Alessandro Vulpio

In industrial applications such as chemical plants, cement factories, and glassmakers, large-sized centrifugal fans are commonly used for dust-laden flow processing. In many cases, the contamination is due to solid particles responsible for fouling and erosion issues. Erosion induces the reduction of mechanical resistance and, at the same time, the modification of the geometry and the surface characteristics of the internal flow path. The process works according to the characteristics of the erodent particles, such as dimension and hardness, which have to be coupled with the mechanical properties of the substrate, like hardness and roughness level. In addition to this, the intensity of the erosion depends on the dynamic characteristics of particles, especially velocity and impact angle. For these reasons, erosion-related issues are difficult predict and reduce. In an attempt to preserve the structural integrity of the internal walls, wear-resistant plates are positioned where the impacting contaminants are supposed to be more detrimental. In the present work, a combined experimental and numerical approach is proposed to evaluate the proper setup of wear-resistance plates over the flow path of a large-sized centrifugal fan. The results show how different regions (rotating and stationary walls) are subjected to different impact behavior, determining that the design of the position of the wear-resistant plate is not straightforward. Suggestions related to reducing the erosion intensity are reported, highlighting the possibility of designing the best compromise between erosion, performance, and costs.

Heavy-duty centrifugal fans are employed for the transport of dust-laden flows in industrial plants, for cement or steel production, or in energy production of plants and mine ventilation systems. These applications require the disposal of huge amounts of suspended particles, which can lead to a gradual erosion of the machine parts where impacts take place. The wear of the fan components can lead to premature failure of the machine, threatening human safety and reliability of the whole plant. The assessment of the wear severity of the machine, according to the process parameters, can aid the plant owner in scheduling overhaul operations along with the operative life of the machine. Moreover, through a reliable estimation of the wear severity, fan manufacturers can optimize the whole machine design process, from the material selection to the warranty time assessment. This work aims to develop a semi-empirical method capable of estimating the erosion severity of centrifugal fans employed for heavy-duty operations. A mechanistic model which accounts for the erosion on the blade leading edge is proposed. The model is derived by means of an analytical approach and accounts for a number of operating parameters (i.e.,, fan geometry, fan operating point, particle concentration in the flow, fluid properties, and material erosion resistance). A comparison of the theoretical model to the computational fluid dynamic (CFD) simulation results obtained through the use of multiphase particle tracking is also provided to assess the reliability of the present method.

The detrimental effects generated by the gas turbine fouling phenomenon are well known. Due to soil and soot particles ingestion, gas turbines experience performance drops related to greater fuel consumption and even lower efficiency. These effects are related to the modification of the shape and surface roughness of relevant surfaces (compressor and turbine blades and vanes, especially) due to the presence of a thin layer generated by micro/nanosized particle adhesion. Such contaminants are swallowed by the unit and, as a function of the operating conditions, adhere to the surface, causing a sort of dangerous coating to the surface. In this work, a microtomography analysis of the deposited layer is reported. The deposited layer has been generated using microsized soil and soot powders under specific impact conditions and substrate surface roughness similar to those in the cold section of a gas turbine compressor. The microtomography analysis has been carried out using the beamline at the ELETTRA Sincrotrone research center. Thanks to the resolution of the beamline, the detection of the three-dimensional internal structure of the soil and soot layers have revealed that within the layer, the structure is characterized by discontinuities. Soot and soil particles, even characterized by similar diameter distributions and test conditions, generate layer structures that differ by the magnitude, orientation, location of the internal discontinuities, and surface morphology (i.e., roughness). The comprehension of the packing process allows us to understand the adhesion process and define general guidelines to predict the fouling phenomenon.

Gas turbine particle ingestion may lead to the deposition of contaminants in the compressor section, inducing the performance losses of the whole engine. The economic losses derived from this issue push great interest in the investigation of such a phenomenon from a numerical and experimental standpoint. This article describes a quantitative approach to predict particle deposition on the vanes of an axial compressor starting from the flow field obtained employing computational fluid dynamic (CFD) simulations. The results are then compared to the experiments performed on the Allison 250 C18 compressor unit subject to particle ingestion under controlled conditions. The results derived from the experimental and numerical investigations are presented, providing insight into the mass deposited on the vanes and the corresponding zones most affected by the particle deposition issue. The methodology showed good agreement in the estimation of the predicted values of the deposited mass and the corresponding patterns through the compressor stages. The low-complexity approach proposed here could help the designer to predict the contamination of the stationary rows starting from a simple set of single-phase numerical results. Furthermore, with the implementation of this approach into the design path, the designer could reduce the impact of fouling, looking at the effects of their solutions under the fouling-reduction light.

Biomass represents a programmable renewable energy source that is useful for reducing issues related to the transfer from fossil fuels to the renewable energy era. The exploitation of biomass is strongly related to the development of power technologies that are designed to improve efficiency; however, at the same time, they have to be designed to improve the life cycle of the entire installation—especially in relation to maintenance operations. In this paper, a numerical analysis is proposed to assess the performance of a heat exchanger used for separating condensing tar from syngas generated by the gasification of lignocellulosic wood chips and pellets. The analysis included clean, fouled, and clogged conditions. Flow maldistribution characterized the inlet section of shell-and-tube configurations and was responsible for clogging phenomena. Starting from field detection, analyses of fouled and clogged conditions showed a reduction in the effectiveness of the heat exchanger, causing dangerous conditions for the internal combustion engine used to exploit the syngas flow.

Natural events and human activities are responsible for the generation and transport of large amounts of microsized particles, which could contaminate several engineering devices like solar panels, wind turbines, and aero-engines. In industrial processes, systems as heat exchangers, fans, and dust collectors are continuously affected by nanoparticles' interaction. For several applications, the adhesion of such nanoparticles is detrimental, generating safety and performance issues. Particle-to-particle and particle-to-surface interactions are well known, even if a general explanation of nanoparticle deposit growth is still unknown. In this paper, an interpretation of deposit growth due to nanoparticle deposition can predict particle adhesion, and layer accretion is proposed. A statistical model and a set of coefficients are used to generalize nanoparticle deposits' growth by an S-shaped function. In particular, the nanoparticle deposits grow analogously to a typical autonomous population settlement in a virgin area following statistical rule, which includes the initial growth, the successive stable condition (development), and catastrophic events able to destroy the layer. This approach generalizes nanoparticle adhesion/deposition behavior, overpassing the constraints reported in common deposition models, mainly focused on the mechanical aspect of the nanoparticle impact event. The catastrophic events, such as layer detachment, are modeled with a Poisson's distribution, related to material characteristics and impact conditions. This innovative approach, analogies, and coefficients applied to common engineering applications may be the starting point for improving the prediction capability of nanoparticle deposition.

Compressor fouling is one of the main causes of performance degradation of gas turbines. Miscrosized particles adhere to the blade surfaces increasing the surface roughness and modifying the airfoil shape. In the present work, the contamination of the Allison 250 C-18 compressor engine with four sorts of micrometric dust has been provided. The tests were performed changing the

Particle adhesion characterizes compressor fouling, which its comprehension represents the basis for predicting the gas turbine performance losses, accurately. The airborne micrometric particles that enter the compressor can deposit on the internal surfaces, causing the loss of performance of the machine. The analysis of the performance losses of a multistage compressor in relation

Surface material loss due to erosive wear is responsible for the increased cost of maintenance and downtime in industries. Hence, hardfacing is one of the most valuable and effective techniques employed to improve the wear resistance of heavy-duty components. The present paper investigates the microstructural and erosive wear characteristics of a hypereutectic high-chromium cast iron, considering the erosion resistance, resulting from the impact of micro-sized particles, of both as-received and heat-treated conditions. Micro-sized particles involve the erosion-resistant characteristics of carbide and matrix, contemporary. Due to this, the enhancement of the matrix strength could improve the mechanical support to withstand cracking deformation and spalling. Accordingly, the effect of a destabilization heat treatment on the microstructure was firstly investigated by hardness tests, X-ray diffraction analyses, optical and scanning electron microscopy. Specifically designed erosive tests were carried out using a raw meal powder at an impingement angle of 90°. The resulting superior wear resistance of the heat-treated samples was relayed on the improved matrix microstructure: consistent with the observed eroded surfaces, the reduced matrix/carbides hardness difference of the heat-treated material is pivotal in enhancing the erosion resistance of the hardfacing. The present results contribute to a better understanding of the microstructure–property relationships concerning the erosive wear resistance.