A Comprehensive CFD Assessment of Wheat Flow in Wheat Conveying Cyclone Validation and Performance Analysis by Experimental Data

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In this study, the effect of the cyclone body height on the flow field within the specific cyclone and also on the performance parameters of the cyclone has been investigated. The five heights of the cyclone as various configurations were I = 600, II = 675, III = 750, IV = 825, and V = 900 mm. A pressure‐based solver was used and the turbulent Reynolds stress model was utilized to simulate the flow. Then, the Lagrangian discrete phase model was used to simulate the solid phase. As the height of the cyclone increases, the pressure drop decreases. Also, the best separation efficiency and the highest particle velocity value were achieved at a height of 750 mm. The maximum values of turbulence intensity, skin friction coefficient, and strain rate were obtained as negative components of cyclone performance at the cyclone body height of 900 mm. The height of 750 mm was recognized as the best height of the cyclone's body.Practical ApplicationsApplying numerical simulation in food processing is a novel method to minimize equipment construction and reach a high‐accuracy design. Computational fluid dynamics can provide an accurate and detailed flow analysis in the cyclone separators utilized in the flour processing plant. The dimensional analysis can help the researchers to achieve the optimum design and enhance the cyclone performance by reducing pressure drop and increasing separation efficiency. Also, the maintenance cost would be significantly reduced due to detecting the critical sections and strengthening them.

Section: Introductionmentioning

confidence: 99%

A numerical assessment to select the optimal geometry of a specific cyclone separator of wheat flour processing

Emami,

Rostampour,

Rezvanivand Fanaei

et al. 2024

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“…They calculated the highest exergy destruction and the lowest exergy efficiency for the first evaporator (Bapat et al, 2016). Recently, some innovative studies were conducted related to the various processes in the field of foods and industrial applications, so these fields still need more detailed investigations using new methods (Abdi et al, 2023;Aghaei et al, 2022;Aghdamifar et al, 2023;Akhoundzadeh Yamchi et al, 2024;Dizajyekan et al, 2021Dizajyekan et al, , 2022Emami et al, 2024;Mohammadzadeh et al, 2021Mohammadzadeh et al, , 2022Rezvanivand Fanaei et al, 2021;Rezvanivand Fanayi & Nikbakht, 2015;Zobeiri et al, 2021).…”

Section: Introductionmentioning

confidence: 99%

A comparative evaluation of energetic and exergetic performance parameters in syrup purification and evaporation lines

Piri,

Fanaei,

Rostampour

2024

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Considering the global challenges of environmental destruction, limited fossil reserves, and the reduction of the share of energy in the final price of the product, a detailed evaluation of energy‐intensive systems is needed to improve performance. The syrup heating process is one of the basic processes in sugar factories. In this study, the syrup heating system in the purification and evaporation lines, located in the Urmia sugar plant, was evaluated, analyzed, and compared with energy and exergy analysis. Also, the subsystems of the syrup heating process were evaluated with thermodynamic analysis. Mass, energy, and exergy balances were carried out by coding in EES software, and energetic and exergetic operational parameters were extracted. The heat loss rate and exergy destruction rate in the syrup heating system of the purification line were calculated as 121.29 and 404.36 kW, respectively, and in the syrup heating system of the evaporation line as 112.70 and 238.62 kW, respectively. The recovery potential rate was 134.99 kW for the purification line and 37.70 kW for the evaporation line. The stability index and exergy efficiency for the purification line were calculated as 3.03% and 67.01% for the purification line and 6.54% and 84.71% for the evaporation line. The results of the thermodynamic analysis showed that the syrup heating process in the purification line has weaker performance from the energetic and exergetic point of view, is accompanied by large losses, and imposes a greater environmental burden. Accordingly, it is suggested that the improvement of the syrup heating performance in the purification line should be prioritized for engineering optimization and redesign in sugar processing plants.Practical applicationsMonitoring the operational state of the systems and determining system losses are critical steps in food thermal processing. A practical and accurate method to evaluate the purification and evaporation lines is required to improve the thermal efficiency. According to exergy analyses, the performance of the syrup heating process in the purification line is low due to large losses and imposes a greater environmental burden. Therefore, the improvement of the syrup heating performance in the purification line should be prioritized for engineering optimization and redesign in sugar processing plants.

“…Many researchers are interested in enhancing the cyclone's separation performance. The researchers attempt to increase its performance by using various methods, including innovation in construction and using new techniques (Dizajyekan, Shahgholi, Fanaei, Rostampour, Sharabiani, Szymanek, & Kulig, 2022; Dizajyekan, Shahgholi, Fanaei, Rostampour, Sharabiani, Szymanek, & Marczuk, 2022).…”

Section: Introductionmentioning

confidence: 99%

A novel idea to increase the performance of a wheat flour cyclone separator: Controlling the reverse flow

Aghaei

Rostampour

Fanaei

et al. 2022

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In this study, as a novelty, the reverse flow effect on a wheat flour cyclone performance was evaluated. A computational fluid dynamics (CFD) simulation was realized using a Reynolds stress turbulence model. Also, particle-air interactions were modeled applying a discrete phase model. Besides the experimental measurement, the numerical simulation was conducted in a main (without reverse flow) and six various reverse flow levels (I = 0.0385 m 3 s À1 , II = 0.0396 m 3 s À1 , III = 0.0484 m 3 s À1 , IV = 0.0583 m 3 s À1 , V = 0.0704 m 3 s À1 , and VI = 0.0836 m 3 s À1 ) by CFD. The validation between pressure drop in experimental data and numerical results revealed a good agreement with a maximum deviation of 8.2%. Cyclone performance including pressure drop and separation efficiency was assessed in the mentioned reverse flow levels. Moreover, velocity field, centrifugal force, and turbulence parameter were evaluated, comprehensively. It was found that the flour separation efficiency increased with enhancing the reverse flow level to IV = 0.0583 m 3 s À1 , but decreased with a sharp slope in the reverse levels of V = 0.0704 m 3 s À1 and VI = 0.0836 m 3 s À1 . Practical ApplicationsCyclone separators are widely used in various industries such as flour and cement.The various parameters of cyclones in a food processing unit effectively affect cyclone efficiency. Therefore, an innovative method for increasing cyclone performance is presented in this study. Computational fluid dynamics (CFD) is a powerful tool for simulation of the food processing phenomenon. Validation could be guaranteed by the usage of numerical results that are obtained from CFD simulations. The innovative methods can play a key role in decreasing energy usage by reducing the pressure drop and enhancing separation efficiency.