The developments in computer hardware combined with more sophisticated modelling tools have during the last decades created a wealth of new possibilities for understanding and explaining physical phenomena in complex systems. This is indeed true also for the aluminium industry, where the processes range from “simple” gas flow all the way to multi-phase flow with phase changes coupled with electromagnetic forces.
Models are however still only approximations of the real processes, and comparison with measurements is still crucial and necessary. Previous presentations (Manger 2014 and Manger 2017) showed the importance of correct problem descriptions, as well as access to experimental data with good quality.
On the other side, among the possibilities within digitization is also the ability to obtain real time data such as e.g. pressure and temperature from processes being continuously monitored. The true value of these measurements does however not appear before combining the data with models and theoretical understanding. By utilizing all available knowledge, important and useful characteristics on the physical system of interest can be obtained.
In this paper the combination of simulations, theoretical knowledge and measurement equipment is explored and used to design an online system for monitoring flow through a Gas Treatment Center (GTC) line. By developing a CFD model and using the results from this, suitable positions for measuring differential pressure can be found. The principles for selecting and, if necessary, constructing geometries enabling such points correctly are described.
Later the model, together with known physical principles, are used to establish a correlation between measured differential pressure, temperature and flow. This relationship is then used to monitor the flow rates online and in real time, also providing information on the fluctuations in the system and give warnings if experiencing large deviations/changes due to e.g. equipment failure.
References:
MANGER, E. (2014), “CFD in Problem Analysis and Optimization – the Importance of Correct Boundary Conditions”, Proc. CFD 2014 – 10th International Conference on Computational Fluid Dynamics in the Oil & Gas, Metallurgical and Process Industries, Trondheim, Norway, June 17th – 19th, 2014.
MANGER, E. (2017), “Modelling and Measurements in the Aluminium Industry – Where are the Obstacles?”, Proc. CFD 2017 – 12th International Conference on Computational Fluid Dynamics in the Oil & Gas, Metallurgical and Process Industries, Trondheim, Norway, May 30th – June 1st, 2017.