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NUMERICAL SIMULATION OF DRYING OF REFRACTORYCONCRETEZ. X. Gong a , B. Song a & Arun S. Mujumdar ba Mechanical Engineering Department , Tianjin Institute of Light Industry , Tianjin, P. R.,Chinab Chemical Engineering Department , McGill University , Montreal, Quebec, CanadaPublished online: 25 Apr 2007.
To cite this article: Z. X. Gong , B. Song & Arun S. Mujumdar (1991) NUMERICAL SIMULATION OF DRYING OF REFRACTORYCONCRETE, Drying Technology: An International Journal, 9:2, 479-500, DOI: 10.1080/07373939108916677
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DRYING TECHNOLOGY, 9(2), 479-500 (1991)
NUMERICAL SIMULATION OF DRYING OF REFRACPORY CONLRETE
2 . X. Gong, B . Song Mechanical Engineering Department Tianjin Institute of Light Industry
Tianjin, P. R. China and
Arun S. Mujlrmdar Chemical Engineering Department
McGill University Montreal, Quebec, Canada
Key Words and Phrases: drying model; finite elements; volumetric heating; pore pressure.
The drying process of refractory concrete is simulated numerically using a newly-developed one-pint quadrature finite element algorithm. The effect of volumetric heat supply (e.g. simplified microwave heating) is also examined numerically. Time-dependent temperature, pore pressure and moisture profiles are presented at selected locations. Integrated water release curves are also given.
Refractory concrete is an essential material in the
fabrication of various industrial reactor vessels. Drying process
of monolithic refractory concrete is of significant practical
interest.
Copyright 1991 by Marcel Dekker, Inc.
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480 GONG, SONG, AND MUJUMDAR
Initial heating of refractory concrete may produce a signifi-
cant build-up of pore pressure which can cause explosive
"spalling". Although the causes are manifold, the influence of the
drying process is undoubtedly a main one. Therefore, rational
prediction of the response of refractory concrete to heating is of
great importance and much attention has been paid to it.
On the basis of Luikov's theory for coupled heat and mass
transfer, Bazant developed a mathematical model to describe the
drying process of refractory concrete [1 ,2 ,31 . Experiments to
measure the parameters used in his model were also carried out.
Recently, Dhatt and his co-workers solved the mathematical model
for one dimension using a finite element method [ 4 1 . The results
were reported to be in agreement with the experimental ones.
In this paper the Luikov model is solved numerically in two
dimensions using a newly-developed one-point quadrature finite
element procedure. The drying process of increasing temperature at
the boundary as well as a simplified volumetric heat supply is
simulated and analyzed. The volumetric supply term does not
strictly simulate dielectric heating.
FIELD EQUATIONS
One important characteristic of heat and moisture transfer in
porous bodies is their coupling. Thus, the fluu of moisture J
should consist of a flux due to the gradient of moisture content
W, as well as a flux due to the temperature gradient. Similarly,
the heat flux q should consist of a flux due to the temperature
gradient and a flux due to the gradient of moisture content.
Accordingly,
J = -a,,,grad W - a YT grad T q : -aT&-& W - aTTgrad T
in which W = mass of all free (not chemically bound) water per m3 of concrete. Coefficients a,,,,, a,,, , aTU, and aTT depend on W and T.
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE 481
Because W is a function of temperature T and pore pressure P,
W = W(P,T), Eq. 1 can be rearranged as
a aW in which g = 9.806 m/s2, gravity acceleration; and = a,, (&,, a = a aw (-1 . Experiments show that a, is rather small [21.
1 ,I+ m P Therefore, the thermal gradient contribution, atgrad T, can be
neglected. Thus, Eq. 3 can be simplified as
in which a = permeability of moisture, in m/s. In fact, grad P
in Eq. 4 has already, included a part of the contribution of the
temperature gradient because P is related to temperature.
The coupled heat flux, aTygrad W, in Eq. 2 can also be
neglected. As a result, setting aTT= k = heat conductivity, we may write
q = -k grad T ( 5 ) According to the conservation laws of heat and moisture in
concrete, the simplified field equations are as follows:
awd *--divJ+- at - at
aw aw ap aw a in which = - - + - -, Wd= water liberated by dehydration aP at a~ at during heating (see Figure 1 141); p , C = mass density and isobaric heat capacity of concrete; C = absorption heat of water; C,,= heat capacity of water; Q = volumetric heat supply; and the tern C J-grad T = rate of heat convection by moving water during rapid heating.
Moisture and heat transmission at the surface are given as
follow..
For moisture flux:
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GONG, SONG, AND MUJUMDAR
E
e = Cemant Content:
FIGURE 1 Dehydration Curve
and for heat flux:
n.q = B (T - Ten) + Can.J , (9 )
where By and BT are transfer coefficients, and n is the outward
normal.
FINITE !&EKENT MODEL
The semi-discrete finite element equations of Eq. 6 and Eq. 7
are
in which Pnand Tn stand for nodal pore pressure and temperature.
The matrices Cm(m=1,2,3,4), Km(m=1,2) are obtained by assembling
the elementary matrices. If the problem dealt with is axi-
symmetric, the elements in the elementary matrices can be
calculated as follows:
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NUMERICAL S I M U L A T I O N O F DRYING O F REFRACTORY CONCRETE
where A = A = -C aw ah' aw awd aP, , A ~ = z, A ~ = PC - C. 5, A d = - at
a aW A"= -, CUPl, ; and 3 can be calculated from Figure 2 which is
obtained from W = W(P,T) [3] . For Cartesian coordinates, r in the
equations above is equal to 1.
Because of the strong non-linearity and the existence of two
degrees of freedom in this problem, the calculation of the element
diffusion matrices occupies a large portion of the total work.
Generally, the calculation of the element diffusion matrices is
performed by numerical quadrature. For isoparametric bilinear
quadrilateral elements adopted in this paper, four-point
quadrature is often required. This is very timesonsuming, so, a
substantial amount of time is needed to complete a run. In order
to speed up the computation, a newly-developed one-point
quadrature procedure is introduced.
The major drawback of one-pint quadrature is known as
hourglass. Recent studies have indicated the difficulty can be
overcome by adding a stabilization matrix [5].
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GONG, SONG, AND MUJUMDAR
0.4
0.3
e - 2 I
0.2
0.1
0 1 .O i
h = P/PslT)
FIGUB 2 b a t i m of State I = I ( P , T I
e(l) . where [K,] is the element matrix by one-pint quadrature; the
stabilization matrix is given by
T [ K , ] : ~ , ~ = ;,A (71 (7) (m = 1, 2) (12)
T T where t y ) = [(h) - ( ( h ) (x))(bll - ((h) (YI )(b,) I
7 1 (bl) = - [yz4, YS1t Yq21 Yl31 2 A
T 1 (bZl = 2 Ax4,' Xlj* XZ4* x3,1
X = x - X r~ I J "1,' '1- YJ
1 A = 5 (x3,yZ4+ X,~Y.,~)
T [h} = 11, -1, 1, -11
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE
for m = l in the equations above km =
for m = 2 For non-linear heat conduction problems, almost two-thirds of
the total solution time is saved when one-point quadrature is used
in [61. Comparison in terms of the muracy and solution time is
made between one-point and four-point quadrature.
TIME INTEGRATION
The time integration of Eq.10 is obtained by a predictor
-corrector scheme. The final discrete forms of Eq. 6 and Eq. 7 are
[K*(u;+~,)] {A'}={~(u:+~~)) ( 1 3 )
in which
[K*(U:+~~)I = [c(u:+At)l + aht[K(u:+At)l {r(ut+Ai)} = {F(U:+~~)) - [K(u:+AL)I{u~+AL}
- [c(u;+Ac)l{'t+At) where i designates ith iteration. For i = 0
With these two starting vectors, {AC) can be computed by
solving Eq. 13. The updating procedures are:
where a is a parameter, a = 0.25 N 0.75.
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GONG, SONG, AND MlJUMDAR
If convergence is achieved,
and
NUMERICAL SIMULATION
Based on the procedure described above, a computer code to
solve two-dimensional problems was written. This code can be used
for the analysis of the drying process of refractory concrete and
for the failure analysis of concrete reactor vessels in accidents
of structure due to rapid heating.
Using the computer code, calculations have been made for a
typical refractory concrete cross-section as shown in Figure 3.
The sylmnetry of the problem allows analysis of half of a quarter of the section. The finite element mesh is shown in Figure 4. Two
cases of the problem are simulated. One is direct heating, and the
other is for simplified volumetric heating.
Case 1: Direct heating
The boundary conditions are:
on side AB
PZv for t r; tm
IT(~)=T m a x fort > tm
where B"= 1.0~10'~s/m, P~~/P~(ZOOC) = 45% 1 3 1 ,
V = 125O~/h Along side CD,
where BY= 1 .~xl~"s/m, Pen/P, (BOOC) = 45%,
BT= 1.0 J/~'.s.K, Ten= 20°c [3 ] .
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NUMERICAL SIMULATION OF DRYINGeOF REFRACTORY CONCRETE
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GONG, S O N G , AND MlJUMDAR
FIGURE 5 Relative Change in Perneabil i ty '
The sides AD and BC are zero-flux boundaries due to sylmnetry.
Initial conditions are assumed to be uniform temperature of
T = 2 0 ' ~ and po/pS ( 2 0 " ~ ) = 90%. 0
The permeability in practice is strongly temperature-
dependent. The permeability-temperature relation is given in
Figure 5 [$I in which aois specified at 2 0 " ~ as ao= 8.5 x
m/s. Absorption heat Ca is also temperature-dependent. It can be
calculated from the following equation [21:
3 . 5 ~ 1 0 ~ ( 3 7 4 . 1 5 - T)"~ for T s 3 7 4 . 1 5 ' ~ c = { a 0
The following values are assumed constant [ 2 ] :
p = 2200 kg/m3 C = 1100 J/kg.K
k = 1.67 J/m.s.K Cy= 4100 J/k.K
Case 2: Simplified microwave volumetric heating
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE 489
For comparison, a simplified microwave heating model is also
computed. The microwave energy input is assumed to be proportional
to the local moisture content according to:
Q = S u W + S C p
where SU and Sc are coefficients dependent on the material,
microwave intensity etc.. Here the following values are specified:
Su= 1040 J/kg.s, Sc= 13 J/kg.s.
Note that this case does not represent true microwave drying. With
proper specification of Q the code can, however, simulate the
realistic case.
RESULTS AND DISCUSSION
For the two cases studied, relatively rapid convergent
results were obtained by using a time step of At = 7--10 seconds. Figure 6.1 shows the temperature profiles along side BC at
different times for case 1. In this(and the following) figure
x/BC=O is point B and x/BC=I is point C. Initial temperature of
the concrete is uniform at 20°c. As the drying process begins the
interior surface, e.g. side AB, is heated at a rate of V=125 Oc/h
until 5 0 0 ~ ~ is reached. With time the temperature of the concrete
slab rises monotonously. As the thennal conductivity of the
concrete is small, temperature of the area far from the heated
surface, e.g. the area near point B, increases more slowly. It can
be seen that between tz2.0 hrs and tz2.5 hrs the temperature at
point B has risen significantly. The reason is due that before
tz2.0 hrs temperature of every point from x/BC=O to x/BC=l goes
through the phase change temperature of the free water, about
100-120~~, therefore, temperature changes slowly; after tz2.0 hrs
most of the free water is dried out, the heat transported in is
only used to raise the temperature of the concrete itself, not for
evaporation of free water. Therefore, the temperature rises
rapidly.
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GONG, SONG, AND MUJUMDAR
- - - I Side BC
Distance From The Heated Surfacs(x/EC)
Fig. 6.1
Distonce From The Heated Surface(x/BC)
fig. 6.2
200 -
- 150.- & 5 100.;
i E
50.-
FIGURE 6 Temperature Profiles Along Side BC A t D i f f e r e n t Times
Side BC Microwave Heating
3.Oh
'2.5h ' 2 m \I.% 1.0h
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE 491
Figure 6.2 gives the temperature profiles along BC for case
2. Initially the temperature of the concrete is 20°c. Energy
needed in the drying process is provided by a microwave s o m e
described above. During the first hour temperature reaches 100'~
quickly, while between tz1.5 hrs and tz2.5 hrs it changes slowly.
After t-2.5 hrs rise rate of temperature is accelerated. This is
due to the fact that after tz2.5 hrs phase change is completed and
almost all the free water is removed, heat supplied is only used
for the sensible heat of the concrete. In this figure the
temperature difference at different points along BC is very small.
It is determined by the heating characteristics of microwave
radiation.
Figure 8.1 displays the pore pressure profiles along BC for 2
case 1. The initial pore pressure is unifonnly 2100 N/m . With increasing temperature during the drying process , the rate of evaporation of the free water increases constantly, leading to the
elevation of the pore pressure. As the steam pressure in the
environment is assmed constant and quite low, pore pressure near
the two boundaries remains low during the whole process. The pore
pressure profile is in the shape of a parabola, and the peak of
the parabola gradually rises and migrates from x/BC:O to
x/BC=l(e.g. the interior surface to the exterior). At around t:
2.0 hra it is at x/BC-0.7 and reaches its highest value, 2.7 atm.
Afterwards the pressures along the whole side fall off rapidly. In
fact, after t12.0 hrs there is only a small amount of free water
left inside the concrete which can be evaporated to maintain the
pore pressure.
F i m 8.2 gives the pressure profiles along BC for case 2. 2 The initial pore pressure in the concrete is uniformly 2100 N/m .
In the drying process, with increase of temperature, steam
pressure of the free water rises, resulting in the elevation of
the pore pressure. During the first 1.5 hours the pore pressure
increases more rapidly near the center area, but keeps quite low
at x/BC=O and x/BC:l. At t31.5 hrs the pore pressure at x/BC=O. 5
is at its maximum value, 1.8 aim. After t-1.5 hrs the pressure
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: GONG, SONG, AND MUJUMDAR
Distance From The Heated Surfoce(x/AO)
Fig. 7.1
0 0.0 0.2 0.4 0.6 0 8 1 .O
Distance From The Heoted Surface(x/AD)
Fig. 7.2
150
E e! 1 100.- e x E 2 50.-
FIGURE 7 Temperature Profiles Along Side AD A t Different Times
Side AD Microwave Heating
-- 3.0h 2.5h
\2.0h \1.5h - 1 .Oh
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NUMERICAL SIMULATION O F DRYING OF REFRACTORY CONCRETE
Distance From The Heated Surfoce(x/BC)
Fig. 8.1
4.0
4 . 0 Side BC I
h N E 3.0.-
Microwave Heating I
Side BC
~ = 1 2 5 ' ~
2.0h
Distance From The Heated Surface(x/BC)
Fig. 8.2
0
0.0 0 . 2 0.4 0.6 0.8
FIGURE 8 Pressure Profiles Along Side BC At Different Times
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GONG, SONG, AND MUJUIIDAR
Distance From The Heated Surface(x/AD)
Fig. 9.1
4.0 Side AD -
N Microwave Heating E 3.0.- \ <
2.0.- a 1.5h
0.0 0.2 0.4 0.6 0.8
Distance From The Heated Surface(x/AD)
Fig. 9.2
FIGURE 9 Pressure Profiles Along Side AD At Different Times
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE
Oistonce From The Heoted Surface(x/BC)
Fig. 10.1
Microwave Healing A
Side BC RE 80.-
0.0 0.2 0.4 0.6 0 . 8
Distance From The Heated Surface(x/BC)
Fig. 1 0 . 2
FIGURE 10 Moisture Profiles Along Side BC At Different Times
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496 GONG, SONG, AND MUJUMDAR
begins to decrease. At t-3.0 hrs little free water is left in the
concrete and the pore pressure decreases to very low values.
Figure 10.1 displays the moisture profiles along side BC for
case 1. The initial free water content is about 100kg/rn3. At the
beginning moisture in the area near the heated surface.diffuses
quickly towards the environment under the driving force of the
pore pressure and the free water content near x/BC=O decreases
rapidly to very low values. With the drying process proceeding
pressure gradients are set up gradually in the concrete; free
water migrates from the interior to the boundaries and then
diffuses to the environment. The integrated free water contained
in the concrete decreases continuously. The moisture profiles are
in the form of a parabola. The zeniths of the parabolas are at
x/BC-0.78. At tS.5 hrs the free water content decreases to nearly
zero, e.g. , the material is dry. Figure 10.2 shows the moisture profiles for side BC for case
3 2. The initial free water content is again about 100 kg/m In a
very short time after drying starts the free water content at
x/BC=O and x/BC=l decreases to very low levels. At tz1.O hr the
moisture content has a bow-form distribution. Later the moisture
profile evolves into a parabola. After t-3.0 hrs the moisture
content is nearly zero, e.g., the material is dry.
Figure 7, 9 and 11 are for side AD. The results are analogous
to those for side BC.
Figure 12 shows the integrated water release curves for the
two cases. The initial free water content is 0.375kg/m3. The rate
of water release begins to decrease around t-2.0 hrs for V-125 OC
but at t-1.5 hrs for microwave heating. It tends to zero at
t-3.0 hrs for microwave heating and at t-3.5hrs for V-125 OC. The
amount of water released in case 1 is obviously more than that of
the initial free water contained, but that in case 2 is not. The
reason is that in case 1 when temperature is above 200 OC, there
is free water that is released into the pores by dehydration, but
in case 2 this is not so because the maximum temperature reached
is only 130~~.
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NUMERICAL SIMULATION O F DRYING OF REFRACTORY CONCRETE
Distance From The Heated Surface(x/AD)
Fig 11.1
OD- Microwave Heating Side AD
m- E 80.- 1.0 h
0 . 0 0.2 0 . 4 0.6 0.8
Distance From The Heated Surface(x/AD)
Fig. 1 1.2
FIGURE 11 Moisture Profiles Along Side AD At Different Times
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GONG, SONG, AND HUJUHDAR
Time (hour)
FIGURE 12 Integrated Water Release Curve
Fl GURE 13 Maxi mum Pressure Curve
A comparison of the maximum pressure-time curves for the two
cases is given in Figure 13. It can be seen that in completing the
same drying process using the same time, the maximum pre pressure
is less when employing volumetric heating than hen using
direct boundary heating. The direct boundary heating curve shows
some numerical oscillations. This is caused by high temperature
gradients.
It was also found in other numerical experiments that the
influence of the boundary conditions of moisture transfer on the
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NUMERICAL SIMULATION OF DRYING OF REFRACTORY CONCRETE 499
variation of pore pressure is not obvious. This is due to the fact
that the resistance of moisture transfer is mainly in the interior
since the permeability of the refractory concrete is very small.
For comparison the two cases are computed not only with
one-point quadrature, but also with four-point quadrature. The
superiority of one-point quadrature in solution time is clear from
the following table:
The difference of the solution between one-point and four
-pint quadrature methods is detected only in the fourth digit.
CASE
1
2
This work is being extended to predict the drying-induced
stress field; in order to further speed up the computation a
highly efficient three-time-level scheme will be intmduced into
the finite element model. Effects of intermittent thennal energy
input as well as spatially varying permeability will be evaluated
numerically.
CONCLUSIONS
Four-pint
CPU time
8159 sec
4475 sec
The numerical experiments presented here lead to the
following conclusions. (1) It seems that the efficiency of
volumetric heating is higher than that of direct heating for thin
materials. (2) The permeability of the refractory concrete is the
main factor that controls the variation of pore pressure, not the
One-point
CPU time
4486 sec
2631 sec
Percent of
Time Saved
45.02 %
44.90 %
Type of
Computer
HITACHI
M 240-D
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500 GONG, SONG, AND MUJUMDAR
boundary condition of moisture transfer. (3) he-point quadrature
can save about 45% CRI time compared with four-point quadrature
with no loss of accuracy in finite element modeling..
REFERENCES
[I] Bazant, Z.P.and Najjar, L.J., 1972, Nonlinear water diffusion in nonsaturated concrete, Materials and Structures: Research and Testing, 5(25), 3-20.
[21 Bazant, Z.P., ASCE, M. and Thonguthai, W., 1978, Pore pressure and drying of concrete at high temperature, Proceedings of the American Society of Civil Ehgineers, 104(EM5), 1059-1079.
[31 Bazant,Z.P., and Thonguthai, W., 1979, Pore pressure in heated concrete walls: theoretical prediction, Magazine of'Concrete Research, 31(107), 67-76.
[41 Dhatt, G., Jacquemier, M. and Kadje, C., 1986, Modelling of drying refractory concrete, Drying'86 (Edited by A. S. Mu.idr). Vol. 1. 94-104.
[5] L ~ U , w.K;, and &lytschko, T., 1984, Efficient linear and nonlinear heat conduction with a quadrilateral element, Int. J. N u n . Meth. Eng., 20, 931-948.
[61 Gong, Z.X. and Zhang, Y.F., 1987, Application of one-point quadrature to non-linear heat conduction (in Chinese), J. Tianjin Institute of Light Industry, 2, 71-76.
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