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w
= h
w
(T
B
T
w
) (17)
The thermal properties, including heat conductivity and
specic heat capacity, change with temperature and the
phases in the workpiece.
The potential for the transformed phase, i.e., the energy
absorbed or released in phase transformation processes, is
calculated from
q
p
=
X
n
i=1
L
i
V
i
(18)
In the present study, the isothermal timetemperature-trans-
formation (TTT) diagram and Scheil's nucleation `additivity
principle' were used to calculate the fraction of the phase
transformed. The volume fraction of austenite transformed
on heating or of austenite transformed into pro-eutectoid
ferrite, cementite, pearlite, bainite and martensite in cool-
ing can be given [11,12] by (except for the martensitic
transformation):
V
i
= 1 exp(b
i
t
n
i
) (19)
The values of b
i
and n
i
depend on the transformation
temperature and are tted for each individual grade of steel
from the transformation curves plotted in the isothermal
TTT diagram. i = 16 refer to austenite, ferrite, cementite,
pearlite, bainite, and martensite, respectively.
Because the athermal transformation of austenite into
martensite below the martensite starting temperature M
S
does not depend on time, it can be described by
V
M
= 1 exp[a(M
S
T)[ (20)
where a is a coefcient depending on the components of
steel, and a = 0:011 K
1
for most steels.
Fig. 3. The variation of the radiative view factor.
W.M. Gao et al. / Journal of Materials Processing Technology 125126 (2002) 170178 173
3.2. Carbon transfer
The transfer of carbon in the workpiece surface is gover-
ned by the difference between carbon concentration in the
gas near the workpiece surface C
g
and the carbon concen-
tration C
S
at the steel surface. The carbon transfer ux is
dened by
j
C
= b
2
(C
g
C
S
) (21)
where the mass-transfer coefcient b
2
is determined by
1. The absorption behaviour of hydrocarbon complexes
and other kinds of gaseous molecules, such as CO, CH
4
,
etc., on the steel surface.
2. The decomposition of hydrocarbon complexes into
atomic carbon.
3. The desorption of oxygen obtained through the decom-
position of CO.
4. The reaction of oxygen with H
2
or CO.
Because of the high temperature in carburising, the absorp-
tion of hydrocarbon and desorption of oxygen in the above
processes are signicant for the mass transfer. A universal
relation determining the mass-transfer coefcient b
2
is
b
2
= b
0
exp
E
RT
(22)
If the surface mass-transfer coefcient is dened by
b =
j
C
B
C
S
(23)
b is given by
1
b
=
1
b
1
1
b
2
(24)
because the carbon transfer ux in Eq. (21) should equal the
diffusion transfer ux in Eq. (9). Fick's 2nd law was applied
to simulate the mass transfer within the workpiece.
4. Results and discussion
The mathematical model given above was integrated into
FLUENT 5.5, a nite difference CFD software developed by
Fluent Incorporation. A mesh size of 10 mm was chosen for
both the particle layers, while 50 mm was used for both
porous medium and the immersed object. The wall of the
immersed surface and that of the emulsion or bubble phase
were then analysed at the same heat and mass-transfer uxes
and temperature. The minimum uidising velocity U
mf
used
was the gas velocity in the emulsion. The time for which the
emulsion phase or bubble phase contacted the immersed
surface was determined by the emulsion residence time t
r
and bubble time fraction f
b
proposed by Thring [13]. The
time step in the calculation was chosen by dividing the
residence time t
r
into 10 intervals. Normally the time step Dt
was 0.040.1 s depending on bed conditions.
4.1. Heat transfer
The same operation and uidising medium parameters as
were used in the experiments reported in the literature were
used in the present work to validate the model. Table 1 lists
the experimental conditions used in this work, which were
adopted from the various sources cited in the table.
Figs. 4 and 5 allow comparison to be made of the total
heat-transfer coefcient (h
w
) and radiative heat-transfer
coefcient (h
r
) predicted from the model developed in this
work and the experimental results. It is found that the
predictions by the present model are very close to the
experimental results of H. S. Li et al. [15] and Saxena [3]
for a ne particle uidised bed. H. S. Li et al. [15] measured
the spatial average heat-transfer ux for particles of mean
diameter of 622 mm. Saxena and Mathur measured the total
heat-transfer and radiative heat-transfer coefcient for beds
of 559 and 751 mm sand particles at ve different bed
temperatures. A deviation of 25% predicted with the model
developed in this work is much lower than the 50%predicted
by other models [3]. For a large particle uidised bed, the
model over-predicts the total heat-transfer coefcient, as
suggested by comparison with the experimental results of
Pidwerbecki and Welty [14], who measured the total and
radiative heat ux around an immersed bronze tube of outer
diameter of 51 mm and inner diameter of 32 mm in a
uidised bed of large particles with a size of 2.9 mm and
temperature of 7001003 8C, probably due to different
uidising materials being used. The particles of 53.5%
silica, 43.8% alumina, 2.3% titania, and 0.4% other sub-
stances were used as the bed material in that work. In the
present work, pure silica sand was chosen as the uidising
medium.
In this work, the radiative heat transfer between emulsion
and immersed surface is simulated by directly calculating
Table 1
The experimental parameters of reference
Reference Immersed object Bed media Diameters (mm) Bed temperatures (8C) U/U
mf
Pidwerbecki and Welty [14] Horizontal bronze tube,
51/32 mm
Silica alumina others 2.900 700, 810, 908, 1003 1.01.5
H.S. Li et al. [15] Horizontal stainless tube,
40/20 mm
Silica sand 1.815, 1.103, 0.622 424, 618, 735, 872, 1028 1.02.0
Saxena [3] Sand 0.559, 0.751 112, 222, 472, 547, 712 1.02.0
174 W.M. Gao et al. / Journal of Materials Processing Technology 125126 (2002) 170178
the particle radiation based on the particle array assumed in
the double-particle layer and porous medium model. This
results in improvement in the accuracy of prediction of the
radiative heat-transfer coefcient. Fig. 5 shows that the
predictions from this model are in good agreement with
the experimental data for all particle sizes, mostly being
within 25%.
The heat transfer between a uidised bed of 200 mm silica
sand particles with an emissivity of 0.6 and the surface of an
immersed object with a temperature of 300 K and an emis-
sivity of 0.8 was simulated with different bed temperatures
and air uidisation number of 2.0 to enhance the under-
standing of the heat-transfer mechanism. Fig. 6 shows how
the variation in average temperatures of the gas and particles
in the emulsion change with distance from the immersed
surface at different residence times. It is clear that a change
in gas temperature only occurs within a distance of approxi-
mately 2/3-particle diameter and is less than one particle
diameter for the longest residence time, 10 s. The change in
the temperature near the immersed surface decreases loga-
rithmically with the increasing of the residence time.
The temperature of particles only change very slightly for
all residence times. Therefore, heat transfer between particle
surfaces facing the immersed surface is signicant to the
total heat transfer. Fig. 7 shows the distribution of heat-
transfer coefcients between the emulsion and the immersed
surface around a particle. It shows that the average heat-
transfer coefcient on the immersed surface at the point in
contact with particles is about 610 times that at the other
surfaces. The section with a high heat transfer is within a
Fig. 4. Comparison of h
w
predicted by the present model with experiments by Saxena [3], Hong Shun et al. [15], and Pidwerbecki and Welty [14].
Fig. 5. Comparison of h
r
predicted by the present model with the experiments by Saxena [3], and Pidwerbecki and Welty [14].
W.M. Gao et al. / Journal of Materials Processing Technology 125126 (2002) 170178 175
circle of diameter 0.5d
p
. Gas dynamics clearly show that the
gas is still in this section. The heat transfer can therefore also
be called conduction, as in the analyses of heat transfer by
most researchers [3] who consider that heat transfer consists
of conduction and convection. However, a uniform gas lm
of about 0.1d
p
has to be introduced into conduction models
to agree with experimental results. From the result of the
present simulation, the mean gas lm thickness in the
circular section of diameter 0.5d
p
is about 0.064d
p
.
Fig. 8 shows the effect of the bed temperature T
B
on the
total heat-transfer coefcient h
w
, convective heat-transfer
coefcient h
c
, radiative heat-transfer coefcient h
r
, and
relative radiative contribution h
r
/h
w
. The radiative compo-
nent h
r
, increases at a higher rate as the bed temperature
increases. In contrast, the total heat-transfer coefcient h
w
increases more slowly with bed temperature. The convective
heat-transfer coefcient h
c
increases with bed temperature
initially (less then 1000 K) at a smaller rate, and then
decreases when bed temperature is above 1000 K. A rela-
tively stable convective heat-transfer coefcient is found in
the high temperature uidised bed. The change in total heat-
transfer coefcient is mainly affected by radiation. Saxena
[3] summarised the relations between heat-transfer coef-
cient and other parameters:
h
w
= (1 f
b
)
k
eo
r
e
C
PS
t
r
1=2
f
b
se
t
(T
2
B
T
2
w
)(T
B
T
w
)
(25)
h
e
= (1 f
b
) k
eo
8
9
d
p
sT
3
B
r
e
C
PS
pt
r
1=2
f
b
q
rb
T
B
T
w
(26)
The effective emulsion density is assumed to be r
e
=
r
S
(1 d
mf
) and does not change with bed temperature.
Fig. 6. Variation of gas temperature in emulsion.
Fig. 7. Distribution of heat-transfer coefficient.
176 W.M. Gao et al. / Journal of Materials Processing Technology 125126 (2002) 170178
The emulsion residence time and bubble time fraction were
calculated from the correlations by Thring [13], and the
effective thermal conductivity was calculated from the
model of Kunii and Smith [16] at ambient temperature.
The component h
c
of the convective heat-transfer coefcient
in the total heat-transfer coefcient h
w
in Eqs. (24) and (25)
does not therefore vary with bed temperature.
Radiation becomes important with increase in bed tem-
perature. About 25% of the total heat ux comes from
radiation at a bed temperature of 1300 K, which was also
reported by Shafey et al. [17] who simulated conductive
and radiative heat transfers using an unsteady state packet
model.
4.2. Mass transfer
At present the diffusion coefcients D
g
of hydrocarbon
complexes and other kinds of gaseous molecules in uidised
beds, and the diffusion coefcients D
C
of carbon in most
alloy steels are not well documented and the mass-transfer
coefcient b
2
can only be determined under some special
experimental conditions. The so-called ``inverse method''
should therefore be used, by putting the measured distribu-
tion of the concentration of elements in the thermomecha-
nically treated layer and other heat treating parameters into
the mathematical model and then repeating the calculation
until D and b
2
are extracted.
In the present work, D
g
was assumed to be the diffusion
coefcient of CH
4
in air, D
C
be a constant of 0:248
10
4
mm
2
/s, while b
2
was determined using the model
developed by Zhu et al. [18].
The carbon distribution in a uidised bed with 1.2%
carbon and within an immersed object at different carburis-
ing times are shown in Fig. 9. This shows that the change in
carbon concentration in the emulsion and the bubble near the
surface of the immersed object is very small. The carbon
Fig. 8. Effect of bed temperature on the heat-transfer coefficients.
Fig. 9. Carbon profile curves in fluidised bed and within workpiece.
W.M. Gao et al. / Journal of Materials Processing Technology 125126 (2002) 170178 177
transfer is mainly controlled by the mass-transfer coefcient
b
2
and diffusion coefcient of carbon D
C
in the workpiece.
Because the mass-transfer coefcient b
2
on the surface of
the workpiece is only determined by the temperature as
indicated in Eq. (22), a result similar to that for heat transfer
is found. When the immersed object is at a steady carburis-
ing temperature, a constant surface mass-transfer coefcient
is obtained. However, b is actually affected by the carburis-
ing atmosphere and the uidisation parameters, namely
particle diameter, uidisation number, and the bed tempera-
ture. Further experimental work is needed to provide the
basis for an adequate understanding of the mass-transfer
mechanism in the uidised bed carburising process to allow
modication of the mass-transfer model.
5. Conclusions
The gas momentum, heat and mass transfers have been
calculated based on the model consisting of a double layer of
particles and a porous medium presented in this work.
Radiative heat transfer was investigated by simulating
photon emission in the particle array. The heat-transfer
model developed here shows a high accuracy for predicting
the coefcients of total and radiative heat transfer. The
convection is approximately constant, 25% of the total heat
rate is radiation in a heat treatment uidised bed at a
temperature of 900 8C. The heat-transfer coefcient on
the immersed surface near the particles is about 610 times
of that on the other surface. The heat and mass-transfer
model based on the simulation of gas dynamics can help to
understand the heat and mass-transfer mechanisms.
A theoretical model with coupling heat transfer, phase
transformation and potential for phase transformation in the
workpiece has been developed. Fick's 2nd lawwas applied to
simulate mass transfer within workpiece in thermo-chemical
processes. The simulation gives the transient heat and mass-
transfer coefcient, heat and mass-transfer ux on any sur-
face of workpiece, non-steady distributions of temperature
and carbon at any position of the workpiece during the heat
treatment process. This provides an insight into the optimisa-
tion of heat treatment processes in auidised bed furnace.
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