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.     

Pressure Drop and Mass Transfer Study in Static Mixers with Gas Continuous Phase

The aim of this work was to characterize both the influence of the gas and the liquid flow rates on the pressure drop generated by static mixers type Sülzer, and on the mass transfer performances of these gas‐liquid contactors. The originality of this work rests on the use of the static mixers with a gas continuous phase. Several configurations were studied: vertical upward flow, vertical downward flow, and horizontal positions, with one to five mixing elements. It was concluded that the pressure drop is mainly generated by the gas phase, whatever the configuration chosen. Moreover, the volumetric mass transfer coefficients k_La found were lower than those obtained with the same static mixers used in classic conditions (that is with a liquid continuous phase), but greater than values obtained with classic reactors like bubble columns or packed columns. The efficiency of these gas‐liquid reactors was found high, as well as the energy dissipated, unfortunately.     

Numerical investigation of blade shape in static mixing

The mixing performance of the KMX and SMX static mixers have been compared using 3D high-resolution computational fluid dynamics (CFD) simulations. Although these mixers have a similar design composed of layers of blades, their blade shape is different: curved for the KMX and flat for the SMX. The flow of a Newtonian fluid in steady laminar regime has been considered as the benchmark of the study. The simulation was first validated by assessing the pressure drop vs. the number of mixer elements and the results were found to be in good agreement with experimental data. To evaluate the mixing quality, cross-section stream function, extensional efficiency, mean shear rate, residence time, intensity of segregation, stretching, and Lyapunov exponent have been selected. Analysis of the flow pattern and mixing parameters shows differences between the mixers and it appears that the curved blade is more efficient than the flat blade design at the expense of a slightly higher pressure drop. In practice, the KMX mixer should provide a higher mixing rate at high viscosity ratio than the SMX mixer. © 2004 American Institute of Chemical Engineers AIChE J, 51: 44–58, 2005     

Residence Time and Concentration Distribution in a Kenics Static Mixer

Static mixers, often referred to as motionless mixers, are in-line mixing devices that consist of mixing elements inserted into a length of pipe. Most of the experimental works in this field have concentrated on establishing design guidelines and pressure drop correlations. Due to experimental difficulties, few articles have been published on the investigation of the flow and mixing mechanisms. In this work, a Kenics KMX static mixer was utilized to study concentration and residence time distribution (RTD) and effect of Reynolds number on mixing. The static mixer had six mixing elements arranged in-line along the length of the tube, and the angle between two neighboring elements was 90°. The length of the mixer was 0.98 m with internal and external diameters of 5.0 cm and 6.0 cm, respectively. The main continuous fluid was water, and NaCl solution was used as a tracer. All experiments were conducted with three replications at three Reynolds numbers, Re = 1188.71, 1584.95, and 1981.19. A dispersion model was used to model the RTD data. The experimental results were compared with the model results and reasonable agreement was achieved.     

Einsatz und Auslegung statischer Mischer

Application and design of static mixers . Static mixers are units without, or only with fixed, internal fittings which effect the mixing of flowing materials with the aid of their kinetic energy. They are used for continuous homogenization and dispersion, for limitation of the residence time spectrum, and for raising heat and mass transfer in all areas of chemical engineering. Over 20 static mixers are presented, and compared with regard to pressure drop, mixing quality, energy consumption, and residence time and heat transfer behaviour. Important selection criteria are reported. Static mixers have the following advantages over dynamic mixers: use for a wide range of viscosities, narrow residence time spectrum, readily adaptable to existing pipe systems, frequently require no extra space (in-line mixers), negligible maintainance and wear, low investment and operating costs.     

A general correlation for pressure drop in a Kenics static mixer

A new pressure drop correlation in a Kenics static mixer has been developed. Pressure drop data were generated from computational fluid dynamics (CFD) calculations, avoiding the experimental limitations in obtaining comprehensive data enough for developing a reliable pressure drop correlation. Dimensional analysis reveals that the pressure drop characteristic of the Kenics static mixer can be described by three dimensionless groups, i.e., the friction factor, Reynolds number (Re), and aspect ratio of a mixing element (AR). A systematic graphical analysis led to a single master curve governing the pressure drop behavior of the Kenics static mixer, which had never been achieved before. We derived a pressure drop correlation fitting well with the obtained master curve in a general form into which the AR effect on the pressure drop is directly incorporated. Unlike the already existing correlations available in the literature, the correlation proposed in this study can cover the whole range of Re from laminar to turbulence. The reliability of the proposed correlation was validated by the comparison with various pressure drop data reported in the literature.     

Heat transfer performance of NETmix—A novel micro‐meso structured mixer and reactor

NETmix is a novel static mixing technology consisting on a network of unit cells, comprising chambers interconnected by channels. To assess the heat transfer capacity of NETmix, the NUB model was implemented to perform hydrodynamics and heat transfer simulations. Due to the periodic nature of the NETmix structure, two central chambers and six half‐chambers were found to be sufficient to be representative of the whole network. The Nusselt numbers were determined based on the CFD simulations, and when compared with theoretical results for laminar flow between parallel plates, 3–5 times higher Nusselt number values were obtained with NETmix. This observed heat transfer rate enhancement, makes it suitable for fast reactions where heat transfer is crucial. Finally, results obtained from this study show that NETmix presents a heat transfer capacity one order of magnitude greater than microreactors, and 2–5 orders of magnitude greater than the most commonly used devices in industry. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2496–2508, 2017     

A continuous flow reactor for the flexible production of different formulations: CFD-aided design

The increasing need to improve the sustainability of industrial processes requires more flexible and intensified solutions. For this purpose, nowadays lots of efforts are made to switch from batch to continuous processes, the latter being able to ensure the same processing history to all fluid elements, with a consequent better control of the operating conditions and product quality. The present work aims at developing a continuous flow reactor for the production of several fine chemicals, including medical-surgical aids, but also other substances for specific industrial sectors. The plant is basically an inline reactor equipped with various static mixers and side inlets, and it is conceived to ensure on-site production. This is an important feature also in light of the recent COVID-19 pandemic, which asked for flexible and distributed production of chemicals. Numerical simulations based on computational fluid dynamics are employed to study the performance, in terms of pressure drops and degree of mixing, of different static mixers, that is, the Lightnin Inliner Series 50 and Ross low pressure drop (LPD), combining various elements of mixing and injections in different operating conditions in both laminar and turbulent regimes. The results highlighted how numerical simulations may represent a valid tool for supporting the detailed design of such flow reactors by allowing the evaluation of the optimal design solutions.     

不同结构静态混合器内熔体流动及混合效果的数值模拟

构建长度、直径相同,但具有不同扭曲率、分割次数的3种静态混合器,然后利用Polyflow软件模拟低密度聚乙烯(HDPE)熔体在静态混合器内的流动情况,得到熔体在静态混合器内的速度场、压力场、停留时间、分离尺度等参数,并通过分析示踪粒子在静态混合器内的分布情况,表征其混合效果。结果表明,扭曲率大的静态混合器,压降较大、横向速度分量较大、分离尺度较小、混合效果更佳;而分割次数多的静态混合器,压降增大,但是分割次数对横向速度、混合效果的影响较小。     

Kenics型静态混合器和GK型静态混合器流场的数值模拟及比较

采用计算流体动力学(CFD)的方法,分别计算了Kenics型静态混合器和GK型静态混合器内的流场。数值模拟的结果表明,Kenics型静态混合器内流场的湍动强度大于GK型静态混合器的,导致了Kenics型静态混合器的流体阻力和传热系数大于GK型静态混合器的。GK型静态混合器的压力降大约只是Kenics型静态混合器压力降的0.554~0.579倍,但两者的传热膜系数相差不大。GK型静态混合器具有较强的综合性能。     

有无静态混合器时的机械搅拌气升式环流反应器传递特性研究

The mechanically stirred internal loop airlift reactors equipped with or without static mixers are devised for intensification of gas-liquid mass transfer rate. The influences of superficial gas velocity, agitation or static mixers on gas hold-up, mixing time, liquid circulating velocity and volumetric mass transfer coefficient have been investigated with tap water and carboxymethyl cellulose (CMC) aqueous solution. The experimental results indicate that mechanical agitation is more efficacious than static mixer in highly viscous media for improving mass transfer in airlift reactors. The empirical correlation of volumetric mass transfer coefficient with apparent viscosity, and energy consumption for mechanical agitation and aeration is developed.     

Experimental study on energy consumption characteristics of rotational–perforated static mixers

An ideal static mixer can achieve efficient mixing at low pressure drops. Owing to the excellent performance of the tridimensional rotational flow sieve tray (TRST) in a gas–liquid two-phase system, the TRST structure was modified into a rotational–perforated static mixer (RPSM) to enhance mixing in multicomponent liquid systems. The energy consumption characteristics of the RPSM were experimentally studied based on Reynolds numbers in the range of 986–7892, gap L = 0–80 mm, and relative angle γ = 0–45°. The effects of the element installation method, number, gap, relative angle, fluid Reynolds number, fluid properties, and other parameters on the RPSM pressure drop were also investigated. An interaction analysis of each factor was performed using the factorial design method and an empirical model of the RPSM Z-factor was established. Additionally, pressure drop in the RPSM was compared with those of other commonly used static mixers. Results show that, when the element is backward-installed, the pressure drop is higher than that in the forward direction because the fluid is constantly twisted. Moreover, the pressure drop increases with increasing element gap, and the average increase is 43.64% and 19.28% for the forward and backward installations, respectively. The influence of the relative angle on the pressure drop is mainly reflected when the gap L = 0. Subsequently, the degree of influence of each factor was determined, and the Z-factor was calculated and found to be consistent with the experimental values (relative error of less than 15%).     

Static mixers: Mechanisms,applications, and characterization methods – A review

Static mixers and multifunctional heat exchangers/reactors (MHE/R) are qualified as efficient receptacles for processes including physical or chemical transformations accompanied by heat transfer due to their high productivity and reduced energy expenditures. The present work reviews recent conceptual and technological innovations in passive static mixers and continuous in-line reactors. Current industrial applications are discussed from a process intensification perspective, focusing on mixing and mass transfer performance. Typical experimental techniques employed to characterize and quantify the mixing process are explored. The work is complemented by a review of mixing fundamentals, knowledge of which allows the development of theoretical models crucial for the analysis of experimental data, like the chemical probe mixing assessment method. Considering the development of continuous flow equipment in numerous processes, advances in this field will certainly be of increasing interest to the scientific and industrial communities.     

Scale-up of pump-mix mixers using CFD

Effect of scale on the drop size distribution in a pump-mix mixer has been studied. A network of zones model was developed to predict the drop size distribution at different locations in the mixer. Computational fluid dynamics model was used to obtain the flow patterns in the mixer and to identify zones based on the flow patterns. Population balance equation was solved for all the zones of the mixer. The model was validated with the experimental data over a wide range of parameters as well experimental data from the published literature. The model was further extended for scale-up studies. Two different scale-up criteria were studied. It was observed that equal power consumption per unit mass and geometrical similarity is a better scale-up criterion as compared with equal tip speed criterion for pump-mix mixers.     

Drop Breakup in an SMX Static Mixer in Laminar Flow

The mechanism of drop breakup inside SMX static mixers in the laminar flow regime was studied using experimental observations and computational fluid dynamics (CFD). The deformation and breakup of a single drop was simulated using the volume of fluid (VOF) model. It was observed that drops break up after collision with the leading edges and cross‐points of the bars in the SMX static mixer. It was found that drop collision with the bar cross‐points of the SMX static mixer elements is most effective for drop breakup. Elongation and folding result in drop breakup at the cross‐points.     

Polymerization of styrene in a continuous filled tubular reactor

Free radical solution polymerization of styrene has been studied using a binary mixture of symmetrical bifunctional initiators in a filled tubular reactor packed with static mixers. Owing to intensive radial mixing induced by the static mixers, a near plug flow pattern was obtained in the reactor with some axial dispersion effect. The axial mass dispersion coefficient was determined from the residence time distribution experiment and a dynamic axial dispersion model has been developed and solved to investigate steady state and transient behavior of the filled tubular reactor. With a solvent volume fraction of 0.3, the monomer conversion up to 70% was obtained without fouling problems in the temperature range 90 to 120°C. The experimental filled tubular reactor was operated under various reaction conditions and a reasonably good agreement between the model and the experimental data was obtained without using any adjustable parameters.     

Pressure drop and mixing behaviour of non‐Newtonian fluids in a static mixing unit

Static or motionless mixers have received wide application in chemical and allied industries due to their low cost and high efficiency. The pressure drop and mixing behaviour of such mixers have been widely studied. However, the available information for non‐Newtonian fluids is scanty. The results of pressure drop and mixing studies conducted with a locally made motionless mixer (MALAVIYA mixer) and four non‐Newtonian fluids—aq. CMC, PVA, and PEG solutions are reported in this article. The new mixer causes less pressure drop compared to some of the commercial mixers. Mixing behaviour of the unit is more closer to plug flow and a two‐parameter model correlates the dispersion data.     

A comparative study for nanoparticle production with passive mixers via solvent-displacement: Use of CFD models for optimization and design

Active and passive mixers, including a considerable variety of micro-devices, are nowadays widely used for the production of nanoparticles. Polymer nanoparticles for controlled drug delivery applications are investigated in this work with two specific objectives. The first one is to experimentally quantify the efficiency of confined impinging jets reactors and Tee-mixers in the production of nanoparticles constituted by two polymers: poly-?-caprolactone and poly(methoxypolyethyleneglycolcyanoacrylate-co-hexadecylcyanoacrylate). The second objective is the development of a simple and reliable mathematical model to be used for the design, optimization and scale up of mixers for polymer nanoparticle production. Although the behaviour of the polymers investigated is quite different, it is possible to conclude that confined impinging jets reactors are more efficient than Tee-mixers, in converting the pressure drop into turbulent kinetic energy and as a consequence in producing smaller particles. The very simple modelling approach proposed here (based on the evaluation of the mixing time) seems to be able to correlate well experimental data obtained under different operating conditions, independently on the type of device used. Moreover, in the case of poly-?-caprolactone it was also possible to successfully quantify the particle formation time with a simple power law, further exploiting the model.     

The effects of power characteristics on the heat transfer process in various types of motionless mixing devices

The main objective of this paper is to present the measurement results of the pressure drop and the heat transfer coefficient in the various types of static mixers. The experimental investigations are provided for the explanation of the influence of hydrodynamic conditions on the heat transfer enhancement for different static mixers. Based on the analysis of the experimental database and theoretical considerations, original formulas are proposed for the determination of the power consumption and the heat transfer in various types of motionless mixing devices. In this paper a new criterion is also defined which takes into consideration both the heat transfer process and hydrodynamic conditions. This criterion may be successfully applied to the selection of a static mixer for the heat transfer problems.     

Numerical investigation of the performance of several static mixers

The performance of six static mixer (Kenics, Inliner, LPD, Cleveland, SMX and ISG) are compared using 3D numerical simulations in laminar creeping flow regime. Numerical pressure drop results are tested against experimental ones, showing overall a good agreement. Besides pressure drop, four criteria (extensional efficiency, stretching, mean shear rate and intensity of segregation) are chosen to compare the static mixers. It appears that Kenics, Inliner, LPD and Cleveland mixers are rather similar. The ISG mixer seems better than this first group of mixers, but pressure drop is too high compared to other advantages. From our numerical results, SMX appears to be the most efficient of the six compared static mixers.