Chemical Engineering Science 58 (2003) 49654973

www.elsevier.com/locate/ces
3-D numerical simulations of ows in a cylindrical pleated lter
packed with activated carbon cloth
A. Subrenat

, J. Bellettre, P. Le Cloirec
Ecole des Mines de Nantes, GEPEA UMR CNRS 6144, DSEE, 4 rue A. Kastler, BP 20277, 44 307 Nantes Cedex 3, France
Received 24 June 2002; received in revised form 12 November 2002; accepted 4 July 2003
Abstract
This paper focuses on activated carbon cloths used for VOC treatment. The studied device is a cylindrical pleated lter that is developed
for the implementation of these materials in dynamic systems. 3-D numerical simulations of ows have been performed to determine
the ow structure in this kind of geometry. The analysis of the ow structure reveals preferential ow directions in the pleated medium.
The local velocity range near the fabric could be 10 times higher than the average velocity calculated for the whole developed surface of
the lter, but even the maximal value of the velocity (0.3 m s
1
) is acceptable for adsorption. Overlap phenomena are revealed and dead
zones estimated. The inuence of the number of pleats in such a device on the aerodynamic performance is also studied.
? 2003 Elsevier Ltd. All rights reserved.
Keywords: Adsorption; Fluid mechanics; Porous media; CFD; Pleated lter; Activated carbon cloths
1. Introduction
Environmental regulations demand the design and devel-
opment of increasingly ecient VOC treatment processes.
Several processes use the adsorption phenomena of organic
molecules onto a porous material. It is thus essential to
improve and optimise this type of installation in terms of
porous material and reactor geometry. In this context, acti-
vated carbon cloths, recent forms of adsorbent, have been
developed. Previous studies have shown their eciency in
terms of adsorption capacities and kinetics (Brasquet & Le
Cloirec, 1997; Subrenat & Le Cloirec, 2000). Moreover,
the Joule eect heating of these cloths could be used as a
regenerative process because of their interesting electrical
properties (Subrenat, Bal eo, & Le Cloirec, 2001). Their tex-
ture promotes new implementations in dynamic systems of
these media and the design of new adsorbent reactor and
lter geometries. The aerodynamic behaviour of these sys-
tems is one of the most important considerations in the de-
sign and the sizing of such an air treatment process, in terms
of pressure drops and ow structure. Indeed, it is important
to limit the preferential ow directions of the uid into the

Corresponding author. Tel.: +33-2-51-85-82-93;

fax: +33-2-51-85-82-99.
E-mail address: albert.subrenat@emn.fr (A. Subrenat).
adsorbent fabric in order to avoid a premature breakthrough
point of the lter, and thus to guarantee an emission level in
accordance with future standards (increasingly low). Cylin-
drical pleated lters using activated carbon cloths have al-
ready been designed and used to perform pressure drops and
adsorption capacity measurements. Experimental results re-
veal the eciency of such a geometry and the diculty of
sizing the pleat number in this kind of device (Subrenat,
Bal eo, & Le Cloirec, 2000). 2-D numerical simulations of
ow have already been performed to describe and envis-
age the ow structure and the pressure drop in such reactors
(Chen, Pui, & Liu, 1995; Bal eo, Subrenat, & Le Cloirec,
2000). In this description of the reactor, the pleated medium
is modelled overall by a porous zone, taking into account
the material permeability and the pleating eects. Thus, it
does not allow the precise study of the ow structure near
the adsorbent and, more particularly, the preferential ow
directions into the pleated medium. This is a very important
consideration for the eciency of the lter.
The objective of the present study is to evaluate in three di-
rections the ow characteristics in such a cylindrical pleated
lter. With this intention, the computational uid dynamic
is used. The geometry of the lter is precisely described by
a 3-D representation of the system. The physical proper-
ties of the medium are rst experimentally determined. Nu-
merical simulation pressure drop results are then compared
0009-2509/$ - see front matter ? 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ces.2003.07.012
4966 A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973
Fig. 1. Cylindrical pleated lter geometry.
Fig. 2. Geometry of the reactor.
with experimental data. Finally, an analysis of ow struc-
ture through the pleated lter is presented and discussed.
Particular attention is given to the possibility of accurately
predicting quantitative pressure losses and distribution of
the ow rates in the lter device. The design and sizing of
such a lter is carried out taking into account the optimisa-
tion in terms of pressure drop, residence time of the uid in
the adsorbent and also industrial constraints, such as the ad-
sorbent mass per lter, width of the manufactured cloth and
pleat techniques. So, a rst empirical geometry is proposed
and studied taking into account most of the industrial con-
straints. Then, other geometries are simulated with dierent
numbers of pleats to examine the pleat angle eect on the
ow velocity distribution in the medium.
2. Materials and methods
A cylindrical pleated lter using activated carbon cloth
was built and set up in a pilot plant for pressure drop exper-
imental measurements. The precise geometry of this lter
was also used to perform a numerical simulation of ows.
In this way, calculated and measured pressure drops could
be compared to validate the simulation method.
2.1. Filter device
The lter is made of pleated activated carbon cloth
(Fig. 1). It is positioned between an open and closed ange.
The geometrical characteristics of this lter are the inner
diameter (noted d
11
), the outer diameter (noted d
12
), the
length of the lter (noted L
1
) and the number of pleats (N).
The lter is enclosed in a cylindrical reactor. The geomet-
rical characteristics of the reactor (see Fig. 2) are the inner
diameter (noted d
21
), the external diameter (noted d
22
) and
its length (noted L
2
).
Table 1
Characteristics of the studied lters
Filter reference P-10 P-30 P-45 P-60
Number of pleats 10 30 45 60
Pleat angle (

) 36 12 8 6
Developed surface (m
2
) 0.18 0.51 0.77 1.02
Adsorbent mass (g) 78.65 225.64 337.42 449.42
Table 2
Main characteristics of the material used
Cloth reference RS-1301
Weave 3-ply serge
Carbonisation temperature (

C) 1300
Activation process H
2
O
Activation temperature (

C) 1300
Porous volume (cm
3
g
1
) 0.743
Microporous volume (cm
3
g
1
) 0.506
Median pore diameter (

A) 7.3
Specic surface (BET) (m
2
g
1
) 1300
Thickness (mm) 0.60
External porosity (%) 87
Specic weight (g m
2
) 220
In this study, the dimensions of the system are the fol-
lowing:
d
11
= 0.05 m, d
12
= 0.1 m, N = 45 pleats, L
1
= 0.34 m,
d
21
= 0.036 m, d
22
= 0.16 m, L
2
= 0.41 m.
Hence, the total developed surface of the lter (noted
S
lter
) is about 0.76 m
2
. This lter geometry (named P-45)
is a realistic design in terms of industrial manufacturing and
constitutes an interesting device to study. Other geometries
will also be studied. All the dimensions of these lters are
the same as the P-45 lter previously described, except for
the number of pleats. The main characteristics of the studied
lters are summarised in Table 1.
2.2. Medium used
This lter has been especially designed for VOCtreatment
but may also be used for water applications. Hence, the pleat
is made of a recent form of adsorbent well known for its
interesting adsorption capacities, activated carbon cloth. The
main physical characteristics of the material used in this case
are given in Table 2, although only geometrical parameters
are required to perform the present work.
A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973 4967
The medium used in the studied lter is composed of two
RS-1301 activated carbon cloth layers with a total thickness
(denoted e) of 1.2 mm, pleated together.
3. Model description
3.1. Equations governing turbulent ow
The uid dynamics core model used has been described
in detail elsewhere (Bellettre, Bataille, & Lallemand, 1999;
Bal eo et al., 2000). It consists respectively of mass (1) and
momentum (2) conservation equations where the Reynolds
decomposition has been applied:
c
cx
i
(j u
i
) = 0, (1)
c
cx
)
(j u
i
u
)
) =
c
cx
i
+
ct
i)
cx
)
+ jq
i

c
cx
)
(ju

i
u

)
) + S
i
(2)
and of a turbulence quantities transport equation. The choice
of a turbulence regime is made because of the Reynolds
numbers involved in the range of the studied uid velocities
(Re = 24009100 at the device inlet).
In Eqs. (1) and (2), j is the uid density, u
i
is the velocity
component in the i direction, is the pressure, t
i)
is the
viscous stress tensor and q
i
is the gravitational acceleration
in the i direction. Inside the porous medium, momentum
(2) is augmented by a source term, S
i
, incorporating the
additional pressure gradient in the porous medium (dened
later by Eq. (5)). This source term is valid whatever the ow
regime is (Bal eo et al., 2000; Fluent, 1998). In practice, its
value makes the other terms of Eq. (2) negligible except the
pressure one. This leads to a computation equivalent to the
replacement of the momentum equation by a pressure drop
law. In the present study, the owis considered as steady and
isothermal while the porous material properties are isotropic.
The thermophysical properties of the uid are set constant
(j = 1.225 kg m
3
and j = 1.7894 kg m
1
s
1
). Constant
density is assumed because the expected pressure drops are
low compared to the absolute atmospheric pressure.
Momentum equations (2) are closed by the standard kc
model (Jones & Launder, 1972) because no complex ow
structures (such as recirculations) are expected. Hence, there
is no need to use a higher order closure turbulence model.
3.2. Boundary conditions
Close to the solid walls, the standard law of the wall
(Launder & Spalding, 1974) accounts for the no-slip condi-
tion eect:
U
U

=
1

ln(E,
+
), (3)
where U

t
w
}j
w
, t
w
is the wall shear stress, is the
von-Karmans constant and E is an empirical constant set
equal to 9.0 (smooth wall). ,
+
is the wall unit (it is a di-
mensionless coordinate dened by relation (4)).
The assumption of an equilibrium turbulent boundary
layer is adopted, and the wall unit ,
+
is computed as
,
+
=
jU

o
j
=
jC
1}4
j
k
1}2

o
j
, (4)
where o is the distance from the wall and k

is the near wall

value of the turbulent kinetic energy (C
j
being a constant
of the turbulence model).
Boundary conditions for k and c values can be found in
Bellettre et al. (1999).
At the inlet of the device, a constant velocity value is
imposed. At this location, the turbulence intensity, I , and
the hydraulic diameter, d
h
, are set respectively at 10% and
0.16 m (i.e. d
22
), leading to the boundary conditions for
k and c equations. The reference pressure is xed at the
inlet. Its value is 101325 Pa. It may be added to the relative
static pressure deduced from the ow calculation in order
to determine the absolute pressure. Finally, at the outlet of
the device, the diusion ux normal to the exit surface is
assumed to be zero. This corresponds to an outlet boundary
condition of a developed ow.
3.3. Numerical method
The numerical procedure is based on a nite volume ap-
proach with quadrilateral control volumes and structured
meshes. The diusion terms are discretised according to
a central dierence method and the convective terms us-
ing a power law scheme (Patankar, 1980). Pressure ve-
locity coupling is calculated with the SIMPLE cell-centred
scheme (Patankar, 1980). The discrete algebraic equations
are solved using a line-by-line tri-diagonal matrix (Fluent,
1998).
Furthermore, the convergence of the results is tested ac-
cording to two criteria. First, all the normalised residuals
must be less than 10
3
. Secondly, supplementary iterations
do not change the calculation results (the evolution is less
than 0.5%).
3.4. Computational domain and grid
The geometrical symmetry of the system enables only a
small part of the lter to be described, that is to say a volume
including only one half pleat (Fig. 3). The three directions
are indicated in Fig. 3, the origin of the positions being
located at the inlet on the device axis.
The mesh is unstructured and is composed of 350,000
nite volumes with a higher density close to the porous
media. Inside the porous media, seven nodes occur along
the thickness. The law of the wall (Launder & Spalding,
1974) is used only for the rst point over the solid walls.
This point is set in order to stay in the validity domain of the
law without going into the laminar sublayer (,
+
11.2, as
explained in detail in Bellettre et al., 1999). In the present
case, a minimum distance between the solid walls and the
4968 A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973
Fig. 3. Computational domain.
rst cells set at 0.5 mm enables the condition ,
+
11.2 to
be respected.
3.5. Determination of porous medium properties
The pressure drop due to the porous medium is introduced
in the source term of the momentum equations (5). It is
expressed as
=
j
:
J + C

1
2
jJ|J|

, (5)
where : is the porous medium permeability, C is an
inertial factor and J is the supercial velocity close to the
medium.
The physical parameters (: and C) of the medium may
be deduced from experimental pressure drops performed in
planar conguration (Fig. 4).
The pressure drop due to the two layer medium is a func-
tion of the supercial velocity (which is also the mean ve-
locity in the device), and is tted by the following classical
polynomial expression:
= a
1
J + a
2
J
2
= 2340.8J + 3192.2J
2
, (6)
where a
1
is a viscous term coecient and a
2
is the inertial
coecient.
Fig. 4. Planar device.
One may write, integrating in the ow direction (noted
O
x
):
=

e
0
dx =

e
0

j
:
J +
C
2
jJ
2

dx
=
je
:
J +
Ce
2
jJ
2
. (7)
By identication of Eqs. (4) and (5) one obtains
: =
je
a
1
, (8)
C =
2a
2
je
. (9)
The numerical values for the two layer medium (referred to
as RS-1301) are
: = 1.07 10
11
m
2
and C = 7.30 m
1
.
4. Results and discussion
4.1. Validation of the numerical simulations in the case
of the 45 pleats lter
In order to validate the simulations, the computational
pressure gap between the inlet and the outlet of the device is
compared with the measured ones (Fig. 5). The lter device
described in Part 2 is used to perform experimental pressure
drop measurements. Satisfactory agreement is obtained be-
cause the discrepancy is always less than 200 Pa. This dis-
crepancy between numerical and experimental results is sig-
nicant only in the case of the lowest volumetric ow rate. It
is important to note that the pressure drop due to the porous
media is less than 10% of the total pressure drop in the de-
vice (for example, 140 Pa against 1750 Pa for the highest
studied ow rate, 2.86 10
2
m
3
s
1
). Thus, not only the
porous pressure jump but also all the pressure losses due to
singularities and wall friction are well predicted.
Validation of the numerical method is also carried out
by testing the eect of a mesh modication on the com-
putational results. A slightly dierent mesh is tested by
increasing the cell number by 10%. Results are shown in
Figs. 5 and 6 regarding, respectively the total pressure drop
A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973 4969
0
500
1000
1500
2000
0 5.10
-3
10.10
-3
15.10
-3
20.10
-3
25.10
-3
30.10
-3

Q (m
3
.s
-1
)

p

(
P
a
)
Experiments
Simulation 2
Simulation 1
Fig. 5. Comparison of predicted and measured pressure drops.
and the map of the velocity component that is normal to the
upstream side of the porous medium (dened U
n
later). No
signicant gap is observed. Thus, the rst mesh is kept for
the following simulations.
4.2. Analysis of the ow structure in the case of the 45
pleats lter
An example of stream lines is plotted in Fig. 7. The
ow coming inside the device seems to be rather uniformly
Fig. 6. U
n
velocity (component that is normal to the surface) on the upstream side of the porous layer (Q = 2.86 10
2
m
3
s
1
).
Fig. 7. Stream lines inside the device (Q = 2.86 10
2
m
3
s
1
).
distributed when it crosses through the porous layer. Thus,
the surface of the porous medium seems to be correctly used.
In contrast, if the ow direction is reversed, the useful sur-
face of the medium becomes very small (as shown in Fig. 8).
Flow direction is thus kept as in the rst conguration in
the following work.
Present simulations provide the characteristics of the ow
inside the device. The relative pressure eld is rst given in
Fig. 9. Before analysing this relative pressure eld, it could
be interesting to note that the total applied force of the whole
device is around 10 N in the case of the highest volumet-
ric ow rate. This force is essentially due to the pressure
force (resulting from the integration of the dierences be-
tween internal and external pressure), the viscous force be-
ing negligible in the present case. The pressure (plotted in
Fig. 9) normally decreases from the inlet to the outlet ex-
cept for just before the upper part of the bottom wall where
the kinetic energy of the ow is changed into static pres-
sure. This increase in pressure above the last part of the lter
favours the passage of uid. This will now be analysed in
detail.
The component of the velocity which is normal to the
lter surface is directly linked to the local volumetric ow
rate. Its calculation leads to an accurate knowledge of the
ow rate distribution across the lter. The velocity normal
to the porous layer, U
n
, is directly deduced from the angle
of the lter pleats (5

) according to Eq. (10):

U
n
=0.087U
x
0.996U
,
. (10)
4970 A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973
Fig. 8. Stream lines in the opposite ow direction (Q = 2.86 10
2
m
3
s
1
).
Fig. 9. Relative static pressure eld (Q = 2.86 10
2
m
3
s
1
).
Fig. 10. Flow distribution in the upstream side of the medium with the 45 pleats lter.
Fig. 10 presents this distribution on the upstream and
downstream side of the porous layer for a ow rate of
2.86 10
2
m
3
s
1
. We can observe a uniform and low
value (around 5 10
2
m s
1
) of the normal velocity in
the major part of the medium, which constitutes the useful
zone. Higher values of the velocity can be observed in
the bottom right corner of the lter, because of the slight
increase in the static pressure above this part that we previ-
ously observed. However, this higher value of the velocity
(close to 0.3 m s
1
with the highest volumetric ow rate)
constitutes a preferential ow zone (but it is small). We can
also observe a very low velocity zone (close to 0 m s
1
)
at the bottom of the pleats of the two sides of the medium
which constitute dead zones due to the overlap phenom-
ena.
Fig. 11 presents this distribution on the upstream side of
the porous layer (in front view) for the four ow rates stud-
ied. We can observe that the preferential ow decreases with
the volumetric ow rate. It must also be noted that the de-
tailed analysis of the simulation results did not reveal a high
A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973 4971
Fig. 11. Flow distribution in the upper side of the medium in front view (U
n
in m s
1
).
0
0.05
0.1
0.15
0.2
0.25
0.05 0.1 0.15 0.2 0.25 0.3 0.35
X = 0.048 m
X = 0.041 m
N
o
r
m
a
l

v
e
l
o
c
i
t
y

(
m
.
s
-
1
)
Z position (m)
X = 0.035 m
Fig. 12. U
n
curves at dierent distances from the axis (Q =
2.86 10
2
m
3
s
1
).
sensitivity of some calculated elds to the most important
parameter in the study: the volumetric ow rate.
Fig. 12 gives some curves of the normal velocity calcu-
lated at dierent distances from the device axis when the
highest ow rate is simulated. The increase in the ow near
the end of the lter is again observed. We can also notice
that the normal velocity is higher when the distance from
the axis is decreased. This is partially due to the reduction of
the cross-section experienced by the ow when approaching
the axis.
Fig. 13 shows velocity curves at dierent longitudinal
positions. The major part of the uid ows through the lower
part of the lter (X less than 0.042 m).
The normal velocity range observed in Figs. 12 and 13 is
compared with the calculated average velocity (noted U
aver
)
taking into account the total developed surface of the lter.
This is given by
U
aver
=
Q
S
lter
4 10
2
m s
1
,
where Q is the ow rate (m
3
s
1
) and S
lter
the total devel-
oped surface of the lter (m
2
).
The discrepancy between U
aver
and those observed in
Figs. 12 and 13 can essentially be explained by the larger
Fig. 13. U
n
curves at dierent longitudinal positions (Q =
2.86 10
2
m
3
s
1
).
thickness of the lter in its highest part. The thickness of the
lter is indeed greater in its upper part when two sides are
joined. Consequently, the porous medium allows very low
passage of uid in this upper zone, which has previously
been called a dead zone. However, the values of veloc-
ity in the central part of the media are always low enough
to perform adsorption eciently. The surface of the use-
ful zone is estimated by analysing the ow structure given
by the numerical simulations. It is about 0.29 m
2
, which is
37% of the total developed surface of the lter. Hence, the
average velocity in the preferential ow zone is given by
U

aver
10
1
m s
1
.
This value could be correlated with the normal velocity
curves described in Figs. 12 and 13. Hence, this analysis of
the computational uid dynamic simulations reveals that, in
this kind of geometry, the average ow velocity across the
medium is much higher than the velocity estimated for the
total developed surface of the lter. Thus, the quantity of
adsorbent actually used for adsorption phenomena is about
60% lower than the total amount of material used in the
lter. This fraction of useful media could be increased by
using wider pleats.
4972 A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973
Fig. 14. Flow distribution in the upstream side of the medium with the 30 and 60 pleats lter.
4.3. Inuence of the pleat number
Other geometries with dierent numbers of pleats
are studied at a total volumetric ow rate equal to
2.86 10
2
m
3
s
1
. The normal velocity eld upstream of
the medium is presented in Fig. 14 for the 30 and 60 pleats
lters. The velocity distribution is more homogeneous for
the 30 pleats lter. In this case, the pleat angle is higher
and so overlap phenomena are reduced, thus limiting the
preferential ow area.
In the case of the 60 pleats lter, the two sides of the
mediumare very close to each other and there is an important
overlap of the medium over the whole length of the pleat.
Hence, we can observe a large dead zone (at the bottom of
the pleat) and a large preferential ow zone in the hollow
of the pleat with very high velocity values up to 0.3 m s
1
.
The change in ow structure in relation to the pleat number
is complex. Low and high numbers of pleats generate dead
zones and thus preferential ow. The performance of such
pleated lters in terms of ow structure could also be anal-
ysed in terms of pressure drops (Fig. 15). Between 10 and
30 pleats, the pressure drops decrease due to an increase of
the developed area without a signicant overlap eect. Over
30 pleats, the pressure drops increase due to the increase of
the dead zone and thus preferential ow. The lowest pres-
sure drops and best ow distribution is obtained with the 30
pleats lter.
5. Conclusion
Activated carbon cloths are well-known adsorbents for
VOC treatments in terms of their physical and chemical
properties and adsorption capacities. The implementation of
these materials in dynamic systems may be done in new
0
500
1000
1500
2000
2500
3000
0 0 1
Flow rate = 2.86 10
-2
m
3
.s
-1

p

(
P
a
)
Pleat number
70 60 50 40 30 20
Fig. 15. Pressure drop as a function of the pleat number (Q =
2.86 10
2
m
3
s
1
).
reactor designs, such as cylindrical pleated lters. 3-D nu-
merical simulations of ows in this kind of geometry allow
the evaluation of the ow structure in such a lter and the
local ow velocity near the medium. The best ow direction
to increase the eciency of the lter is from outside to inside
the cylindrical lter. An increase in the ow velocity was
observed downstream of the lter due to the local increase
in the static pressure at the end of the pipe. Results also re-
veal overlap phenomena, which lead to dead zones and
thus preferential ows for the lter. With the tested geome-
try, 60% of the medium surface is well used for adsorption
in the case of a 45 pleats lter. Compared to the average ve-
locity estimated for the total developed surface of the lter,
local velocities across the medium are higher. Nevertheless,
A. Subrenat et al. / Chemical Engineering Science 58 (2003) 49654973 4973
the maximal velocity value (0.3 m s
1
) in such a geometry
is acceptable for adsorption in a dynamic system. The opti-
misation of cylindrical pleated lters using activated carbon
fabric may be achieved by decreasing the number of pleats.
In fact, the 30 pleats lter shows good results in terms of
velocity distribution and pressure drop. It corresponds to a
pleat angle of around 6

.
Notation
d diameter, m
d
h
hydraulic diameter, m
I turbulence intensity (I =

u
2
i
}u)
k turbulent kinetic energy, m
2
s
2
pressure, Pa
Q volumetric ow rate, m
3
s
1
S
lter
total developed cross-section, m
2
u velocity mean value, m s
1
u

velocity uctuation, m s
1
U

friction velocity, m s
1
(U

t
w
}j)
U
aver
average velocity, m s
1
, U
aver
= Q}S
lter
U

aver
average velocity in the preferential ow zone,
m s
1
X distance from the axis, m
,
+
wall unit ,
+
= jU

o}j
Z longitudinal position, m
Greek letters
o distance from the solid wall, m
c turbulent kinetic energy dissipation rate, m
2
s
3
j dynamic viscosity, kg m
1
s
1
j density, kg m
3
t shear stress, Pa
Subscripts
i, ) i, ) directions
close to the wall
w on the wall
x, , X, Y directions
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