声波测量在搅拌釜中固体颗粒临界悬浮转速测定的应用

基于声发射测量技术,结合声信号的频谱分析、小波分解和R/S分析,获得了代表颗粒运动的特征信号频段（d₁、d₂频段）。同时,根据声波特征信号频段能量随搅拌转速的规律性变化,以固体颗粒碰撞壁面产生信号高频区域的声能量分率值为特征参数,提出了搅拌釜临界悬浮转速的测量判据,即声能量分率快速减少并开始趋于稳定时所对应的搅拌转速为临界悬浮转速。以水-玻璃珠体系为例,与目测法相比,声波法测量值的平均相对误差为3.51%,具有较高的精度。利用经典的Zweitering临界悬浮转速计算公式对声波法测得的实验数据进行拟合,计算值与测量值之间的平均相对误差为3.17%,表明公式对于临界悬浮转速的计算具有较高的准确性。由此获得了一种快速、准确、安全的搅拌釜反应器临界悬浮转速测量技术,有利于工业生产流程的优化和控制。     

利用声发射技术测量搅拌釜的淤浆悬浮高度

根据颗粒运动碰撞搅拌釜壁面产生声波的机理,结合声信号的频谱分析、小波分解和R/S分析,获得了代表颗粒运动的特征信号频段（d1、d2频段）。同时,基于声波特征信号频段能量沿搅拌釜轴向的规律性变化,提出了声波法测量搅拌釜淤浆悬浮高度的判据,即当声波特征信号频段能量或声波特征信号频段能量比出现阶跃性变化时的高度为淤浆悬浮高度。以水-玻璃珠体系为例,研究发现,无论是盘式涡轮还是桨式叶轮的搅拌桨,基于声信号测定淤浆悬浮高度的判据都能较好地得到验证,与目测法相比,其平均相对误差小于10 %,具有较高的精度。由此,获得了一种简单快捷、灵敏准确、非侵入式的搅拌釜淤浆悬浮高度测量技术,能够实现淤浆悬浮高度的实时监控。     

气液搅拌釜泛点转速的声波测量

通过对采集的搅拌釜中声信号的频谱分析、小波分解和R/S分析,获得了代表气液体系运动的特征信号频段（d₄、d₅、d₆频段）,针对声波特征信号频段能量随搅拌转速的规律性变化,提出了搅拌釜泛点转速的声波测量判据,即声能量分率快速增加并开始趋于稳定时所对应的搅拌转速为泛点转速。以空气-水体系为例,考察了不同通气量和静液位高度下的泛点转速,发现泛点转速随通气量的增加而增加,随静液位高度的增加而减小。与目测法相比,声波法测量值的平均相对误差为2.62%,优于传统的功耗法。由此获得了一种快速、准确、安全的搅拌釜反应器泛点转速测量技术,具有良好的工业应用前景。     

声波的多尺度分解与搅拌釜中浆液浓度的测量

利用声发射检测技术,根据固体和液体碰撞壁面产生不同频率的声发射信号的机理,结合小波分析,建立了搅拌釜中浆液浓度的预测模型,模型可以定量描述特征频段的声能量值随浆液浓度和搅拌转速的变化规律.以水-沙子体系为例,分别考察了浆液浓度为0～0.4 g·ml^-1、搅拌转速为350～550 r·min^-1条件下的声发射信号.实验发现,在完全悬浮的条件下,将声发射信号在0～30 kHz频率范围内作8尺度小波分解,第4、5、6等3个频段的声发射信号的能量值之和随浆液浓度的增加线性增加,随转速的增加呈三次方关系增加.而浆液浓度预测模型的计算值与实验值之间的平均相对误差为7.62%.研究表明,声发射检测技术能快速、准确地实现浆液浓度的在线检测.     

声发射信号分析与旋风分离器内颗粒粒径测量

采用声发射检测技术,在颗粒碰撞壁面产生声发射信号的机理上,结合小波算法,建立旋风分离器中固相颗粒粒径的声发射预测模型。在旋风分离器中,分别考察4种不同粒径的活性炭颗粒在0.137,0.214,0.296 m/s3个气相条件下的声发射信号,在流态稳定情况下,在0—500 k Hz采样频率范围内对声发射信号做二阶Daubechies9尺度小波分解,得到代表固体颗粒粒径的特征频段。实验发现特征频段下的声发射信号能量与气相速度的二次方、固相颗粒粒径存在线性关系。固相颗粒粒径的声发射模型的计算值与实际测量值之间的平均相对误差为14.3%,表明声发射技术能够实现固相颗粒粒径的准确、非侵入式的实时在线测量。     

声波信号多尺度分解与固体颗粒质量流率的测定

利用声发射检测技术，根据不同速度的颗粒撞击壁面产生不同能量的声发射信号，结合小波分析，建立了单粒径颗粒质量流率预测模型，该模型可以定量描述颗粒质量流率随特征频段的声发射信号能量与表观气速的变化规律。以空气-聚乙烯颗粒体系为例，分别考察了0.84、0.59、0.42、0.21 mm 4种线性低密度聚乙烯颗粒，在表观气速为4.62～6.35 m·s-1条件下的声发射信号。在考察的气速范围内，在0～500 kHz频率范围内对声发射信号做7尺度的小波分解，发现特征频段的声发射信号能量与表观气速平方之比和固体颗粒的质量流率呈线性关系。同时，基于单粒径颗粒质量流率预测模型，根据混合颗粒声发射能量为各单一粒径颗粒声发射能量的线性叠加，得到混合颗粒的质量流率预测模型，模型的计算值与称重法获得的质量流率相比，平均相对误差为4.15%，表明声发射检测技术能便捷、快速、准确、环保地实现循环管内颗粒质量流率的在线检测。     

声发射技术测量卧式搅拌床反应器中的料位

针对工业上普遍采用的核料位计即不安全环保又无法精确测定卧式搅拌床反应器料位的问题,提出了根据多点声发射信号来确定卧式搅拌床反应器料位的新方法,在工业规模卧式搅拌釜上进行了在线检测.结果表明,声发射技术与核料位计检测的料位变化趋势相同,二者相对偏差在15%左有,多点声发射技术能够检测出床层的高低端料位分布.由此获得了一种简单快捷、非侵入式的卧式搅拌床料位的实时测量技术.     

三轴搅拌釜不同桨径比下固-液悬浮特性的数值模拟

利用FLUENT软件对不同桨径比下立式三轴搅拌釜内单相和固-液两相混合过程分别进行三维数值模拟,对流场分析可知增大桨径比能改善立式三轴搅拌釜内流场的结构。利用修正速度判据得出不同桨径比下搅拌釜的临界悬浮转速,并通过计算临界悬浮转速下的搅拌功率,初步得出立式三轴搅拌釜桨径比的最佳取值范围在0.1～0.125之间。     

滚动轴承故障声学信号小波分析方法研究

采用小波分析方法,对非接触式声学测试中的滚动轴承故障声学信号进行多尺度分解,计算分解后每层信号的能量系数,结合噪声信号频率特性,去除能量较低的频段信号,对能量集中的频段进行波形重构,得到最能代表声发射源特征的信号,并利用功率谱分析了其频域特性。     

基于LED光源反射的液固搅拌槽中颗粒悬浮特性测定的光纤法

提出一种基于LED光源反射的液固搅拌槽中固体颗粒悬浮特性测定的光纤法. 在直径0.38 m、底部为椭圆形的搅拌槽中,用该法对水-二氧化硅两相体系固体颗粒悬浮特性进行了测定. 结果表明,测量临界离底悬浮转速Njs的测量点应选择在搅拌槽下部区域,径向位置对Njs影响不大;在整个固含率范围内,光纤测量法与取样法测量结果较接近,平均相对误差为4.0%,目测法测定结果比取样法与光纤测量法稍高,光纤法比取样法更快速、简便,具有适用于不透明容器的优势,能快速测定最小均匀悬浮转速Nus,Nus随固含率增大而增大.     

MIXING CHARACTERISTICS IN SLURRY STIRRED TANK REACTORS WITH MULTIPLE IMPELLERS

Hydrodynamic parameters such as power consumption, gas holdup, critical impeller speed for solid suspension and mixing time were measured in slurry stirred tank reactors with multiple impellers. The experiments were mainly conducted in a stirred tank of 0.2mi.d. with baffles. It contained two four-pitched blade downflow turbines for gas dispersion and one Pfaudler type impeller for solid suspension. As a part of scaling studies, additional experiments were also carried out in a larger stirred tank reactor (0,8m i.d.) geometrically similar to the smaller one. Glass beads and polymeric particles were used as a solid phase. Solid concentration was in the range of 0-20% (K/K). Tap water and methanol were used as a liquid phase

The power consumption decreased due to an introduction of gas and the presence of solids caused a decrease in the extent of reduction in power consumption. A correlation for power consumption in aerated slurry systems was proposed, It was found that the presence of solids is responsible for a decrease in gas holdup. A new correlation for gas holdup in gas-liquid-solid three-phase stirred tank reactors was developed. It fit the present experimental data reasonably. The critical impeller speed for solid suspensions increased with increasing gas flow rate. However, its increase was rather smaller as compared with the predictions of the correlations available in the literature. We proposed a correlation of the critical impeller speed for solid suspension in the presence of gas. The mixing time complicatedly increased or decreased depending on gas flow rate, impeller speed, solids type and concentration.     

改进型INTER-MIG搅拌槽内固液悬浮特性的数值模拟

应用CFD软件Fluent 12.0和并行计算机工作站对双层改进型INTER-MIG桨式搅拌槽内的固液悬浮特性、临界离底悬浮转速及功率消耗进行数值模拟,分析了在固体体积分数as=30%下,转速n、桨叶离底距离C1和桨间距C2等因素对搅拌槽内颗粒悬浮特性的影响. 结果表明,在一定的转速和桨径下,改变C1和C2会改变流场的局部结构,选取适合的C1和C2可使固液混合更均匀,有利于颗粒悬浮和整个搅拌槽传质传热的进行. 最佳桨叶离底高度与槽径比为0.36,最佳桨叶间距与槽径比为0.44;在该最佳工况下临界离底悬浮转速Njs=118.3 r/min;得到既能达到完全离底悬浮、又能使搅拌功耗最小的最佳转速为n=124 r/min.     

Design factors affecting the dynamic performance of soil suspension in an agitated,baffled tank

The effects of particle size, impeller clearance and impel er speed are assessed to show how condition variations influence power consumption in the water-solid slurry suspension in an agitated tank. The energy efficiency of slurry height variation, impel er type and diameter, and solid movement speed has been investigated with six soil series stirred in a soil-water slurry. Coarser sand particles are observed to significantly increase power consumption, while finer particles, for instance clay, decrease the stirring power requirement. The 3-blade HR100 SUPERMIX? impeller manufactured by SATAKE general y performs more efficiently than a conventional 4-pitched blade turbine. The impeller's geometric design, including diameter and number of blades influences the impeller's energy efficiency, and HR100 impellers with greater diameters remarkably reduce power consumption. The tests demonstrated that the power required to provide off-bottom solid suspension and solid dispersion can be reduced dramatically by increasing the slurry height rather than by accelerating the impel er, if this option is possible.     

无挡板搅拌槽中液－固体系的分散特性

在内径0.3 m、高0.45 m的无挡板搅拌槽内,采用直径0.15 m的三叶70o下推斜叶透平桨(PBTD, Pitched Blade Turbine Downflow)进行水-二氧化硅两相体系液固分散特性的研究. 应用PC-6A粉体浓度测量仪对体系中颗粒局部浓度进行测定. 考察了颗粒平均相含率为0.005的条件下,不同搅拌转速、搅拌桨离底高度对颗粒局部浓度分布的影响. 结果表明,采用较高搅拌转速、较低的搅拌桨离底高度有利于固体颗粒的悬浮. 本实验中,在搅拌转速为173 r/min、搅拌桨离底高度为0.08 m的操作条件下,颗粒悬浮效果最好.     

Suspension of solid particles in multi‐impeller three‐phase stirred tank reactors

Solids suspension characteristics in gas—liquid–solid three‐phase stirred tanks with multi‐impellers were experimentally examined. Minimum impeller speeds for ultimately homogeneous solid suspension have been measured stirred tank reactors. Three impellers were installed: two four‐pitched blade downflow disk turbines and one Pfaudler type impeller chosen to provide good gas dispersion and to accomplish off‐bottom suspension of solid particles, respectively. Gas dispersion causes an increase in particle sedimentation associated with a decrease in power consumption and as a result, minimum impeller speeds for ultimately homogeneous solid suspension increase with increasing gas flow rates. A correlation was developed to predict minimum impeller speeds for ultimately homogeneous solid suspension. The proposed correlation, which agrees satisfactorily with the experimental results, is expected to be useful in design and scale‐up.     

新型自吸式多相搅拌槽临界悬浮特性的实验研究

在不通气的情况下,对新型多相搅拌槽进行实验,得出了其固相含量w、颗粒密度r、搅拌槽内径D与临界悬浮转速Nc的关系,在相同条件下,与给定结构尺寸的标准搅拌槽对比了临界悬浮转速. 结果表明,Nc随固相分率j增加和粒径dp增大而增大,不利于达到良好的悬浮效果;固相颗粒密度越大,临界悬浮转速随之增大;槽径增大使达到悬浮状态的临界转速降低. 该新型搅拌槽临界悬浮转速的关联式是Nc=6.3dp0.21(gDr/rL)0.45w0.19/D0.55;同一固相分率下,新型多相搅拌槽的临界悬浮转速比标准搅拌槽降低了30%,在较低转速下就能使颗粒悬浮.