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.     

翼形桨在气液固三相搅拌反应釜中的混合性能

<正>机械搅拌槽中高速旋转的叶轮产生的排出流中,径向速度主要用于气体的剪切分散,而其轴向速度是固体悬浮和液相轴向混合的主要动力。三相体系的混合不仅要求叶轮具有较强的径向剪切分散能力,而且要有一定的轴向混合能力,以此达到对气体和固体的同时分散。理想的混合水平不仅要求达到二者在宏观上的均匀,而且在微观混合上也要达到一定的均匀度,为此对搅拌桨的设计提出了较高的要求。在气液二相的混合操作中比较多的采用了盘式涡轮桨,而在液固二相的混合操作中比较多的使用螺旋桨,这都是为了利用各自不同的混合优势。涉及到气液固三相混合,由于气体和固体的分散是一个相互制约的问题,完全的径向     

GAS DISPERSION AND SOLID SUSPENSION IN A THREE-PHASE STIRRED TANK WITH MULTIPLE IMPELLERS

Despite much research on gas-liquid-solid systems and their widespread application in industry, gas dispersion with solid suspension in multistage stirred reactors equipped with multiple impellers has received little attention. We report here the critical just-suspension impeller speed for different concentrations of solid particles, gas holdup, and shaft power in a vessel of 0.48 m diameter with four baffles and dished base. Five agitator configurations, each with three impellers mounted on a single shaft, have been used in the experiments. Two novel impeller designs were used, a deep hollow blade (semi-ellipse) disc turbine (HEDT) and four-wide-blade hydrofoil impellers. The hydrofoils were used in both up-pumping (WH_U) and down-pumping (WH_D) modes. Glass beads of 50 ∼ 150 μm diameter and density 2500 kg · m^-3 were suspended at solid volumetric concentrations of 1.5, 3, 6, 9, and 15%. Results show that these suspended solids have little effect on the relative power demand. Agitators using the HEDT radial dispersing impeller at the bottom have a higher relative power demand (RPD = P_G/P_U) than those with WH_D or WH_U as the lowest one. For all impeller combinations there is little or no effect on gas holdup with increasing solid concentrations. Of the five different impeller combinations, those with an axial flow bottom impeller have significantly higher just-suspension agitation speeds and power consumption, so mounting the hydrofoil impeller at the bottom is not the optimal configuration for particle suspension. Of these impeller combinations, at a given gas flow rate the arrangement of HEDT + 2WH_U has the highest relative power demand, gas holdup, and power input for both the suspension of settling particles and gas dispersion.     

GAS DISPERSION AND SOLID SUSPENSION IN A THREE-PHASE STIRRED TANK WITH MULTIPLE IMPELLERS

Despite much research on gas-liquid-solid systems and their widespread application in industry, gas dispersion with solid suspension in multistage stirred reactors equipped with multiple impellers has received little attention. We report here the critical just-suspension impeller speed for different concentrations of solid particles, gas holdup, and shaft power in a vessel of 0.48 m diameter with four baffles and dished base. Five agitator configurations, each with three impellers mounted on a single shaft, have been used in the experiments. Two novel impeller designs were used, a deep hollow blade (semi-ellipse) disc turbine (HEDT) and four-wide-blade hydrofoil impellers. The hydrofoils were used in both up-pumping (WH_U) and down-pumping (WH_D) modes. Glass beads of 50 ～ 150 μm diameter and density 2500 kg · m^?3 were suspended at solid volumetric concentrations of 1.5, 3, 6, 9, and 15%. Results show that these suspended solids have little effect on the relative power demand. Agitators using the HEDT radial dispersing impeller at the bottom have a higher relative power demand (RPD = P_G/P_U) than those with WH_D or WH_U as the lowest one. For all impeller combinations there is little or no effect on gas holdup with increasing solid concentrations. Of the five different impeller combinations, those with an axial flow bottom impeller have significantly higher just-suspension agitation speeds and power consumption, so mounting the hydrofoil impeller at the bottom is not the optimal configuration for particle suspension. Of these impeller combinations, at a given gas flow rate the arrangement of HEDT + 2WH_U has the highest relative power demand, gas holdup, and power input for both the suspension of settling particles and gas dispersion.     

Impeller power draw during turbulent operation in solid‐liquid suspensions

Experimental measurements with six impeller types in solid‐liquid suspensions indicate that impeller power draw in the turbulent regime is approximately proportional to the solid‐liquid suspension density when the solids are distributed throughout the liquid; however, the accuracy of this approach is limited and there are clear differences in the behaviours of the various impellers. In general, power draw increases are less than suspension density increases for impellers with large blade‐trailing vortices, while power draw increases are equal to or greater than suspension density increases for impellers with smaller blade‐trailing vortices. The power draw data is well‐described using linear relations between the impeller power number and the density difference correlating parameter proposed by Micheletti et al.,^[9] with the slope of the relation being dependent on impeller type. More extensive testing with a pitched‐blade turbine, using a greater variety of solids, found that the relation between the impeller power number and the density difference correlating parameter is independent of particle size for particles as large as 1 mm (1000 microns). For particles larger than 1.7 mm (1700 microns), in addition to suspension density, the solid volume fraction affects the pitched‐blade turbine power number; however, it is difficult to determine if this effect exists at all scales or if it is a result of the large particle size relative to the impeller dimensions in the experimental system. For large particles, the power draw is increased by the addition of neutrally‐buoyant particles that do not change the suspension density, with the magnitude of the increase being dependent on impeller type.     

Power Consumption in Gas‐Liquid Contactors Agitated by Double‐Stage Rushton Turbines

The dependence of power consumption on impeller spacing in unaerated and aerated gas‐liquid contactors agitated by dual Rushton turbine systems was studied, and the gas flow rate and viscosity effects were measured in relation to these parameters. The experiments were carried out in a 0.19 m i.d. vessel stirred by two Rushton turbines with a diameter d = 0.10 m; with blade length and blade height 0.25 d and 0.2 d, respectively. In tap water the impellers acted independently for spacings greater than 1.65 d, while in glycerol solutions the two impellers already acted independently at an impeller spacing equal to 1.2 d. In aerated systems, a notable increase in the power consumption with increasing impeller spacing could be detected for small gas flow rates and low viscosities, while a decrease in the Newton number with increasing Froude number could be observed at constant impeller spacing. The Newton number was not affected by flow number at high viscosity values.     

GAS-LIQUID MASS TRANSFER CHARACTERISTICS OF LARGE-SCALE IMPELLERS: EMPIRICAL CORRELATIONS OF GAS HOLDUPS AND VOLUMETRIC MASS TRANSFER COEFFICIENTS IN STIRRED TANKS

Gas dispersion with large-scale impellers consisting of modified large paddle impellers in stirred tanks, with rather large ratios of both impeller diameter and impeller height to tank diameter, was experimentally examined in transition and turbulent mixing ranges. Gas holdups and volumetric gas-liquid mass transfer coefficients with large-scale impellers, i.e., Maxblend and Fullzone impellers, were measured in 0.31 and 0.6 m I.D. stirred tanks, and the gas dispersion performance of large-scale impellers was compared with that of double conventional small-scale high-speed impeller systems, i.e., double four-flat blade disk turbine impellers and double four-flat paddle impellers.

The gas holdups of the large-scale impellers were comparable with those of the small-scale impeller systems at a given rotational speed. The volumetric gas-liquid mass transfer coefficients for large-scale impellers were also similar to those of the small-scale impeller systems. It was found that the large-scale impellers are not more energy efficient than the small-scale impellers in obtaining good gas dispersion.

Empirical correlations for gas holdups and volumetric gas-liquid mass transfer coefficients were developed. They fit the experimental data in transition and turbulent mixing ranges reasonably well, with correlation factors greater than 0.84.     

GAS-LIQUID MASS TRANSFER CHARACTERISTICS OF LARGE-SCALE IMPELLERS: EMPIRICAL CORRELATIONS OF GAS HOLDUPS AND VOLUMETRIC MASS TRANSFER COEFFICIENTS IN STIRRED TANKS

Gas dispersion with large-scale impellers consisting of modified large paddle impellers in stirred tanks, with rather large ratios of both impeller diameter and impeller height to tank diameter, was experimentally examined in transition and turbulent mixing ranges. Gas holdups and volumetric gas-liquid mass transfer coefficients with large-scale impellers, i.e., Maxblend and Fullzone impellers, were measured in 0.31 and 0.6 m I.D. stirred tanks, and the gas dispersion performance of large-scale impellers was compared with that of double conventional small-scale high-speed impeller systems, i.e., double four-flat blade disk turbine impellers and double four-flat paddle impellers.

The gas holdups of the large-scale impellers were comparable with those of the small-scale impeller systems at a given rotational speed. The volumetric gas-liquid mass transfer coefficients for large-scale impellers were also similar to those of the small-scale impeller systems. It was found that the large-scale impellers are not more energy efficient than the small-scale impellers in obtaining good gas dispersion.

Empirical correlations for gas holdups and volumetric gas-liquid mass transfer coefficients were developed. They fit the experimental data in transition and turbulent mixing ranges reasonably well, with correlation factors greater than 0.84.     

Critical Rotational Speed for a Floating Particle Suspension in an Aerated Vessel

The critical suspension speeds of floating particles in a gas‐liquid‐floating particle three‐phase system were measured in a multiple‐impeller agitated vessel. Three types of impellers, i.e., simple axial‐flow impeller upflow (SPU) and downflow (SPD), disk turbine (DT) and wing turbine (WT), twelve types of baffles and three kinds of gas spargers were used. The influences of impeller types, baffle configurations, gas spargers, gas superfacial velocity and particle loading on the critical suspension speeds of floating particles were systematically investigated. The optimum regressions of critical suspension speeds were respectively obtained for some better combinations of impellers, bafffles and spargers, such as (a) the 45SPU+45SPD+DT triple impellers, two high‐level baffles and two low‐level baffles (symmetric allocation), gas spargers, (b) the 45SPU+45SPD+DT three‐impeller, standard baffle and small gas sparger. Their errors were smaller than 11 %.     

通气条件下桨型对自浮颗粒悬浮的影响

考察了五十二种搅拌桨的组合对搅拌釜内自浮颗粒的气液固三相体系混合问题的功耗、气含率和釜底部的颗粒含量的影响。研究表明 ,对自浮颗粒三相体系的搅拌混合应采用多层桨 ,且上层最好用上推式桨 ;实验发现 ,当高径比为 1 .6时 ,三层桨的混合参数优于两层桨的 ;给出了优异的搅拌桨型。     

Mixing of Shear‐Thinning Fluids with Dual Off‐Centred Impellers

Mixing times for inelastic shear‐thinning fluids in stirred tanks have been experimentally investigated using a combination of two off‐centred impellers operating in both co‐ and counter‐rotating modes. A colour‐discolouration technique based on fast acid‐base reaction was used for the determination of the mixing times as well as to reveal the possible presence of caverns and dead regions. A statistical plan of experiments allowed determining the effects of the impeller position, the rotational speed, the flow behaviour index, the impeller type and their mutual interactions. A stronger influence of the impeller position on mixing times was observed for both rotating modes with fluids exhibiting pronounced shear‐thinning. It was also found that segregated regions could be readily destroyed by dual off‐centred impellers as compared with the single centred impeller configuration. Mixed flow impellers were shown to be less efficient in terms of mixing times than radial flow impellers. Results obtained under the best operating conditions were compared to steady stirring experiments showing the potential and drawbacks of the proposed scenarios.     

Gas hold‐up in stirred tank reactors

Based on a study of the gas hold‐up data for stirred tank reactor generated in the present work and the data available in the literature for large stirred tank reactors (T = 0.57 m to 2.7 m) equipped with disc turbines and pitched blade downflow turbines a correlation is presented which reliably predicts gas hold‐up data over wide range of system configurations and operating parameters. The parameter used, N/N_cd, relates gas hold‐up at impeller speed N with respect to the gas hold‐up at minimum impeller speed for complete dispersion of the gas, N_cd. It is shown that the gas hold‐up data of different workers when compared on the basis of N/N_cd, shows unanimity.     

Effect of impeller type on continuous‐flow mixing of non‐Newtonian fluids in stirred vessels through dynamic tests

Mixing of non‐Newtonian fluids with axial and radial flow impellers is prone to a significant extent of nonideal flows (e.g., dead zones and channelling) within the stirred reactors. To enhance the performance of the continuous‐flow mixing of pseudoplastic fluids with yield stress, close‐clearance impellers were utilised in this study. We explored the effects of various parameters such as the type of close‐clearance impeller (i.e., the double helical ribbon (DHR) and anchor impellers), impeller speed (25–500 rpm), impeller pumping direction, fluid rheology (0.5–1.5% xanthan gum solution), fluid flow rate (3.20–14.17 L min^?1) and the locations of outlet (configurations: top inlet–top outlet, top inlet–bottom outlet) on the dynamic performance of the mixing vessel. The performance of the DHR impeller was then compared to the performance of various types of impellers such as axial‐flow (Lightnin A320) and radial‐flow (Scaba 6SRGT) impellers. The dynamic tests showed that the DHR impeller was the most efficient impeller for reducing the extent of nonideal flows in the continuous‐flow mixer among the impellers employed in this study. In addition, the mixing quality was further improved by optimising the power input, increasing the mean residence time, decreasing the fluid yield stress, using the up‐pumping impeller mode and using the top inlet–bottom outlet configuration. © 2011 Canadian Society for Chemical Engineering     

Dispersion Characteristics of Gas‐Liquid Contactors Agitated by Single and Double‐Stage Rushton Turbines

The study of the loading/complete dispersion transition is of great importance especially in processes with enhanced mixing requirements. In the present work, new data and correlations concerning the dispersion characteristics in gas‐liquid contactors agitated by single and dual Rushton turbine systems are reported. The maximum amount of gas which can be completely dispersed, in the presence of gross, well defined recirculation patterns of gas at a given stirrer speed is predicted. Under these conditions, an increase of flow number with increasing Froude number could always be estimated. With decreasing impeller diameter, d, the same gas amount could be dispersed at higher stirrer speeds. At impeller spacing ΔH = 2 d, for d equal to 0.06 and 0.08 m, and ΔH = 1.54 d, for d = 0.10 m, the complete dispersion conditions of the dual impeller systems were slightly better than the corresponding conditions of the single impeller systems.     

CFD Prediction of the Critical Agitation Speed for Complete Dispersion in Liquid‐Liquid Stirred Reactors

A computational fluid dynamics (CFD) model is adopted to simulate the turbulent immiscible liquid‐liquid flow in a stirred vessel based on a two‐fluid model with a k‐ϵ‐A_P turbulence model. An improved inner‐outer iterative procedure is adopted to deal with the impeller rotation in a fully baffled stirred tank. Different drag formulations are examined, and the effect of the droplet size on both the dispersed phase holdup distribution and the velocity field is analyzed. Two different numerical criteria are tested for determining the critical impeller speed for complete dispersion. The simulated critical impeller speeds are generally in good agreement with the correlations in the literature when the fixed droplet size is properly selected. This demonstrates that the modeling approach and the numerical criteria proposed in this work are promising for predicting the dispersion characteristics in liquid‐liquid stirred tanks.     

Experimental Studies on Suspension of Solid Particles in a Low‐Shear Stirred Vessel

A low‐shear stirred vessel was explored. Experimental studies on the suspension of solid particles in solid‐liquid and gas‐solid‐liquid systems were conducted to examine the performance of this new reactor. The method based on the power number curve was modified to determine the critical impeller speeds required for just complete off‐bottom suspension of solids under non‐gassed (N_js) and gassed conditions (N_jsg) in this reactor, and a PC‐6A fiber‐optic probe for the measurement of solid distribution was used to complementarily validate this method. A more homogeneous flow field was gained with a draft tube installed, so that the standard deviations of average shear rate and maximal shear rate are reduced. The modified power consumption method can determine N_js and N_jsg, and the values of N_js with a draft tube are much lower than those without it. N_jsg increases slightly with increasing gas flow rate, and N_jsg with a higher solid weight fraction is larger in this lower‐shear reactor.     

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.     

Coaxial Mixer Hydrodynamics with Newtonian and non‐Newtonian Fluids

The performance of several combinations of a wall scraping impeller and dispersing impellers in a coaxial mixer operated in counter‐ and co‐rotating mode were assessed with Newtonian and non‐Newtonian fluids. Using the power consumption and the mixing time as the efficiency criteria, impellers in co‐rotating mode were found to be a better choice for Newtonian and non‐Newtonian fluids. The hybrid impeller‐anchor combination was found to be the most efficient for mixing in counter‐rotating or co‐rotating mode regardless of the fluid rheology. For both rotating modes, it was shown that the anchor speed does not have any effect on the power draw of the dispersing turbines. However, the impeller speed was shown to affect the anchor power consumption. The determination of the minimum agitation conditions to achieve the just suspended state of solid particles (N_js) was also determined. It was found that N_js had lower values with the impellers having the best axial pumping capabilities.     

Influence of impeller type on hydrodynamics and gas‐liquid mass‐transfer in stirred airlift bioreactor

The influence of impeller type in a mechanically stirred airlift bioreactor was analyzed in relation to the non‐Newtonian viscous fluids. The agitation was carried out through a marine impeller (axial impeller) and a paddle impeller (radial impeller) located along with the gas sparger in the region comprised by the riser. The bioreactor was sparged with air under different velocities (0.036–0.060 m s^?1). Carboxymethylcellulose 1.94% and xanthan 1.80% were used as a fluid model. The gas holdup and volumetric mass‐transfer coefficient increased in up to five and three times, respectively, when compared to a conventional airlift bioreactor; however, better results were obtained when the straight paddle impeller type was used. The results suggest that the studied bioreactor can be used successfully in viscous fluid, and it can be more efficient than conventional airlift bioreactors. The results obtained suggest the use of radial impellers. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3159–3171, 2015     

Gas—liquid dispersion and mixing characteristics and heat transfer in a stirred vessel

Properties of gas—liquid dispersion and mixing of seven types of impellers were studied and compared in a stirred vessel with aeration. New correlations for the properties including critical dispersion impeller speed, dispersion regime, power consumption, gas hold-up, discharge flow number and discharge efficiency have been developed. The fluid/wall heat transfer was also studied with several types of dual impeller combinations. There is a critical impeller speed which determines how aeration changes the heat transfer coefficient. Operating conditions influence heat transfer interactively by three factors, which can be expressed by proper dimensionless variables.