Development of ice particle production system for ice jet process

This thesis presents a comprehensive study of the ice particle production process through experimentation and numerical methods using computational fluid dynamics (CFD) that can be used to produce ice particles with controlled temperature and hardness for use in ice jet (IJ) process for industrial applications. The analytical and numerical modeling for the heat exchanger system are developed that could predict the heat, mass and momentum exchange between the cold gas and water droplets. Further, the feasibility study of the deployment of ice particles produced from the ice jet system for possible cleaning and blasting applications are analyzed numerically. Although the use of Abrasive Water Jet (AWJ) technology in cutting, cleaning, machining and surface processing is a very successful industrial process, a considerable amount of secondary particle waste and contamination impingement by abrasive materials has been an important issue in AWJ process. Some alternate cryogenic jet methods involving vanishing abrasive materials, such as plain liquid nitrogen or carbon dioxide have been tried for these applications, but they also suffer from certain drawbacks relating to the quality, safety, process control and materials handling. The use of ice jet process involving minute ice particles has received relatively little attention in industrial applications. Some researches have concentrated on the studies of effects of Ice Jet outlet parameters of the nozzle and focus tube for machining soft and brittle materials. Most of the work in this area is qualitative and researchers have paid a cursory attention to the ice particles temperature and the efficiency of production of these particles. An extensive investigation to gain insight knowledge into the formulation of ice formation process parameters is required in arriving at a deeper understanding of the entire ice jet process for production application. Experimental investigations were focussed on the measurement of ice particle temperature, phase transitions, ice particle diameter, coalescence and hardness test. The change in ice particle diameter from the inlet conditions to the exit point of the heat exchanger wasinvestigated using the experimental results. These observations were extended to numerical analysis of temperature variations of ice particles at different planes inside the custom built heat exchanger. The numerical predictions were carried out with the aid of visualization studies and temperature measurement results from experiments. The numerical models were further analysed to find out the behaviour of ice particles in the transportation stage, the mixing chamber of the nozzle and focus tube. This was done to find out whether the methodology used in this research is feasible and if it can be used in applications such as cleaning, blasting, drilling and perhaps cutting. The results of the empirical studies show that ice particles of desired temperature and hardness could be produced successfully with the current novel design of the heat exchanger. At the optimum parameters, ice particles could be produced below -60°C, with hardness of particles comparable to gypsum (Moh's hardness of 1.5 to 3). The visualization studies of the process assisted in observation of the phases of ice at various points along the heat exchanger. The results of numerical analysis were found to agree well with the experiments and were supported by the statistical model assessments. Numerical analyses also show the survival of ice particles at the nozzle exit even with high-pressure, high-velocity water/air mixture