Home DEM investigation on effect of internal pipe on active layer characterization in a drum
Article
Licensed
Unlicensed Requires Authentication

DEM investigation on effect of internal pipe on active layer characterization in a drum

  • Yong Zhang EMAIL logo , Guoqing Chen and Baosheng Jin
Published/Copyright: March 24, 2025
Become an author with De Gruyter Brill
Submit Manuscript Author Information
International Journal of Chemical Reactor Engineering
From the journal International Journal of Chemical Reactor Engineering Volume 23 Issue 2

Abstract

The incorporation of internal pipes is recognized as effective strategy to augment the heat transfer area within an externally heated drum, but their presence can substantially alter the granular flow dynamics, potentially affecting the thermal and mass transfer processes. This study utilizes the Discrete Element Method (DEM) to analyze the interaction between an internal pipe and particles within a rotary drum. The focus is on how the pipe diameter, position, and rotational speed affect the active layer’s proportion, velocity distribution, active-passive boundary dynamics, and particle diffusion coefficient. Based on the observed flow phenomena, the rolling flow pattern within a free drum is further divided into several sub-patterns. The results demonstrate that the presence of an internal pipe divides the bed into five distinct flow patterns: Single-Cycle, Dual-Cycle, Triple-Cycle, Slumping-Rolling and Moving-Bed flow mode. When the pipe is positioned within the active layer and its diameter is smaller than the maximum thickness of the active layer in a free drum, the bed is inclined to develop a Dual-Cycle mode. In this mode, an increase in pipe diameter results in an increase in the time-averaged proportion of the active layer but a decrease in velocity and diffusion coefficient. Conversely, if the pipe’s diameter is larger, a Slumping-Rolling flow structure emerges, leading to a decrease in the active layer’s time-averaged proportion, velocity, and diffusion coefficient. As the pipe is moved from the active-passive interface towards the drum wall, the bed undergoes a transition from Single-Cycle and Triple-Cycle modes to Moving-Bed flow mode. During this transition, there is an initial rise followed by a notable drop in the time-averaged proportion, velocity, and diffusion coefficient of the active layer. Additionally, increasing the rotational speed does not alter the Triple-Cycle pattern but promotes the expansion of the active layer’s volume and enhances particle activity.

Keywords: active layer; internal pipe; flow regime; rotating drum; DEM
Corresponding author: Yong Zhang, Key Laboratory of Energy Thermal Conversion and Control of Ministry of Education, School of Energy and Environment, Southeast University, Nanjing, 210096, China, E-mail:

Acknowledgments

The authors gratefully acknowledge financial support from an Open Project of State Key Laboratory of Clean and Efficient Coal-fired Power Generation and Pollution Control (D2022FK100).

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: All other authors state no conflict of interest.

  6. Research funding: None declared.

  7. Data availability: The data presented in this study are available on request from the corresponding author.

References

[1] G. H. Ristow, “Pattern formation in granular materials – introduction,” in Pattern Formation In Granular Materials, vol. 164, Berlin, Germany, Springer-Verlag, 2000.Search in Google Scholar

[2] H. Henein, J. K. Brimacombe, and A. P. Watkinson, “Experimental study of transverse bed motion in rotary kilns,” Metall. Trans. B, vol. 14, no. 2, pp. 191–205, 1983, https://doi.org/10.1007/BF02661016.Search in Google Scholar

[3] D. Bonamy, F. Daviaud, and L. Laurent, “Experimental study of granular surface flows via a fast camera: A continuous description,” Phys. Fluids, vol. 14, no. 5, pp. 1666–1673, 2002, https://doi.org/10.1063/1.1459720.Search in Google Scholar

[4] N. Jain, J. M. Ottino, and R. M. Lueptow, “An experimental study of the flowing granular layer in a rotating tumbler,” Phys. Fluids, vol. 14, no. 2, pp. 572–582, 2002, https://doi.org/10.1063/1.1431244.Search in Google Scholar

[5] M. Nakagawa, S. A. Altobelli, A. Caprihan, E. Fukushima, and E. K. Jeong, “Non-invasive measurements of granular flows by magnetic resonance imaging,” Exp. Fluids, vol. 16, no. 1, pp. 54–60, 1993, https://doi.org/10.1007/BF00188507.Search in Google Scholar

[6] K. Yamane, M. Nakagawa, S. A. Altobelli, T. Tanaka, and Y. Tsuji, “Steady particulate flows in a horizontal rotating cylinder,” Phys. Fluids, vol. 10, pp. 1419–1427, 1998, https://doi.org/10.1063/1.869858.Search in Google Scholar

[7] M. Rasouli, F. Bertrand, and J. Chaouki, “A multiple radioactive particle tracking technique to investigate particulate flows,” AIChE J., vol. 61, pp. 384–394, 2015, https://doi.org/10.1002/aic.14644.Search in Google Scholar

[8] O. Dube, E. Alizadeh, J. Chaouki, and F. Bertrand, “Dynamics of non-spherical particles in a rotating drum,” Chem. Eng. Sci., vol. 101, pp. 486–502, 2013, https://doi.org/10.1016/j.ces.2013.07.011.Search in Google Scholar

[9] A. Ingram, J. P. K. Seville, D. J. Parker, X. Fan, and R. Forster, “Axial and radial dispersion in rolling mode rotating drums,” Powder Technol., vol. 158, nos. 1-3, pp. 76–91, 2005, https://doi.org/10.1016/j.powtec.2005.04.030.Search in Google Scholar

[10] S. Y. Lim, J. F. Davidson, R. N. Forster, D. J. Parker, D. M. Scott, and J. P. K. Seville, “Avalanching of granular material in a horizontal slowly rotating cylinder: PEPT studies,” Powder Technol., vol. 138, pp. 25–30, 2003, https://doi.org/10.1016/j.powtec.2003.08.038.Search in Google Scholar

[11] H. Yang, G. L. Jiang, H. Y. Saw, C. E. Davies, M. J. Biggs, and V. Zivkovic, “Granular dynamics of cohesive powders in a rotating drum as revealed by speckle visibility spectroscopy and synchronous measurement of forces due to avalanching,” Chem. Eng. Sci., vol. 146, pp. 1–9, 2016, https://doi.org/10.1016/j.ces.2016.02.023.Search in Google Scholar

[12] R. Li, H. Yang, G. Zheng, and Q. Sun, “Granular avalanches in slumping regime in a 2D rotating drum,” Powder Technol., vol. 326, pp. 322–336, 2018, https://doi.org/10.1016/j.powtec.2017.12.032.Search in Google Scholar

[13] D. J. Parker, A. E. Dijkstra, T. W. Martin, and J. Seville, “Positron emission particle tracking studies of spherical particle motion in rotating drums,” Chem. Eng. Sci., vol. 52, no. 13, pp. 2011–2022, 1997, https://doi.org/10.1016/S0009-2509(97)00030-4.Search in Google Scholar

[14] R. Brewster, G. S. Grest, and A. J. Levine, “Effects of cohesion on the surface angle and velocity profiles of granular material in a rotating drum,” Phys. Rev. E., vol. 79, no. 1, p. 011305, 2009, https://doi.org/10.1103/PhysRevE.79.011305.Search in Google Scholar PubMed

[15] H. Watanabe, “Critical rotation speed for ball-milling,” Powder Technol., vol. 104, no. 1, pp. 95–99, 1999, https://doi.org/10.1016/S0032-5910(99)00031-5.Search in Google Scholar

[16] J. Mellmann, “The transverse motion of solids in rotating cylinders – forms of motion and transition behaviour,” Powder Technol., vol. 118, no. 3, pp. 251–270, 2001, https://doi.org/10.1016/S0032-5910(00)00402-2.Search in Google Scholar

[17] I. A. Resende, M. V. C. Machado, C. R. Duarte, and M. A. S. Barrozo, “An experimental analysis of coffee beans dynamics in a rotary drum,” Can. J. Chem. Eng., vol. 95, no. 12, 2017, https://doi.org/10.1002/cjce.22961.Search in Google Scholar

[18] X. Y. Liu and E. Specht, “Predicting the fraction of the mixing zone of a rolling bed in rotary kilns,” Chem. Eng. Sci., vol. 65, no. 10, pp. 3059–3063, 2010, https://doi.org/10.1016/j.ces.2010.01.031.Search in Google Scholar

[19] H. Rezaei and S. Sokhansanj, “A review on determining the residence time of solid particles in rotary drum dryers,” Dry. Technol., vol. 39, no. 11, pp. 1762–1772, 2021. https://doi.org/10.1080/07373937.2021.1912081.Search in Google Scholar

[20] K. G. Irgat, T. Kreutzer, M. Behrens, and H. J. Schultz, “Solid flow in rotary drums with sectional internals: An experimental investigation,” Chem. Eng. Technol: Ind. Chem. Plant Equip. Process Eng. Biotechnol., vol. 44, no. 2, 2021, https://doi.org/10.1002/ceat.202000148.Search in Google Scholar

[21] J. Priessen, T. Kawka, J. Alisic, M. Behrens, and H. J. Schultz, “Rotary drums with sectional internals: experimental investigation on the influence of section number and section length,” Powder Technol., vol. 386, no. 7, pp. 262–274, 2021. https://doi.org/10.1016/j.powtec.2021.03.031.Search in Google Scholar

[22] A. V. Orpe and D. V. Khakhar, “Scaling relations for granular flow in quasi-two dimensional rotating cylinders,” Phys. Rev. E, vol. 64, no. 3, p. 031302, 2001. https://doi.org/10.1103/PhysRevE.64.031302.Search in Google Scholar PubMed

[23] Y. L. Ding, J. P. K. Seville, R. N. Forster, and D. Parker, “Solids motion in rolling mode rotating drums operated at low to medium rotational speeds,” Chem. Eng. Sci., vol. 56, no. 5, pp. 1769–1780, 2001, https://doi.org/10.1016/S0009-2509(00)00468-1.Search in Google Scholar

[24] I. R. Y. Hellou, F. Lominé, I. Benhsine, and Y. Roques, “Theoretical description of the motion of a particle in rotary dryer,” The Can. J. Chem. Eng., vol. 97, no. 1, 2019, https://doi.org/10.1002/cjce.23213.Search in Google Scholar

[25] W. Rong, B. Li, and Y. Feng, “The development and application of a TFM for dense particle flow and mixing in rotating drums,” Processes, vol. 10, no. 2, p. 234, 2022, https://doi.org/10.3390/pr10020234.Search in Google Scholar

[26] M. Yu, H. Zhang, J. Guo, J. Zhang, and Y. Han, “Three-dimensional DEM simulation of polydisperse particle flow in rolling mode rotating drum,” Powder Technol., vol. 396, pp. 626–636, 2022, https://doi.org/10.1016/j.powtec.2021.10.058.Search in Google Scholar

[27] D. Gidaspow, Multiphase Flow and Fluidization: Continuum and Kinetic Theory Descriptions, Academic Press, 1994.Search in Google Scholar

[28] D. A. Santos, F. O. Dadalto, R. Scatena, C. R. Duarte, and M. A. S. Barrozo, “A hydrodynamic analysis of a rotating drum operating in the rolling regime,” Chem. Eng. Res. Des., vol. 94, pp. 204–212, 2015, https://doi.org/10.1016/j.cherd.2014.07.028.Search in Google Scholar

[29] H. Yin, M. Zhang, and H. Liu, “Numerical simulation of three-dimensional unsteady granular flows in rotary kiln,” Powder Technol., vol. 253, pp. 138–145, 2014, https://doi.org/10.1016/j.powtec.2013.10.044.Search in Google Scholar

[30] D. A. Santos, I. J. Petri, C. R. Duarte, and M. A. S. Barrozo, “Experimental and CFD study of the hydrodynamic behavior in a rotating drum,” Powder Technol., vol. 250, pp. 52–62, 2013, https://doi.org/10.1016/j.powtec.2013.10.003.Search in Google Scholar

[31] M. M. H. D. Arntz, H. H. Beeftink, W. K. den Otter, W. J. Briels, and R. M. Boom, “Segregation of granular particles by mass, radius, and density in a horizontal rotating drum,” AIChE J., vol. 60, no. 1, pp. 50–59, 2014, https://doi.org/10.1002/aic.14241.Search in Google Scholar

[32] D. C. Rapaport, “Radial and axial segregation of granular matter in a rotating cylinder: A simulation study,” Phys. Rev. E, vol. 75, p. 031301, 2007, https://doi.org/10.1103/PhysRevE.75.031301.Search in Google Scholar PubMed

[33] S. E. Cisar, J. M. Ottino, and R. M. Lueptow, “Geometric effects of mixing in 2D granular tumblers using discrete models,” AIChE J., vol. 53, no. 4, pp. 1151–1158, 2007, https://doi.org/10.1002/aic.11165.Search in Google Scholar

[34] G. J. Finnie, N. P. Kruyt, M. Ye, C. Zeilstra, and J. A. M. Kuipers, “Longitudinal and transverse mixing in rotary kilns: A discrete element method approach,” Chem. Eng. Sci., vol. 60, no. 15, pp. 4083–4091, 2005, https://doi.org/10.1016/j.ces.2004.12.048.Search in Google Scholar

[35] J. R. Third, D. M. Scott, and C. R. Müller, “Axial transport within bidisperse granular media in horizontal rotating cylinders,” Phys. Rev. E, vol. 84, p. 041301, 2011, https://doi.org/10.1103/PhysRevE.84.041301.Search in Google Scholar PubMed

[36] H. R. Norouzi, R. Zarghami, and N. Mostoufi, “Insights into the granular flow in rotating drums,” Chem. Eng. Res. Des., vol. 102, pp. 12–25, 2015, https://doi.org/10.1016/j.cherd.2015.06.010.Search in Google Scholar

[37] S. L. Yang, A. Cahyadi, J. W. Wang, and J. W. Chew, “DEM study of granular flow characteristics in the active and passive regions of a three-dimensional rotating drum,” AIChE J., vol. 62, no. 11, pp. 3874–3888, 2016, https://doi.org/10.1002/aic.15315.Search in Google Scholar

[38] R. Y. Yang, A. B. Yu, L. McElroy, and J. Bao, “Numerical simulation of particle dynamics in different flow regimes in a rotating drum,” Powder Technol., vol. 188, no. 2, pp. 170–177, 2008, https://doi.org/10.1016/j.powtec.2008.04.081.Search in Google Scholar

[39] C. Pei, C. Wu, and M. Adams, “Numerical analysis of contact electrification of non-spherical particles in a rotating drum,” Powder Technol., vol. 285, pp. 110–122, 2015, https://doi.org/10.1016/j.powtec.2015.05.050.Search in Google Scholar

[40] D. A. Santos, R. Scatena, C. R. Duarte, and M. A. Barrozo, “Transition phenomenon investigation between different flow regimes in a rotary drum,” Braz. J. Chem. Eng., vol. 33, pp. 491–501, 2016, https://doi.org/10.1590/0104-6632.20160333s20150128.Search in Google Scholar

[41] D. A. Santos, M. A. Barrozo, C. R. Duarte, F. Weigler, and J. Mellmann, “Investigation of particle dynamics in a rotary drum by means of experiments and numerical simulations using DEM,” Adv. Powder Technol., vol. 27, pp. 692–703, 2016, https://doi.org/10.1016/j.apt.2016.02.027.Search in Google Scholar

[42] T. Dong, S. L. Yang, and S. Wang, “Super-quadric DEM study of cylindrical particle behaviours in a rotating drum,” Powder Technol., vol. 437, p. 119511, 2024, https://doi.org/10.1016/j.powtec.2024.119511.Search in Google Scholar

[43] L. M. Grajales, N. M. Xavier, J. P. H, and J. C. Thoméo, “Mixing and motion of rice particles in a rotating drum,” Powder Technol., vol. 222, pp. 167–175, 2012, https://doi.org/10.1016/j.powtec.2012.02.028.Search in Google Scholar

[44] F. Rioual and P. E. E. Gbehe, “Characterisation of the granular dynamics at the interface between a pipe and a granular flow in a rotating drum,” Particuology, vol. 86, no. 3, pp. 117–125, 2024, https://doi.org/10.1016/j.partic.2023.05.003.Search in Google Scholar

[45] H. Komossa, S. Wirtz, V. Scherer, F. Herz, and E. Specht, “Heat transfer in indirect heated rotary drums filled with monodisperse spheres: Comparison of experiments with DEM simulations,” Powder Technol., vol. 286, pp. 722–731, 2015, https://doi.org/10.1016/j.powtec.2015.07.022.Search in Google Scholar

[46] G. Xu, Y. Zhang, X. Yang, G. Chen, and B. Jin, “Effect of drum structure on particle mixing behavior based on DEM method,” Particulary, vol. 74, pp. 74–91, 2023, https://doi.org/10.1016/j.partic.2022.05.008.Search in Google Scholar

[47] Y. Tsuji, T. Kawaguchi, and T. Tanaka, “Discrete particle simulation of two-dimensional fluidized bed,” Powder Technol., vol. 77, pp. 79–87, 1993, https://doi.org/10.1016/0032-5910(93)85010-7.Search in Google Scholar

[48] S. Yang, K. Luo, J. Fan, and K. Cen, “Particle-scale investigation of the solid dispersion and residence properties in a 3-D spout-fluid bed,” AIChE J., vol. 60, pp. 2788–2804, 2014, https://doi.org/10.1002/aic.14494.Search in Google Scholar

[49] S. L. Yang, L. Q. Zhang, K. Luo, and J. W. Chew, “DEM investigation of the axial dispersion behavior of a binary mixture in the rotating drum,” Powder Technol., vol. 330, pp. 93–104, 2018, https://doi.org/10.1016/j.powtec.2018.02.021.Search in Google Scholar

[50] S. Yang, Y. Sun, L. Zhang, and J. W. Chew, “Segregation dynamics of a binary-size mixture in a three-dimensional rotating drum,” Chem. Eng. Sci., vol. 172, pp. 652–666, 2017, https://doi.org/10.1016/j.ces.2017.07.019.Search in Google Scholar
Received: 2024-10-27
Accepted: 2025-03-10
Published Online: 2025-03-24

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Review
  3. A critical analysis on synthesis of nanofluids and factors affecting thermal conductivity of nanofluids for heat transfer applications: a review
  4. Articles
  5. Improving iron-bearing dust pellets performance through synergistic action of dual-component organic binders: cellulose and starch interactions
  6. Preparation of mesoporous lignin-based aerogels for organic dyes removal
  7. Power generation potential and assessment of producer gas quality from blended rubber shell and palm kernel shell in open core downdraft gasifier
  8. Bi2S3 loaded MXene Ti3C2T x nanosheet with an adsorption-photocatalytic synergistic removal for tetracycline
  9. Preparation of activated carbon from waste tea and its performance in adsorptive desulfurization of model fuel
  10. Study on friction pressure drop characteristics of gas flow through multi-size irregular high-purity magnesia bed layer
  11. Unlocking sustainable cooling: a numerical analysis of ice slurry flow in 180° U-bends-impacts of bend radius/pipe radius ratios and pressure drops on system performance
  12. DEM investigation on effect of internal pipe on active layer characterization in a drum
https://doi.org/10.1515/ijcre-2024-0216
Keywords for this article
active layer; internal pipe; flow regime; rotating drum; DEM

Articles in the same Issue

  1. Frontmatter
  2. Review
  3. A critical analysis on synthesis of nanofluids and factors affecting thermal conductivity of nanofluids for heat transfer applications: a review
  4. Articles
  5. Improving iron-bearing dust pellets performance through synergistic action of dual-component organic binders: cellulose and starch interactions
  6. Preparation of mesoporous lignin-based aerogels for organic dyes removal
  7. Power generation potential and assessment of producer gas quality from blended rubber shell and palm kernel shell in open core downdraft gasifier
  8. Bi2S3 loaded MXene Ti3C2T x nanosheet with an adsorption-photocatalytic synergistic removal for tetracycline
  9. Preparation of activated carbon from waste tea and its performance in adsorptive desulfurization of model fuel
  10. Study on friction pressure drop characteristics of gas flow through multi-size irregular high-purity magnesia bed layer
  11. Unlocking sustainable cooling: a numerical analysis of ice slurry flow in 180° U-bends-impacts of bend radius/pipe radius ratios and pressure drops on system performance
  12. DEM investigation on effect of internal pipe on active layer characterization in a drum
Sign up now to receive a 20% welcome discount
Institutional Access
How does access work?
Have an idea on how to improve our website?
Please write us.
© 2025 De Gruyter Brill
Downloaded on 17.11.2025 from https://www.degruyterbrill.com/document/doi/10.1515/ijcre-2024-0216/html?lang=en
Scroll to top button