D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP ANALISYS OF THE COFFEE ROASTING PROCESS UNDER ACTUAL OPERATING CONDITIONS S. Farina 1 , M. Milani 2 , L. Montorsi 2 1 - Petroncini Impianti S.p.A. Ferrara, Italy 2 - HY DRAULIC SY STEMS DE SIGN R ESEARCH G ROUP Dept. of Sciences and Methods for Engineering University of Modena and Reggio Emilia, Italy STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP FOCUS OF THE ANALYSIS: ROASTING MACHINE COFFEE! GREEN COFFEE STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP ANALYSIS OF A LARGE-SCALE COFFEE ROASTER PLENUM 1D-SIMULATION OF THE ENTIRE PLANT BURNER Type #1 THROTTLE VALVES Type #2 STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP ANALYSIS OF A LARGE-SCALE COFFEE ROASTER STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Modeling: STAR-CCM+ v8.05.007 Hot air flow: OUTLET Ideal gas (air) • Coupled energy • Turbulent flow (k- ε model) • Gravity • INLET Coffee beans: Discrete Element Model (DEM) • Constant density • Composite particles • Energy • Two-way coupling • 6 mm Mesh motion: • Rigid body rotation STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Boundary conditions: STAR-CCM+ v8.05.007 Drum rotational speed 100 rpm p out Inlet air temperature 370 °C Coffee mass 15 kg m , T , in in in ~150,000 beans 350 Nm3/h Inlet mass flow rate 250 Nm3/h Air-bean heat transfer: constant properties of the beans 𝑑 𝑞,𝑑𝑝𝑔𝑔𝑓𝑓 = 1.5 𝑙𝐾 𝑈 𝑗𝑜,𝑑𝑝𝑔𝑔𝑓𝑓 = 300 𝐿 𝑙𝐿 STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Coffee beans’ loading phase: Flow rate: 350Nm 3 /h Flow rate: 250Nm 3 /h Frame rate: 1/100 th of real speed STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Coffee beans’ loading phase: coffee mass STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: total pressure drop STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: beans’ velocity distribution AVERAGE VELOCITY ROOT MEAN SQUARE VALUE STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: beans’ temperature distribution AVERAGE VELOCITY ROOT MEAN SQUARE VALUE STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: beans’ temperature distribution AVERAGE VELOCITY TIME GRADIENT STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: temperature distribution +beans’ temperature Section view Flow rate: 350Nm 3 /h Flow rate: 250Nm 3 /h Frame rate: 1/100 th of real speed STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP A CFD ANALYSIS OF THE COFFEE ROASTER Results: velocity distribution +beans’ velocity Section view Flow rate: 350Nm 3 /h Flow rate: 250Nm 3 /h A B B B - B A - A B - B A - A Frame rate: 1/100 th of real speed Section view STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: influence of blades’ design BLADE #1 BLADE #2 BLADE #3 STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP CFD ANALYSIS OF THE COFFEE ROASTER Results: influence of rotor speed 100 rpm (~50Hz) 122 rpm (~60Hz) (~15s) (~15s) STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP TEST RIG FOR THE ROASTING DRUM DEVELOPMENT Transparent model: Pilot scale roasting plant: STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP TEST RIG FOR THE ROASTING DRUM DEVELOPMENT Coffee bean roasting model: New coffee roaster design THERMOGRAPHY FAST IMAGE Optris PI 160 camera • spectral range: 7.5 - 13 µm • temperature range: -20 ° C - 900 ° C • optical resolution: 160 x 120 pixel • picture repetition frequency: 120 Hz STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP NUMERICAL MODEL OF THE AIR-COFFEE HEAT TRANSFER Coffee bean roasting model Lumped parameter approach: Model features 9 2 dX 4.32 10 X 9889 b b exp 2 dt d T b b • moisture evaporation H H H a etot e Q m A exp r b • thermal power obtained from roasting reactions dry R T H g b etot m c dT / dZ h T T dA / dZ • thermal power exchange between air flow and beans gi gi g gb gi b gb Q h A T T • thermal power exchange between air flow and drum walls gmDi gmDi gmDi gi mD / Q T T R gmC gi amb loss • thermal power losses through the case STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP NUMERICAL MODEL OF THE AIR-COFFEE HEAT TRANSFER Coffee bean roasting model Lumped parameter approach: Bean temperature Bean moisture To be implemented CFD • moisture evaporation 9 2 dX 4.32 10 X 9889 b b exp 2 dt d T b b • thermal power obtained from roasting reactions H H H a etot e Q m A exp r b R T H dry g b etot IDEASTORM : access to the results of the Lagrangian phase through the "Monitors" functions STAR Global Conference 2014 - Vienna
D EPT . OF S CIENCES & M ETHODS FOR E NGINEERING – U NIV . OF M ODENA & R EGGIO E MILIA H YDRAULIC S YSTEMS D ESIGN R ESEARCH G ROUP Thank you very much for your kind attention! HY DRAULIC SY STEMS DE SIGN R ESEARCH G ROUP D EPARTMENT OF S CIENCES AND M ETHODS FOR E NGINEERING U NIVERSITY OF M ODENA AND R EGGIO E MILIA STAR Global Conference 2014 - Vienna
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