To investigate the fluid flow characteristics of conventional Ceramic Foam Filters (CFFs) of grades 30 and 50, a 2D macro-scale geometry was generated by converting pixel grid images of the filters into vector format images. The flow behaviour through the filter channels was then numerically modelled using the Stocks equation within the Creeping Flow interface of COMSOL Multiphysics®. Through modelling, the average interstitial velocity was estimated and found to be higher than the corresponding value obtained from the Dupuit-Forchheimer equation. The discrepancy obtained suggested that the flow behaviour within the filter channels differed from that based on the simplified assumptions of the equation. The porosity and permeability of the CFFs were evaluated during the post-processing stage using surface integration and user-defined equations. The experimentally determined porosity closely matched the values obtained from the simulation model, demonstrating the reliability of the numerical approach. However, the permeability values from the simulation of CFFs of grades 30 and 50 were higher than those obtained experimentally. This discrepancy can be attributed to the larger channels in the generated geometrical pattern compared to the original CFF structure. The present findings highlight the effectiveness of the proposed methodology in developing a representative macro-scale geometry for CFFs and in simulating fluid flow behaviour.
Keywords: COMSOL Multiphysics®; DC casting of aluminium; aluminium filtration; aluminium recycling; ceramic foam filters (CFFs); permeability of CFFs.