<p dir="ltr">Biorefineries rely on compression feed screws to transport biomass for biofuel production in chemical reactors. However, flowability issues within these feedscrews often lead to production downtime, impacting profitability. Modeling biomass flow within the feedscrews is crucial to optimize processing parameters like torque and speed, reducing downtime. Biomass is a non-uniform granular material which faces flowability issues. The problems in flowability is influenced by factors such as particle size, moisture content, material composition, and processing methods. Identifying key parameters that can influence the material behavior is vital to minimize production downtimes. Feedscrews operate under high pressures which makes obtaining accurate material parameters at these high pressures challenging. Many methods used within the pharmaceutical industry to obtain material parameters are unable to reach the larger pressures that the material experiences within the feedscrew. However, Triaxial testing can be used to test the material at the high pressure of interest. Triaxial testing has been used within the civil engineering field to test granular materials such as soils, sand, and rocks. The Finite Element Method (FEM) using a continuum model is used for modeling systems with a large number of particles. The modified Drucker-Prager Cap (mDPC) continuum model is often used to capture complex material behavior, including densification and shear yielding in granular materials. This model seems well suited to capture the behaviors of biomass material. The focus of the thesis is to obtain the shear failure properties of corn stover using triaxial testing and the Drucker-Prager Cap continuum model. Simulations and experimental data are utilized to establish a criterion for identifying shear failure. While simulations depict ideal behavior of a DPC material with frictionless and frictional platens, experimental data shows trends of real-life corn stover. Simulation results effectively predict the material’s friction angle but show larger errors in estimating cohesion, potentially due to extrapolation or cohesion’s sensitivity to volumetric plastic strain. Further simulations at smaller hydrostatic unloading pressures are recommended to reduce this error. Experimental trends for shear failure seem to align with simulation trends for shear failure identification. However, the densification trends in experiments lack the clarity observed in the trends from the simulations. More triaxial experiments should be run to determine if the trends are consistent at other hydrostatic loading and unloading pressures. More than two experiments at the same hydrostatic loading pressure should also be run to estimate the shear failure line to obtain a better estimation. Experimentally there are a number of other factors that could contribute to errors such as the estimated material diameter used to calculate Mises stress, if corrections were made for items such as the moving piston, latex membrane, and more, and how far the shear failure line is extrapolated to the vertical axis.</p>

<p>Controllable continuous feeding of biomass feedstock in a biorefinery is critical to upscaling current ethanol conversion techniques to a commercial scale. Mechanical pretreatment of biomass feedstock performed using a compression feed screw (CFS) improves the ethanol yield but is subject to flowability issues, especially the plugging of biomass. The mechanical behavior, and hence, the flowability of biomass feedstock, is strongly affected by several factors, including preparation method, moisture content, physical composition, and particle size distribution. In addition, the current design of CFS is guided by limited experimentation and even fewer theoretical correlations. This thesis aims at developing computational methods to model the flow of densified feedstock in a CFS and experimental techniques to characterize the mechanical properties required for the model. We adopted a modified Drucker-Prager Cap constitutive (mDPC) law for milled corn stover (a widely used feedstock for bioethanol production) to model the material’s rate-independent bulk behavior in a CFS. The mDPC elastoplastic law captures the frictional shear and permanent volumetric changes in corn stover using a continuous porosity-dependent yield surface. The parameters of the mDPC model are calibrated using a unified set of single-ended die compaction and multiple shear failure tests. In addition, we quantified the changes in the mDPC parameters with moisture content up to the water-holding capacity of corn stover particles. A Coupled Eulerian-Lagrangian Finite Element Method model developed for the CFS geometry predicts the deformation of the material using the calibrated mDPC parameters. We model the interaction between the material and the CFS surface using a Coulomb wall friction coefficient calibrated using the Janssen-Walker method for a punch and die system. A laboratory-scale compression feed screw is designed and fabricated to characterize the flow of dense granular materials in collaboration with undergraduate students in the School of Mechanical Engineering. FEM model predictions of feeding torque and mass flow rate are validated against the laboratory-scale feeder for microcrystalline cellulose Avicel PH-200 and milled corn stover. The model predictions agree with the experiments for Avicel PH-200 but have a higher error in the case of corn stover. Some physical effects, such as shear hardening and particle erosion observed in milled corn stover, are not captured using the current implementation of the mDPC model, which explains the different model accuracies for both materials. The continuum model is used to uncover material density distribution, torque, and pressure inside the CFS, otherwise challenging through experiments. The FEM model showed a significantly higher sensitivity of the feeder performance to two material properties, namely the hydrostatic yield stress and the wall friction coefficient. The characterized variation of material properties with moisture content and the effect of each material property on the feeder performance provide strategies to engineer the feedstock for better flowability. Further, the continuum model offers a method to study design changes before manufacturing the equipment. Finally, we propose the possibility of a reduced-order analytical model based on the critical material properties and the material deformation mechanism demonstrated by the FEM model.</p>

<p dir="ltr">The ability to predict and manipulate how a particulate material will flow in a process is challenging for industry and researchers alike. This dissertation presents the results of a model-directed, experimental approach using a concentric cylinder rheometer titled along an axis to enable continuous chute flow of granular media. Experiments were performed using draining flows for constant and oscillatory applied shear rates. Multiple flow and stress sensors were used to investigate the interaction of mass holdup, shear rate, specific torque, particle velocity, discharge mass flow rate, and wall pressure. Depending on the flow configuration, linear ranges were observed wherein the specific torque remained steady during draining. This finding enabled systematic testing of flow behavior as a function of dimensionless shear rates. Results suggest changes in the specific torque, wall slip, and outflow variance occur with the transition from the quasi-static to dense-inertial flow regimes. A pump-curve analogy was also identified for the relationship between the outlet mass flow rate and the specific power relationship for the constant shear rate experiments. Oscillatory shear rate experiments show a significant influence of the phase shift between the applied shear rate and the specific torque. Adding an asperity to the rotor revealed rate-dependent patterns in bulk flow and force chain dynamics. Overall, the study offers valuable insights into the effects of shear rate and boundary conditions on dense granular flows. The effects of particle characteristics (e.g., size and shape distributions, friction, cohesivity) and material properties (e.g., density, modulus) remain topics for future work. </p>

Cette thèse porte sur l'étude numérique des écoulements fluide-particules rencontrés dans l'industrie. Ces travaux se situent dans le cadre de la compréhension des phénomènes qui se déroulent dans des tambours tournants et réacteurs à lit fixe en présence de particules de forme non convexe. En effet, la forme des particules influence de manière importante la dynamique de ces milieux. A cet effet, nous nous sommes servis de la plateforme numérique parallèle Grans3D pour la dynamique des milieux granulaires et PeliGRIFF pour les écoulements multiphasiques. Dans la première partie de cette thèse, nous avons développé une nouvelle stratégie numérique qui permet de prendre en compte des particules de forme arbitrairement non convexe dans le solveur Grains3D. Elle consiste à décomposer une forme non convexe en plusieurs formes convexes quelconques. Nous avons nommé cette méthode « glued-convex ». Le modèle a été validé avec succès sur des résultats théoriques et expérimentaux de tambours tournants en présence de particules en forme de croix. Nous avons aussi utilisé le modèle pour simuler le chargement de réacteurs à lits fixes puis des lois de corrélation sur les taux de vide ont été déduites de nos résultats numériques. Dans ces travaux, nous avons aussi testé les performances parallèles de nos outils sur des simulations numériques à grande échelle de divers systèmes de particules convexes. La deuxième partie de cette thèse a été consacrée à l'extension du solveur PeliGRIFF à pouvoir prendre en compte la présence de particules multilobées (non convexes) dans des écoulements monophasiques. Une approche du type Simulation Numérique Directe, basée sur les Multiplicateurs de Lagrange Distribués / Domaine Fictif (DLM/FD), a alors été adoptée pour résoudre l'écoulement autour des particules. Une série d'études de convergence spatiale a été faite basée sur diverses configurations et divers régimes. Enfin, ces outils ont été utilisés pour simuler des écoulements au travers de lits fixes de particules de forme multi-lobée dans le but d'étudier l'influence de la forme des particules sur l'hydrodynamique dans ces lits. Les résultats ont montré une consistance avec les résultats expérimentaux disponibles dans la littérature. / Non convex granular media are involved in many industrial processes as, e.g., particle calcination/drying in rotating drums or solid catalyst particles in chemical reactors. In the case of optimizing the shape of catalysts, the experimental discrimination of new shapes based on packing density and pressure drop proved to be difficult due to the limited control of size distribution and loading procedure. There is therefore a strong interest in developing numerical tools to predict the dynamics of granular media made of particles of arbitrary shape and to simulate the flow of a fluid (either liquid or gas) around these particles. Non-convex particles are even more challenging than convex particles due to the potential multiplicity of contact points between two solid bodies. In this work, we implement new numerical strategies in our home made high-fidelity parallel numerical tools: Grains3D for granular dynamics of solid particles and PeliGRIFF for reactive fluid/solid flows. The first part of this work consists in extending the modelling capabilities of Grains3D from convex to non-convex particles based on the decomposition of a non-convex shape into a set of convex particles. We validate our numerical model with existing analytical solutions and experimental data on a rotating drum filled with 2D cross particle shapes. We also use Grains3D to study the loading of semi-periodic small size reactors with trilobic and quadralobic particles. The second part of this work consists in extending the modelling capabilities of PeliGRIFF to handle poly-lobed (and hence non-convex) particles. Our Particle Resolved Simulation (PRS) method is based on a Distributed Lagrange Multiplier / Fictitious Domain (DLM/FD) formulation combined with a Finite Volume / Staggered Grid (FV/SG) discretization scheme. Due to the lack of analytical solutions and experimental data, we assess the accuracy of our PRS method by examining the space convergence of the computed solution in assorted flow configurations such as the flow through a periodic array of poly-lobed particles and the flow in a small size packed bed reactor. Our simulation results are overall consistent with previous experimental work.

<p>  </p> <p>Direct reduction ironmaking has gained popularity as a low carbon alternative to the typical blast furnace ironmaking route. A popular method of producing direct reduced iron is through the reduction of iron ore pellets in a reduction shaft furnace. Critical to this process is the use of a reliable continuous pellet feed system to provide a steady flow of pellets to the furnace. Therefore, any disruption in pellet flow can have a significant negative impact on the production rate of iron. </p> <p><br></p> <p>An iron ore pellet feed system for a direct reduction ironmaking furnace is jamming during winter operation. The pellets are jamming in a hopper at the top of the feed system above the furnace, and a hot gas, that seals off the furnace flue gas, flows counter to the pellets. A computational model of the feed system is built utilizing the discrete element method and computational fluid dynamics, using Siemen’s commercial multiphysics software Star-CCM+, to study the conditions that cause the jam to occur. The study is divided into six parts: pellet bulk flow calibration, computational cost reduction, modeling of the baseline operation, modeling the effect of moisture, development of a thermal model, and investigation of the minimal amount of icy and wet material to jam the system. The findings show that the location of jamming during operation matches the area in the simulation where it is most likely to occur, and that moisture alone is unlikely to result in jamming. Results indicate that the system will jam when charged with a minimum of 15% icy pellets, and when charged with 10% icy together with 5% wet pellets. Experimental work is recommended to validate the findings and to calibrate the simulations accordingly.</p>