叶片排列角度对三螺旋静态混合器混合效果的影响

三螺旋结构静态混合器是一种新型的多螺旋流道静态混合器，其扭旋元件能够将混合管内流体分成多股支流，产生相反的螺旋流动，促进流体混合，为探究每个扭旋元件相邻叶片的排列角度对混合效果的影响规律，利用计算流体力学(CFD)中的Fluent软件，在低雷诺数状态下，对5种静态混合器进行数值模拟。结果表明，在低雷诺数状态下，每个扭旋元件相邻叶片间夹角θ在0°～60°范围内变化时，叶片对流体的切割、分流作用不同，随着θ的减小，混合效果增强；流体流经θ=0°的静态混合器3个扭旋元件时，分离强度下降至0.073,达到较好的混合效果；当θ=0°～30°时，静态混合器能耗随着θ增大而降低，当θ=30°～60°时，静态混合器能耗变化较小。     

四叶片组合静态混合器湍流传热性能的数值模拟分析

采用Fluent计算软件对四叶片组合静态混合器内湍流换热进行数值模拟并与SK型静态混合器进行对比,结果表明,在104≤Re≤105范围内,前者的传热效率比后者提高约20%. 运用场协同理论对结果进行了分析,新型静态混合器传热效率较高的主要原因为,在一个截面上有4个旋向与叶片旋向相同、旋涡半径近似等于叶片半径的纵向涡及4个旋向与叶片旋向相反、旋涡半径小于叶片半径的纵向涡,这些纵向涡能强化换热;与SK型静态混合器相比,新型静态混合器管内温度梯度基本相同,管内中心区二次流流速一定程度降低,而近壁区二次流流速差别较小,但速度场与热流场的协同程度得到明显改善.     

SMX型静态混合器湍流特的数值模拟

以SMX型静态混合器为研究对象,运用计算流体力学软件Fluent对3种结构静态混合器管内湍流流场进行数值模拟.结果表明:SMX型静态混合器的混合元件对流体有切割和分散作用,可使径向速度与周向速度的最大值达到轴向平均表观流速的2～2.5倍;流体流经3、4个混合元件后流动基本达到稳定;混合器前3个混合元件对流体湍动强化作用...     

撞击流反应器内幂律流体流动特性的数值模拟

采用数值模拟方法对撞击流反应器内幂律流体的流动特性进行研究,分析了不同喷嘴间距和入口流速下清水和不同质量分数幂律流体的径向射流扩展率、径向速度衰减率、剪切应力、表观黏度等分布规律,研究表明：幂律流体中径向射流的径向速度分布规律与清水径向射流相似。随喷嘴间距的增大,扩展率增大,径向速度衰减率减小,平均剪切应力呈先增大后减小的变化规律,其中L=3D时平均剪切应力值最大,更利于流体混合。入口流速越大,扩展率越小,径向速度衰减率越大,平均剪切应力也随之增大。幂律流体的平均剪切应力大于清水,且随质量分数的增大,其扩展率增大,为清水扩展率的1.3~3.3倍,而幂律流体的径向速度衰减率从-1.268~-1.125降低到-1.144~-1.082,逐渐小于清水。幂律流体径向射流区域的剪切应力呈“M”形分布,表观黏度则呈“W”形分布,流体的流变性质对撞击流反应器内流体的流动规律影响显著。     

Kenics型静态混合器充分发展段纵向涡演变分析

为分析Kenics型静态混合器内充分发展段沿轴向二次流纵向涡的形成诱因及演变过程,运用大涡模拟对混合器内流场进行研究,数值模拟结果与实验结果吻合较好. 结果表明,在第7个扭旋叶片所在区域内含3种旋涡,分别为叶片入口分割上一段流体后产生的合并旋涡、随扭旋叶片一起旋转的内流旋涡和绕流旋涡. 绕流旋涡是扭旋叶片高扭率产生的科氏力导致单侧流体压力不平衡,使边界层产生分离形成的诱导旋涡. 沿轴向将第7个扭旋叶片所在区域流场平均分成4段,第一和第二段的横截面上存在5个纵向涡,涡量和湍动强度平均值分别比第三和第四段高23.0%和8.93%. 在相邻叶片的分界面处,旋涡破碎和聚合产生能量损耗,使近壁面的涡量陡增,高出平均值73.0%.     

混合元件数对SK型静态混合器流场特性的影响

以SK型静态混合器为对象,运用激光多普勒测速仪对混合器内流场进行测量分析,研究混合元件数对混合器内速度分布和湍动性能影响。结果表明：在扭旋叶片作用下,流体在混合器内的速度会重新分布,湍动会被强化,这一过程主要在前3个混合元件中实现,且湍动逐渐增加,但增加速度逐渐减弱,第1个混合元件强化作用最为显著,进入第4个混合元件后基本达到稳定;当混合叶片数量超过3个以后,对流体湍动的强化基本达到混合器强化能力的极限,继续增加元件数量不能提高流体的湍动程度,但可以维持这种湍动。     

高黏度流体在SK型静态混合器内的流动特性

根据流体动力学、非线性动力学及Ottino理论,建立了高黏度流体在SK型静态混合器内的流体流动改进模型,分析二维Navier-Stokes方程基于双极坐标系下流函数形式的边值问题并建立了相应的流体微分运动方程。用Poincare映射方法对静态混合器内的蠕动流的动力学行为进行了数值仿真研究。给出了系统响应随管壁转动角频率变化的分岔图、最大Lyapunov指数曲线图、典型的Poincare截面图和相图。结论表明:高黏度流体在SK型静态混合器内轴截面的径向流动存在混沌特性。     

圆管内含颗粒幂律流体的密相两相湍流

阐述了幂律流体控制方程的特点,研究了幂律流体的稠度系数和流动指数的变化对两相流动的影响.随着流动指数的增加,幂律流体在圆管中心附近的主流速度减小,同时颗粒相速度在圆管中心附近增大,而在管壁附近减小.随着稠度系数的增加,幂律流体和颗粒相的主流速度分布出现了与流动指数带来的影响相似的趋势.对带颗粒的幂律流体的两相流流动与液固两相流流动做了比较,幂律流体两相流的流体速度在管道中心附近的大部分区域比液固两相流的流体速度流动的速度大,而颗粒相的速度分布比较平坦.     

变扭率扭旋叶片强化传热特性

为探究扭旋叶片的结构参数--扭率变化率Tv对管道换热的影响,以水为介质,在Tv=-5~5范围内,采用实验和数值模拟方法研究了恒壁温条件下流体的传热和阻力特性,并分析了综合传热性能及强化传热机理。结果表明,沿流动方向Tv>0的扭旋叶片安装方式强化传热效果优于Tv=0,研究范围内Tv=2.5时综合强化传热比最高,相对Tv=0平均提高5.0%。而Tv<0时强化传热效果劣于Tv=0,应避免此种叶片安装方式。扭率的变化影响了流场结构,当Tv>0时,在近1/2流动区域内绕流旋涡的涡量和影响区域明显增加,同时,在绕流旋涡流动区域,压力、速度和温度的三场协同程度得到提高,进而强化了换热管道的传热效果。     

变扭率扭旋叶片强化传热特性

为探究扭旋叶片的结构参数——扭率变化率Tv对管道换热的影响,以水为介质,在Tv=-5~5范围内,采用实验和数值模拟方法研究了恒壁温条件下流体的传热和阻力特性,并分析了综合传热性能及强化传热机理。结果表明,沿流动方向Tv0的扭旋叶片安装方式强化传热效果优于Tv=0,研究范围内Tv=2.5时综合强化传热比最高,相对Tv=0平均提高5.0%。而Tv0时强化传热效果劣于Tv=0,应避免此种叶片安装方式。扭率的变化影响了流场结构,当Tv0时,在近1/2流动区域内绕流旋涡的涡量和影响区域明显增加,同时,在绕流旋涡流动区域,压力、速度和温度的三场协同程度得到提高,进而强化了换热管道的传热效果。     

Performance of Kenics static mixer over a wide range of Reynolds number

The present study deals with the numerical simulation of flow patterns and mixing behaviour in Kenics static mixer over a wide range of Reynolds number. Three different sets of Kenics mixer (aspect ratio = 1.5) comprised of 3, 9 and 25 elements each have been characterized. The Reynolds number was varied in the range of 1 to 25,000 (i.e., from laminar to turbulent flow regime). The numerical approach takes into account the aspects of the fluid flow at higher Reynolds number values including circumferential velocity profiles at different cross-sections within the Kenics mixer, which were neglected in previous studies. It was observed that cross-sectional mixing in the turbulent flow regime takes place up to 30% of each element length at element-to-element transition; beyond that velocity profiles were uniform. The experiments were also carried out to measure the circumferential and axial velocity profiles and pressure drop in three different Kenics Mixers using air as fluid. The pressure drop per unit element (ΔP/η) was found to be independent of the number of Kenics mixing elements used in the system. The total pressure drop across Kenics mixer obtained by CFD simulations were compared with the experimental pressure drop values and correlations available in the literature. The numerical results were found in good agreement with the experimental as well as the results reported in the literature. A new pressure drop correlation in the Kenics static mixer has been developed.     

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.     

Effects of geometry and flow rate on secondary flow and the mixing process in static mixers—a numerical study

A method based on computational fluid dynamics (CFD) for the characterization of static mixers using the Z factor, helicity and the rate of striation thinning is presented. These measures were found to be well-suited for the characterization of static mixers as they reflect the pressure drop, the formation of secondary flow, i.e. vortices, and their effect on the mixing process. Two commercial static mixers, the Kenics KM and Lightnin Series 45, have been characterized. In the mixers investigated, secondary flow is formed in the flow at the element intersections and due to the curvature of the mixer elements. The intensity of the vortices is higher in the Lightnin than the Kenics mixer due to edges in the middle of the Lightnin mixer elements. The formation of vortices affects the Z factor by an increase in the power requirement, and the rate of striation thinning by an increase in the stretching of the striations. The formation of vortices was observed at a Reynolds number of 10 in both mixers with aspect ratios of 1.5. However, the intensity of the vortices was greater in the Lightnin than the Kenics mixer, which was observed in not only the magnitude of the helicity, but also the Z factor, rate of striation thinning and the distribution of striation thickness.The distribution in striation thickness is shifted towards thin striations as the flow rate is increased from below to above the Reynolds numbers of which vortices were first observed, but some striations still pass the mixer elements almost unaffected, which can be seen in the skewness of the distribution of the striation thickness, which shifts from being negative to positive.     

水平液固循环流化床换热器传热性能评价

对管内插入Kenics静态混合器的水平液固循环流化床换热器进行实验研究,实验考察了静态混合器扭率、静态混合器安装方式、液体流速、颗粒体积分数对传热性能和流阻性能的影响,并运用综合强化传热性能评价指标（PEC）对其进行分析。实验发现,传热性能和阻力系数均随扭率增加而减小。当雷诺数在10000~45000之间时,扭率为1.5、2、2.5、3.5的Kenics静态混合器的PEC指标均大于1,说明了水平流化床换热器插入Kenics静态混合器能够改善传热。在雷诺数达到25000左右、Kenics静态混合器扭率为2.5、颗粒体积分数为4%时,水平流化床换热器的PEC指标最高达到1.18。当两个扭率均为2.5的Kenics静态混合器安装间距为200mm时,水平流化床换热器的PEC指标最高。     

Ross LPD型静态混合器内湍流传热与混合强化特性

在湍流状态Re=2640~17600下,采用恒热通量传热实验与数值模拟相结合的方法,系统研究Reynolds数Re和交错角对Ross LPD型静态混合器内湍流流动与传热性能影响,采用Nusselt数、Darcy摩擦系数、综合传热系数、速度场与温度梯度和压力梯度协同角等参数评价混合器内传热强化性能;基于CFD与LPT相耦合分析混合器内流体微元拉伸率。研究结果表明：SST k-ω模型预测Ross型静态混合器湍流阻力及传热结果与实验结果具有很好一致性;Ross混合器流场内形成与流场尺度较为接近的纵向涡,其涡心在圆形截面与半圆形截面中心间周期性迁移,横截面内湍流分散混合效率是Kenics的3.36~1.72倍;当Re>7040时,Ross LPD综合传热性能明显优于KSM;当叶片夹角为30°时,综合传热性能系数具有最大值;Ross LPD内插件具有高效低阻的技术优势和结构改进潜力。     

Ross LPD型静态混合器内湍流传热与混合强化特性

在湍流状态Re=2640~17600下,采用恒热通量传热实验与数值模拟相结合的方法,系统研究Reynolds数Re和交错角对Ross LPD型静态混合器内湍流流动与传热性能影响,采用Nusselt数、Darcy摩擦系数、综合传热系数、速度场与温度梯度和压力梯度协同角等参数评价混合器内传热强化性能;基于CFD与LPT相耦合分析混合器内流体微元拉伸率。研究结果表明：SST k-ω模型预测Ross型静态混合器湍流阻力及传热结果与实验结果具有很好一致性;Ross混合器流场内形成与流场尺度较为接近的纵向涡,其涡心在圆形截面与半圆形截面中心间周期性迁移,横截面内湍流分散混合效率是Kenics的3.36~1.72倍;当Re>7040时,Ross LPD综合传热性能明显优于KSM;当叶片夹角为30°时,综合传热性能系数具有最大值;Ross LPD内插件具有高效低阻的技术优势和结构改进潜力。     

流量对SK型静态混合器湍流性能影响的实验研究

以SK型静态混合器为研究对象,运用激光多普勒测速仪对管内流体的三维脉动速度进行测量并对测量数据进行分析处理. 结果表明,进口流量变化对截面上时均速度分布规律、脉动均方根分布规律及雷诺应力分布规律的影响不大;进口流量增加使径向、轴向及周向上的速度脉动均增加,对径向上的速度脉动强化作用最显著,特别当雷诺数超过6400后,径向上的速度脉动均方根及湍流强度随流量增加而增加的幅度都迅速提高,此时湍动能也迅速提高;雷诺应力随流量的增加而增加,其分量txy和txz增加的幅度高于tyz,特别当雷诺数超过6400后,txy增加的速度迅速提高.     

Development of positron emission particle tracking for studying laminar mixing in Kenics static mixer

Positron emission particle tracking (PEPT) is a flow visualisation technique that has found application in a wide range of processes. In this work, PEPT has been used to study laminar flow of a high viscosity Newtonian and non-Newtonian fluid in a Kenics static mixer (KM). Through analysis of the trajectories of many hundreds of passes of the tracer particle through the mixer, it is possible to compute the overall flow field and to visualise how the fluid twists and folds as it passes along the mixer. Eulerian velocity maps plotted for the Newtonian and non-Newtonian fluids showed that the length required for the flow to develop is shorter for the non-Newtonian fluid than the Newtonian. The stretching and folding mechanism of mixing was observed by grouping the trajectories into clusters according to whether the trajectory passes to the left or right of the blade at the transition between elements. Those trajectories making the same L–R–L decision tended to remain in the same striation through two or three elements until that striation became stretched and folded back on itself, sandwiching other layers. It is clear that the PEPT data is rich and powerful. We are hopeful that the techniques we develop for the flow and mixing in the Kenics mixer will be applicable to studying more complex laminar flows.     

带有Kenics静态混合器的水平液固两相流化床换热管的压降研究

以饱和硫酸钙为介质,在安装Kenics静态混合器的水平液固两相流化床换热管上进行实验研究,考察介质流速、Kenics静态混合器扭率、颗粒体积分数及颗粒尺寸对压降的影响,并与冷态实验条件下的压降变化规律进行比较。结果表明：同等操作条件,安装Kenics静态混合器后压降比安装前提高20%～140%;压降随雷诺数的增大而增大,随Kenics静态混合器扭率的增大而减小;颗粒体积分数对压降也有影响。根据实验数据,得出了稳定操作条件下压降与上述影响因素之间的经验关联式,为带有Kenics静态混合器的水平液固两相流化床换热器的设计提供计算依据。     

Quantification of laminar mixing in the kenics static mixer: An experimental study

The laminar flow field in a Kenics KM static mixer has been studied using laser induced fluorescence and digital image analysis. Mixing was quantified by measurement of the number average striation thickness, variance of striation widths and interfacial area, for elements of length to diameter (L/D) ratios of 0.8, 1.0, 1.5 with 90° twist per element. From flow visualisations, transitions were observed in the flow where vortices developed above the first and second elements at Reynolds numbers of 43 and 90 for L/D = 0.8 and Reynolds numbers of 55 and 105 for L/D = 1.0. It was found that these vortices did not appreciably enhance mixing based on striation thickness and variance of striation widths measurements after 4 to 5 elements. The influence of viscosity ratio showed a viscosity ratio (dyed stream/bulk stream) of I had faster interfacial area growth and created more uniform mixtures compared to a viscosity ratio of 0.2 for flow rate ratio of 0.2.