LIQUID-LIQUID MIXING IN STIRRED VESSELS: A REVIEW

Liquid-liquid mixing is a key process in industries that is commonly accomplished in mechanical agitation systems. Liquid-liquid mixing performance in a stirred tank can be evaluated by various parameters, namely minimum agitation speed, mixing time, circulation time, power consumption, drop size distribution, breakup and coalescence, interfacial area, and phase inversion. The importance of these liquid-liquid mixing parameters, the measurement method, and the results are discussed briefly. Input parameters such as impeller type, power number, flow pattern, number of impellers, and dispersed phase volume fraction, in addition to physical properties of phases such as viscosity and density, are reviewed. Scale-up aspects are also included.     

疏水缔合聚丙烯酰胺溶解槽内流固混合特性的数值模拟

利用FLUENT软件对在聚酯生产中应用的双层搅拌桨搅拌槽内疏水缔合聚丙烯酰胺AP-P4溶解过程的流场进行数值模拟分析,采用标准k-ε模型和多重参考系法(MRF)。分析了AP-P4溶解过程中刚加入聚合物颗粒时在搅拌槽内的混合情况。得到了搅拌槽内流场状况和固体颗粒的体积分数分布。并对流场的分布规律、固体颗粒体积分数分布特点加以分析,由模拟结果计算出搅拌轴的功率,为搅拌槽的设计和实际应用提供有益的结论。     

具有黏结颗粒的搅拌槽功率特性

功耗是搅拌反应器设计和放大过程的重要参数。在圆柱形搅拌槽内通过实验研究了相对液体体积、转速和物料高度对功耗的影响,采用离散元方法(DEM),用Hertz-Mindlin with JKR模型模拟了不同相对液体体积颗粒的黏结力对功耗的影响。结果表明,随相对液体体积增大,功耗呈先增大后减小的变化趋势,在相对液体体积为0.0162时达到最大值。随转速增大,功耗增长变快,但随相对液体体积增大,转速对功耗的影响指数呈先减小后增大的趋势。不同物料高度的功耗最大值均为饱和颗粒的1.8倍,不同物料高度的单位质量功耗随相对液体体积的增长速率几乎一致。提出了新的间接测量颗粒间黏结力的方法,发现功耗与黏结力呈线性关系。     

立式圆槽内多轴搅拌器固-液悬浮性能

在直径(T)为2 m、高(H)为0.8 m的圆形搅拌槽内,采用三桨搅拌,桨型为CBY III(桨径D=0.174 m),3个桨在槽内均匀分布,通过对临界悬浮叶端线速度、沉积面积的分析,研究了搅拌桨槽内最优安装位置. 结果表明,最优径向安装位置为距壁面0.285R(R为圆形搅拌槽半径,m)处;液位为0.3T时的搅拌效果优于0.2T和0.25T;但液位在一定(0.2T~0.3T)范围内对功率的影响微小. 对比分析实验结果与文献数据可知,达到相同完全悬浮状态,立式多轴搅拌的功率消耗为单轴情况下(D=0.731 m)的2.8倍,但立式多轴搅拌器的制造成本更低;与侧伸式搅拌相比,5%沉积面积时立式多轴搅拌节省20%能耗,且安装维护更简便,在大型储罐中具有广泛的工业应用前景.     

错位六弯叶桨在假塑性流体中的混沌搅拌特性

基于混沌混合理论,提出了一种错位叶片的结构形式,用来消除层流流场的混合隔离区.利用CFD的方法,对六弯叶涡轮(6BT)和错位六弯叶涡轮(6SBT)2种搅拌器在黄原胶水溶液中的流场变化进行研究,分析比较了2种搅拌器的流场结构、速度分布以及功率消耗的不同.结果表明,模拟计算得到的功率值与实验测量值吻合较好,6SBT桨在层流...     

Effect of baffles on fluid flow field in stirred tank with floating particles by using PIV

PIV technique was applied to elucidate the effect of baffles at different shaft positions and different impeller off‐bottom clearances on the flow field in a stirred tank with floating particles. The investigation was carried out in a cylindrical tank with a flat base, and five different baffle configurations: standard baffles, narrow baffles with a width of 15 mm, narrow baffles with a width of 10 mm, down triangular baffles and up triangular baffles. The measurements show that down triangular baffles offers several advantages over standard baffles at C = T/3: high axial and radial velocities, relatively Low critical agitation speed and power consumption for just drawdown of 1.0 vol.% floating particles. While at C = T/2 this superiority disappears and the fluid flow field is similar to that for standard baffles. The other baffles are similar in performance except for a small difference in the critical agitation speed. An off‐centred shaft helps reduce the critical just drawdown speed and the corresponding power consumption for baffle configurations considered. With down triangular baffles, the critical power consumption to draw down the floating particles for the most eccentric shaft is about 42% of that for a centred shaft. © 2012 Canadian Society for Chemical Engineering     

Numerical optimization for blades of Intermig impeller in solid–liquid stirred tank

The multiphase flow in the solid-liquid tank stirred with a new structure of Intermig impeller was analyzed by computational fluid dynamics(CFD).The Eulerian multiphase model and standard k-ε turbulence model were adopted to simulate the fluid flow,turbulent kinetic energy distribution,mixing performance and power consumption in a stirred tank.The simulation results were also verified by the water model experiments,and good agreement was achieved.The solid-liquid mixing performances of Intermig impeller with different blade structures were compared in detail.The results show that the improved Intermig impeller not only enhances the solid mixing and suspension,but also saves more than 20% power compared with the standard one.The inner blades have relatively little influence on power and the best angle of inner blades is 45°,while the outer blades affect greatly the power consumption and the optimized value is 45°.     

偏心组合桨搅拌槽内层流混合过程的数值模拟

目前,处理高黏流体和对剪切敏感介质的层流搅拌槽的报道并不多见。本文建立了描述双层组合桨搅拌槽内高黏非牛顿流体层流流动、混合过程的数学模型,利用Laminar模型、多重参考系法（MRF）和示踪剂浓度法对其流场特性、示踪剂扩散过程进行数值模拟,分析搅拌槽内轴向速度曲线、示踪剂浓度响应曲线和混合时间。结果表明：中心搅拌中间面将介质阻隔在各自的半层内运动,偏心搅拌介质作全局运动,轴向混合能力突出;转轴中心搅拌依靠上下半层浓度差的增大向下扩散,转轴偏心搅拌通过不对称结构扩散示踪剂,叶轮相对转轴偏心搅拌则利用叶片的不对称分布;距离加料点较近和较远的监测点浓度响应曲线因振荡和调整,混合时间较长,处于中间面的监测点拥有最短的混合时间。     

错位桨搅拌槽内污泥与固体颗粒混合过程的数值模拟

以直径1 m的搅拌槽为模型、含水率92%的污泥和粒径0.1 mm的固体颗粒为工作介质,采用Fluent软件对错位六叶螺旋桨搅拌下污泥与固体颗粒的混合过程进行数值模拟,通过与普通六叶螺旋桨对比,分析了2种桨型的浓度场分布、混合时间及单位体积混合能,并将计算的固体颗粒浓度分布与实验结果进行了比较. 结果表明,固体颗粒浓度分布计算结果和实验结果吻合较好,流动场分布对混合过程有一定影响,相同条件下错位桨搅拌的浓度场分布更快趋于稳定. 当转速N=4 r/s时,错位六叶螺旋桨的混合时间为27 s,比六叶螺旋桨的混合时间缩短9 s. 采用错位桨单位体积混合能仅为普通桨的79.6%,节能效果显著.     

Power consumption in a moving baffle oscillatory baffled reactor: A CFD study

Oscillatory baffled reactors (OBRs) can perform high-intensity mixing under low power consumption, and thus are viable replacements for stirred tank reactors in biological, chemical, and polymer processes. This study simulated the flow inside a moving baffle OBR with single orifice baffles using computational fluid dynamics (CFD). The effect of operational and geometrical parameters along with the fluid density and viscosity on average power consumption and maximum power consumption was investigated, and appropriate correlations for both average and maximum power consumption were obtained. It was found that average and maximum power consumption are independent of viscosity, and amplitude has a greater impact on maximum power consumption than on average power consumption. These correlations were then compared with available power models (that showed an acceptable level of discrepancies) in the literature. Lower power consumption values obtained from CFD results compared to those obtained from quasi-steady state model (QSM) and eddy enhancement model (EEM) models (developed for stationary baffle OBRs) under the same operating conditions, along with higher axial dispersion of moving baffle OBRs compared to stationary baffle types under the same operating conditions, indicated that a moving baffle OBR is a more efficient mixing device than a stationary baffle OBR in terms of power consumption. The ratio of average power consumption to maximum power consumption was proven to be independent of the type of fluid and a very weak function of oscillation frequency.     

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。     

搅拌槽内固液两相流的数值模拟及功率计算

使用计算流体动力学的方法对搅拌槽中的流场进行模拟,得到搅拌槽中液体的流动状况和体积分数分布。对流场分布规律、固体颗粒体积分数特点加以分析,进而利用模拟出的数据计算搅拌轴的功率,为搅拌器的设计提供参考。     

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.     

Mixing of medium viscosity liquids in a stirred tank with fractal impeller

Mixing of viscous liquids in a stirred tank is a daunting task. The present paper explores the possibility of using a fractal impeller for mixing of viscous liquids in a stirred tank. The analysis includes power consumptions characteristics, mixing characteristics and the flow patterns in the stirred tank. Ultrasonic velocity profiler (UVP) was used to measure the local velocities in the stirred tank. Fractal impeller found to exhibit different power consumption characteristics than known for conventional impellers. For the range of viscosities 0.58–0.192 Pa s, mixing time found to be directly proportional to the power consumption per unit mass. The normalised mean radial velocity profiles were found to be independent of fluid viscosities studied in the present work.     

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.     

搅拌釜内固-液悬浮体系的CFD-DEM模拟(英文)

Computational fluid dynamics-discrete element method （CFD-DEM） coupled approach was employed to simulate the solid suspension behavior in a Rushton stirred tank with consideration of transitional and rotational motions of millions of particles with complex interactions with liquid and the rotating impeller. The simulations were satisfactorily validated with experimental data in literature in terms of measured particle velocities in the tank. Influences of operating conditions and physical properties of particles （i.e., particle diameter and density） on the two-phase flow field in the stirred tank involving particle distribution, particle velocity and vortex were studied. The wide distribution of particle angular velocity ranging from 0 to 105 r·min-1 is revealed. The Magnus force is comparable to the drag force during the particle movement in the tank. The strong particle rotation will generate extra shear force on the particles so that the particle morphology may be affected, especially in the bio-/polymer-product related processes. It can be concluded that the CFD-DEM coupled approach provides a theoretical way to under-stand the physics of particle movement in micro-to macro-scales in the solid suspension of a stirred tank.     

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。     

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.     

液固搅拌槽中固、液相停留时间分布

本文以海沙和自来水为介质研究了在标准搅拌槽内影响固液两相停留时间分布的主要因素,以便比较两相之间的差异,并利用双区模型描述出口流体中固体和液体的停留时间分布。对所建立模型中的参数进行估值后,建立了模型参数与搅拌雷诺数、固体颗粒浓度及搅拌槽几何参数之间的关联式。     

Influence of power input and aeration method on mass transfer in a laboratory animal cell culture vessel

Large-scale animal cell operation is costly both in terms of facilities and consumables. Hence developmental studies with animal cells normally start at laboratory scale, often using small stirred tanks. In order to better optimise cell performance, it is necessary to know the physical conditions under which the cells are grown. In this study a laboratory-scale vessel (2 dm³ working volume) with two large-bladed paddle impellers was characterised hydrodynamically. Three different aeration methods (surface, sparging and membrane aeration) were investigated and compared. Power input and oxygen transfer rates to culture medium were determined as a function of agitation and gas flow rates. Non-dimensional correlations were established for each case, which can be useful for scale-up purposes. The results obtained indicate that power input is quite dependent on the vessel accessories: for the same agitation rate, the maximum power is required for the membrane structure and the minimum for surface aeration, with the addition of the sparger leading to an intermediate situation. Predictions found in the literature can be used for simple vessels, but may not be applicable when accessories are added to the vessel structure; in such cases, the use of experimental relationships are required. Oxygen transfer rate was dependent on the aeration method and working conditions (agitation and gas flow rates), particularly for sparger aeration. Membrane aeration gave larger oxygen transfer but higher gas pressure and flow rates were required. Surface aeration was the least effective method, nevertheless requiring gas flow rates similar to those used for membrane aeration. The aeration method of choice depends upon the culture and work specificities: surface aeration is limited to small cell concentrations and low oxygen consumption rates. For higher cell concentrations and oxygen consumption rates, both membrane and sparger aeration methods can be applied: the use of the sparger is limited to cells that are not affected by the presence of bubbles or the addition of surfactants, whereas the membrane aeration basket should not be used when a hydrodynamically controlled stirred tank is required.