The numerical simulation of a new double swirl static mixer for gas reactants mixing

For the nitrogen oxide removal processes, high performance gas mixer is deeply needed for the injection of NH₃ or O₃. In this study, a new type of double swirl static mixer in gas mixing was investigated using computational fluid dynamics (CFD). The results obtained using Particle Image Velocimetry (PIV) correlated well with the results obtained from simulation. The comparisons in pressure loss between the experimental results and the simulation results showed that the model was suitable and accurate for the simulation of the static mixer. Optimal process conditions and design were investigated. When L/D equaled 4, coefficient of variation (COV) was < 5%. The inlet velocity did not affect the distributions of turbulent kinetic energy. In terms of both COV and pressure loss, the inner connector is important in the design of the static mixer. The nozzle length should be set at 4 cm. Taking both COV and pressure loss into consideration, the optimal oblique degree is 45°. The averaged kinetic energy changed according to process conditions and design. The new static mixer resulted in improved mixing performance in a more compact design. The new static mixer is more energy efficient compared with other SV static mixers. Therefore, the double swirl static mixer is promising in gas mixing.     

Improving mixing performance by curved-blade static mixer

This article addresses design modification to a flat-blade static mixer to enhance mixing performance. The static mixer elements used in this work consist of four blades with curvature made to intensify turbulent-like flow, while reducing the pressure drop. The blades were mounted on a cylindrical housing with 45° rotation relative to the axial direction. The mixer assembly was used in three different arrangements of 8, 10, and 14 elements for a range of Reynolds number between 600 and 7,000. The coefficient of variance (COV) of samples was used to measure the mixing quality. The curved-blade mixer provides considerable improvement in mixing quality compared with the flat-blade mixer and comparable to the SMX mixer. Compared with the flat-blade static mixer, the new design reduces the COV by up to about 50%. This effect is more pronounced when the number of mixing elements increases. Furthermore, the friction factors for the modified mixer, obtained at a wide range of Reynolds number, were apparently smaller than those for the flat-blade, SMX, and SMV mixers. The correlation presented for the friction factor, when all mixer arrangements and aspect ratios were considered, supports the experimental data with ±15% deviation.     

仿柳叶形静态混合器的流动及混合特性

对仿柳叶形静态混合器内混合气流进行了速度场与浓度场的试验研究,结果表明该混合器内速度场与浓度场偏差均达到了非常理想的效果（优于国家标准偏差值）。同时采用CFD软件对该静态混合器内的流场进行了数值模拟,试验与模拟的数值结果以及两者的浓度云图分布都有着较好的一致性。随后的研究结果表明：在混合元件尾迹区域出现了纵向涡和发卡涡来促进混合;在经过混合元件区域时因为湍流动能耗散率增加形成的高湍流动能耗散率区能够使物质交换更加频繁;整个静态混合器的流动阻力也主要发生在该区域,随之出现的返混现象也在一定程度上加强了混合效果。     

管型混合澄清槽内的液-液两相流的数值模拟

管型混合澄清槽在工业生产中具有广阔的应用前景。通过计算流体力学分别对管型混合澄清槽内的混合室和澄清室进行数值模拟,系统地探究了分散相液滴尺寸（d₃₂₌ 100~500 μm）、进料油水比（O∶A = 1∶1~1∶5）、入口挡板及入口位置对混合澄清效果的影响,并将模拟结果与传统方型混合澄清槽进行对比。结果表明,管型混合室内的流场分布更合理,不易形成流动死区。管型混合室内搅拌桨上方和下方形成压力更小的低压区,流体的湍动能更大,搅拌性能更好。在混合室中,降低分散相d₃₂和进料油水比能够提高混合性能。在澄清室中,提高分散相d₃₂和降低进料油水比能够提高澄清性能,入口挡板能够有效提高澄清性能。     

Effect of swirling addition on the liquid mixing performance in a T-jets mixer

Swirling addition to the stream is beneficial for the fluid mixing. This work aims to study the mixing process intensification in a conventional T-jets mixer by the swirling addition. After experimental verification by the planar laser-induced fluorescence technique, large eddy simulation with the dynamic kinetic energy sub-grid stress model is used to predict how the swirling strength (in terms of swirling number, S_w) and swirling directions affect the mixing performance, e.g. the tracer concentration distribution, mixing time, and turbulent characteristics in the T-jets mixers. Predictions show that the swirling strength is the key factor affecting the mixing efficiency of the process. The overall mixing time, τ₉₀, can be significantly reduced by increasing S_w. Vortex analysis shows that more turbulent eddies appear in the collision zone and the turbulent kinetic energy dissipation rate increases obviously with the swirling addition. When S_w is kept constant, the mixing process can be accelerated and intensified by adding swirling to only one stream, to both streams with the opposite swirling directions, or to both streams with the same swirling directions. Amplification of the mixing process by enlarging the mixer size or increasing the flow rates is also optimized. Thus, this work provides a new strategy to improve the mixing performance of the traditional T-jets mixers by the swirling addition.     

喷射式液液混和器与静态混和器复合的工程应用研究

喷射式液液混和器和静态混和器都是混和过程强化的重要设备。合理设计具有喷射式混和器、静态混和器的复合结构的新混和器能直接混和两种不同压力的流体,使压力较低流体混和后的压力有所提高,保证较好的混和效果。通过对工程实例的应用研究证明新的混和器能降低能耗,简化流程,提高经济效益。     

高压气体氛围中的聚氨酯非等温固化动力学

采用高压DSC对0.1~6 MPa压力范围二氧化碳（CO₂）及氮气（N₂）氛围中的聚氨酯非等温固化动力学进行了研究。利用Kissinger法及两种不同积分形式的等转化率法求取了聚氨酯固化过程的表观活化能E_a,在此基础上采用Málek法确定了固化反应的机理函数及动力学参数,得到固化反应动力学方程,并分析了高压CO₂及N₂的存在对固化过程的影响。研究结果表明,该聚氨酯体系的活化能随着反应转化率的增加呈现出典型的先减小后增加的S型反应特征,由于高压气体的静压作用及溶剂效应,体系的表观活化能随着气体压力的升高而逐渐降低,CO₂的溶剂效应明显强于N₂;利用Sestak-Berggren模型进行拟合,发现在不同压力的气体氛围中该模型与非等温测试得到的DSC曲线较为吻合,表明该体系在常压及高压气体存在下均符合自催化模型。     

喷射式液液混合器与静态混合器复合应用研究

喷射式液液混合器和静态混合器都是混合过程强化的重要设备。合理设计具有喷射式混合器、静态混合器的复合结构的新混合器,可以解决生产上的难题。新混合器能直接进行两种不同压力流体的混合,使压力较低流体混合后的压力有所提高,保证较好的混合效果,降低能耗,提高经济效益,简化流程。降低投资。     

Prediction of the viscosity reduction due to dissolved CO2 of and an elementary approach in the supercritical CO2 assisted continuous particle production of a polyester resin

The dissolution of CO₂ in a polymer causes plasticization of the polymer and hence, its viscosity is reduced. A model based on the free volume theory has been used for a polyester resin, which shows a considerable reduction in the viscosity due to dissolved CO₂. Therefore, supercritical CO₂ has been used as a processing solvent in the continuous production of micron size particles of the resin. Despite the viscosity reduction caused by the dissolved CO₂, an excess quantity of CO₂ with respect to its solubility limit has been used for micronisation of the polymer due to its high viscosity. The mixing of CO₂ and the polymer has not been possible in an extruder at high gas to polymer mass ratios and consequently, a simplified Kenics type static mixer has been used for the mixing purpose. In this study, the effect of various parameters such as temperature, pressure, nozzle diameter and gas to polymer mass ratio on the particle morphology and size has been studied. The experimental results manifest the technological as well as the theoretical insight into the particles production from a high viscosity material.     

Comparative analysis of different static mixers performance by CFD technique: An innovative mixer

The flow and mixing behavior of two miscible liquids has been studied in an innovative static mixer by using CFD,with Reynolds numbers ranging from 20 to 160. The performance of the new mixer is compared with those of Kenics, SMX, and Komax static mixers. The pressure drop ratio(Z-factor), coefficient of variation(CoV), and extensional efficiency(α) features have been used to evaluate power consumption, distributive mixing, and dispersive mixing performances, respectively, in all mixers. The model is firstly validated based on experimental data measured for the pressure drop ratio and the coefficient of variation. CFD results are consistent with measured data and those obtained by available correlations in the literature. The new mixer shows a superior mixing performance compared to the other mixers.     

In-line mixing for high reactive species using swirl flow ejector

An in-line mixing system mainly consists of an injecting part and a mixing part. We consider that the injecting part will be more important for highly reactive species, because some reactions terminate before the mixture reaches the static mixer. This issue has limited the applications of in-line mixing. In this study, we developed an improved injecting system to resolve this issue. We used a swirl f low ejector (SFE) in which a swirl driving f low is supplied from the entire inner circumferential surface and a suction f low is injected at the center of the channel. Through CFD simulations, we revealed that the suction f low is diffused by the swirl driving f low, and mixing proceeded rapidly. In the early step of mixing, the mixing time of the new system was around four times shorter than that of the conventional system. We also performed an experiment using reactive f luids that gel upon poor mixing, and we clearly demonstrated the effectiveness of the SFE. Finally, we found that the combined use of the SFE and the static mixer is the most effective approach.     

数值模拟静态混合器结构对PS/CO_2熔体温度的影响

利用专用CFD软件Polyflow对SMX型和Kenics型静态混合器中PS/CO_2发泡溶液进行数值模拟计算,分析比较不同板厚在不同元件个数条件下两种静态混合器消耗的压力损失,以及不同CO_2浓度对静态混合器压力损失的影响;并引入"离散系数"分析比较两种静态混合器出口温度均匀性的变化.数值模拟的结果表明:SMX型静态混合器冷却效果优于Kenics型静态混合器,并且SMX型静态混合器出口温度均匀性高于Kenics型静态混合器.     

共混纺丝组件用圆盘型静态混合器及模拟实验

从共混纺丝组件内部结构设计出发,根据静态混合器的混合原理,将组件内分配板设计成圆盘型静态混合器,每个分配圆盘中都设计出若干大小相等、径向均匀分布的菱形栅。通过复合纺丝模拟器的冷态模拟实验,分析模拟熔体在分配板流道内的流动混合状态。熔体经过菱形栅之间径向沟槽多次分割和汇集后,获得位置交换,完成多次的混合操作。结果表明,用于纺丝组件的圆盘型静态混合器能满足共混纺丝要求;将静态混合分配圆盘组配置在已有的纺丝组件内,其结构设计可行,混合效果显著。     

基于CFD的旋进旋涡流量计结构改进设计

为了减少150 mm口径旋进旋涡流量计的压损,提出了增加流量计起旋器导程和壳体喉部直径两种方案,在120～2100 m³·h^-1流量范围内,采用数值模拟和实验的方法研究了改进前后旋进旋涡流量计的压损特性与仪表系数,并对旋进旋涡流量计中压电传感器所在截面的内部流动特性进行了分析。通过数值模拟研究发现：两种方案均能降低流量计压损,但流量计的仪表系数均降低,不利于小流量的测量,且仪表系数精确度也有所变化。若仅考虑降低压损,同时增加导程和喉部直径比仅增加导程好。最后在音速喷嘴装置上对两种方案进行了实验,发现实验数据和数值计算结果变化趋势一致,达到了对流量计参数优化提高流量计性能的目的。     

沼气调峰用LNG混空装置的设计与测试

针对沼气产气量不稳定的问题,提出了采用LNG气化掺混空气作为沼气调峰气源的解决方案,设计并加工了一种LNG引射空气混合器,模拟生产实际对引射混合器的运行特性进行了实验研究。结果表明在引射器出口压力一定时,混气比(空气:天然气)随着进口压力的增加而显著提升;进口压力一定时,混气比随着出口压力的增加而逐渐减小;考虑进出口压力对混气比的共同作用时,提高进口压力,混气比随出口压力升高而降低的趋势减缓;提高出口压力,混气比随进口压力升高而上升的趋势加剧。为获得与沼气发酵罐相同的出口压力,引射器进口压力应为0.25 MPa。     

不同结构静态螺旋混合器强化湿法脱硫数值模拟

变螺距静态螺旋混合器可作为一种新型高性能气液传质脱硫装置,为优化其结构参数,利用欧拉-拉格朗日方法,在Barracuda^TM软件中建立了气液两相流动模型,并根据上述模型及二氧化硫吸收速率方程,分别模拟了静态螺旋混合器在不同变螺距系数m、长径比l/d、流道截面回转角φ下SO₂出口浓度和脱硫率的变化规律。结果表明：在反应物充足的情况下,脱硫率随m的增大而降低,并于m≥0.5时趋于稳定;脱硫率随l/d的增大而提高,并于l/d=11~13时趋于稳定,l/d=14时又出现上升;脱硫率随φ的增大而提高,并于φ≥720°趋于稳定。根据上述规律,结合压降等指标,给出了各结构参数的建议值：m=0.45,l/d=11,φ=630°,并在建议结构参数下进行了脱硫试验,SO₂出口浓度为19.56 mg.m^-3,脱硫率达99.35%,达到超净排放标准。为今后工业规模静态螺旋混合脱硫装置的设计与制造提供了依据。     

T型撞击流混合器内流动特性的PIV研究

采用粒子图像测速技术对入射管直径为3 mm、混合腔直径为16 mm的T型撞击流混合器内的流动特性进行了研究,考察了不同流速比和撞击轴线上方空间条件下混合腔内的速度和湍流动能分布. 结果表明,在相同入射管直径和流速下,撞击驻点位于混合腔中心处,无因次化的速度和湍流动能分布趋势基本一致. 高湍流动能区主要集中在撞击点附近区域,其无因次化数值是传统Rushton涡轮搅拌槽叶端处的3倍. 流速比对撞击驻点位置影响显著;减小撞击轴线上方空间可增加高湍流动能分布区域,利于物料混合.     

Continuous Processing of Monodispersed Titania Powders

A new continuous precipitation process for monodispersed ceramic powders using a static mixer was developed. Monodispersed TiO₂ powders were prepared continuously with high reproducibility and reliability by controlled hydrolysis of titanium ethoxide. Important steps were uniform and rapid mixing and aging using hydroxypropylcellulose as a dispersant. The concentrations of titanium ethoxide and water suitable to production of monodispersed TiO₂ powders lay within a limited range. A minimum aging period of 10 min was required to obtain monodispersed powders.     

稀释水掺混用薄板式静态混合器结构设计与优化

稀释水掺混是油田或炼油厂原油电脱盐系统的关键环节,直接影响电脱盐的效率和运行能耗。为进一步简化设备结构、助力系统降本增效,提出将薄板式静态混合器应用于稀释水掺混环节。在对薄板式静态混合器进行初步结构设计的基础上,对油水混合情况进行计算流体动力学(CFD)三维数值模拟,以离析强度的平方根(IOS0.5)、管路压降(Δp)等作为评价指标,考察了注水管长度、注水管?弯曲薄板间距、弯曲薄板导向位置、弯曲薄板厚度四个结构参数对油水两相混合程度及运行能耗的影响。以混合管路内径D为基准参照,借助响应曲面法(RSM)对关键结构参数进行优化,并对最优结构参数组合下的混合性能进行预测。优化所得最优结构参数组合为注水管长度为1/3D、注水管-弯曲薄板间距为4/25D、弯曲薄板导向位置为1/8π、弯曲薄板厚度为1/25D,结构优化后的IOS0.5相比优化前降低了43.06%。定性分析薄板式混合器内的水相速度云图和流线图可知,当注水比为2%时,油水两相在注水管下游3D处即可达到均匀混合状态,可见薄板式静态混合器能够在小注水比下快速实现油水均匀混合。     

填料塔中亚硝酸甲酯再生过程模拟

在气相偶联合成草酸酯工艺过程中,亚硝酸甲酯(MN)再生过程与偶联反应有效匹配是实现整个系统绿色无污染的关键,也是影响草酸酯合成工业放大过程的关键一步。对于MN再生过程的工艺优化和宏观动力学方面进行了较多研究和报道,而对MN再生过程的数学模拟研究较少。通对MN再生过程中发生的主要化学反应进行分析简化,并结合MN再生反应动力学参数,在填料塔中建立了MN再生反应数学模型,并计算了主要工艺参数对MN收率的影响。模拟结果表明,随温度升高、气体流速增大、N₂体积分数增大,MN的收率减小,液体流速增大和NO/O₂摩尔比增大,MN收率增大。通过实验验证了该模型的准确性,MN收率的模拟结果与实验数据的最大相对偏差为-4.39%,为MN再生反应过程的设计和操作提供了理论依据;最后,对于两种不同的NO和O₂混合方式进行了比较,通过模拟计算比较了这两种不同操作方式对MN收率的影响。