning a
number of nodes (Interval Count). The way the nodes are distributed along the edge are also
specified (Double Sided, Ratio) in the Table 3 below.
RG
Table A3: Node Distribution Out
Edge Double Ratio Spacing 8 9

Sided (Interval Count)
12
RG Out Y 1.2 8 11
8, 9 N 1 4 2 5
11, 12 Y 0.8 10
6 7
2, 5 N 1 6
6, 7 N 1 12
3 4
3, 4 N 1 12
Grid
Grid Y 1.25 20
Fig A3: Node Distribution
41
MESH  FACE  MESH FACE
They are used primarily to control mesh density and, thereby, to control the amount of
information available from the computational model in specific regions of interest.
The nodes created in the previous step are used construct the mesh.
The following characteristics for the mesh was applied
ELEMENT  Quad (Specifies that the mesh includes only quadrilateral mesh elements)
TYPE  Pave (an unstructured grid of mesh elements)
The Quad-Pave meshing scheme, GAMBIT creates an unstructured face mesh consisting of
quadrilateral mesh elements
SPACING (INTERVAL COUNT)  10
42
Boundary Types
ZONES  SPECIFY BOUNDRY TYPES
Zone-type specifications define the physical and operational characteristics of the
model at its boundaries and within specific regions of its domain. There are two
classes of zone-type specifications:
 Boundary types
 Continuum types
This reactor model has only three Zones and thus only three boundary types:
Table A4: R1 Boundary types
Edge Name Boundary Type

Grid Mass Flow
RG out Out Flow
2,3,4,5,6,7,8,9,11 &12 Wall
Fig A4: R1 Meshed 2D Simplified Reactor
43
A R
D C
F Fig D1: Exp C Radial Face

Export the Mesh
G
H
44
Appendix D: Exp C Radial Face
Table D1: Exp C Vertex coordinates
Vertex x coordinate y coordinate

A 282 2238
B 282 2108
C 282 1831
D 3 1831
E 3 1566
F 105 901
G 105 366
H 105 361
I 105 183
J 140 183
K 140 90
L 211 55
M 282 40
N 282 0
O 350 0
P 350 361
Q 350 366
R 350 2238
45

Fludizied Reactor Bed Optimization 1

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Fluidized Reactor Bed

Project Manager & Author

 Exp A: Two Dimensional-Simplified Reactor Simulation. This is the simplest experiment

2.0 Process Description

3.0 Reactor 1 Process Overview

4.0 Research Project Objective

5.0 Literature Review

6.0 CFD Trials and Experiments

7.0 Basic Principles in Fluid Mechanics

8.0 Experiment A: Two Dimensional-Simplified Reactor Simulation

9.0 Experiment B: Three Dimensional Simplified Reactor Simulation

12.0 Problems and Recommendations

13.0 Objectives Yet to be Completed

Fig. 12: Exp. B Tetrahedral mesh of Unified volumes

Fig. 13: Exp. B Boundary Types

Fig. 14: Exp. B Fluent Residual Iteration

Fig. 15: Exp. B Contours of Velocity Magnitude

Fig. 17a: Exp. B Velocity Vectors (Scale2, Skip5)

Fig. 1: HBI Plant Port Hedland WA

2.0 Process Description

Fig 2: Reactor Train

2.2.1 Nozzle Fluidisation

2.2.3 Cyclone Separation

Reducing Gas Inlet

Critical fluidisation variables for optimization include

5.1 Computational Fluid Dynamics

5.2 Gambit: Geometry Modelling

5.3 Fluent: Fluid Simulation

6.0 CFD Trails and Experiments

Exp A: Two Dimensional-Simplified Reactor Simulation

7.0 Basic Principles in Fluid Mechanics

8.1 Gambit Method

The Two Dimensional-Simplified Reactor structure constructed on Gambit is essentially a

Creating Gambit geometry can be summed up by the following steps:

8.2 Fluent Simulation

8.2.1 Fluent Method

DISPLAY  COUNTOURS  FILLED 

Fig. 6: Exp.A Contours of Velocity Magnitude

8.2.3 Contour of Total Pressure (Results and Discussion)

DISPLAY  COUNTOURS  FILLED

Fig. 7: Exp.A Contours of Total Pressure

DISPLAY  COUNTOURS  FILLED

Fig. 8: Exp.A Contours of Turbulence Intensity

Fig. 9: Exp.A Velocity Vectors

9.1 Gambit method

Fig 10 : Radial face of simplified Reactor.

Fig 12: Tetrahedral mesh of Unified

Fig. 13: Exp. B Boundary Types

Fig. 14: Exp. B Fluent Residual Iteration

Fig. 15: Exp. B Contours of Velocity Magnitude

Fig. 16: Exp. B Contours of Total Pressure

Fig 17a: 3D Simplified 3D Reactor Fig 17b: 3D Simplified 3D Reactor

10.1 Gambit Method

Table 1 below gives brief overviews of the dimensions of the R1 are

Table 1: Reactor 1 overview of Dimensions

Above Grid Chamber Height 18.89m Largest Diameter 6.90m

Fig 18: Reactor Replica: Radial faces

Fig 19: 360 Rotation of Reactor Replica

Fig 20: Quarter Grid of 137 Nozzles

Fig 21: Full Grid of 548 Nozzles

The progress of the project is documented in terms three experiments.

13.0 Objectives Yet to be Completed

Fig. 5: Exp. A Fluent Residuals Converged

Appendix A: Exp.A Gambit Procedure