放大准则对混合澄清槽混合室中混合时间和流动特性的影响

工业混合澄清槽混合室的放大设计多基于操作经验,缺乏理论基础。基于几何相似放大,采用计算流体力学(CFD)方法,针对间歇操作的单相体系,对4 种不同放大准则下混合室内混合时间和流场特性的变化规律进行研究。结果显示,混合时间的计算值与测量位置有关,但随转速的增加受测量位置的影响减小;充分湍流条件下,本研究体系的功率准数趋于常数N_P=1.3,且几何相似放大可以保证混合室中轴向流动的流型特征;等桨叶端面速度和等Reynolds 数准则下,所需混合时间长,且抽吸压头小;等循环时间准则下,可以得到与基准混合室相同的混合时间和较高的抽吸压头,但单位体积功耗急剧增加到基准槽的24 倍;等单位体积功耗准则下,在满足具有较低的混合时间和较高的抽吸压头的同时还保证了较低的单位体积功耗,优于其他3 种放大准则。     

Mass transfer into simulated fermentation media

The rates of oxygen mass transfer into a simulated fermentation medium, made up of 16 kg of paper pulp per m³ of aqueous sodium sulphite solution with a cupric ion catalyst, were determined in vessels of 0·187, 0·291 and 0·451 m dia., using flat-bladed turbine impellers, and the effect of varying impeller dimensions and operating speed were investigated. Above a critical impeller tip speed the volumetric mass transfer coefficients obtained at the same speed with different power inputs (produced by variations in the impeller blade dimensions) could be represented by the sum of two terms, one depending on the impeller speed, the diameters of the impeller and vessel, and the height of pulp suspension in the vessel, and the other function of the power input per unit volume and the air velocity through the vessel. At each impeller speed the increase in the volumetric mass transfer coefficient with power input was found to be greater below a certain power input per unit volume, and a correlation for this power per unit volume was based on it corresponding to a change in the rate of air recirculation through the impeller. The expression for the mass transfer coefficient provides a more accurate basis for scale-up than the use of simple rules, such as constant power per unit volume.     

Scale-Up Study of Dye RB-19 Ozonation in a New Gas-Inducing Reactor

The purpose of this research was to study the scale-up behavior of dye RB-19 ozonation in a new gas-inducing reactor, which has been used in the NTUST laboratory on various ozonation studies over the past few years. In this scale-up study, three geometrically similar gas-inducing reactors with different diameters (D _t =0.17, 0.29, and 0.51m) were employed. Three common scale-up criteria (i.e., equal liquid surface motion, equal specific power consumption, and equal impeller tip velocity) were investigated in this research. Under the equal liquid surface motion criterion, the scale-up exponent value and constant K of the modified onset Froude number were determined to be 0.5 and 0.61, respectively. The equal specific power consumption criterion was studied under gas input condition and the scale-up exponent was found to be 0.65. The regression equation for the power number of the three different scale reactors was also obtained. The scale-up exponent of equal impeller tip velocity was determined by theory to be 1.0. The scale-up investigation of dye RB-19 ozonation was then carried out in reactors with three different diameters under the same operating conditions (e.g., initial dye concentration, initial dye/ozone molar ratio, superficial gas velocity, temperature and pH value). From the experimental results, the best-fit scale-up exponent was found to be 1.18, resulting in same dye removal rate in reactors with different diameters. The enhancement factors and chemical ozone mass transfer coefficients were also obtained for these sets of ozonation experiments.     

Effect of impeller type and scale-up on spatial distribution of shear rate in a stirred tank

The main spatial distribution features of shear rate in a stirred tank operated with five different radial and axial flow impellers were presented with particle image velocimetry (PIV) experiments. Not only the average shear rate in the whole tank but also the local value in the vicinity of impeller increases linearly with impeller speed. Furthermore, the shear coefficient (K_s,imp) at the impeller outlet is linearly related to the impeller flow number (N_q) and decreases with the increase of N_q in general at the constant power consumption per unit volume (P_v). During scale-up based on the constant P_v and geometric similarity, CFD results show that the volume-averaged shear rate (γ_avg) for RDT decreases faster than that of other impellers with the impeller tip velocity (U_tip). The novel multi-blade combined (MBC) impeller with the increased height-to-diameter ratio of the stirred tank is able to more effectively improve the distribution uniformity of shear rate at the same P_v after scale-up. These studies provide a data basis for selecting the impeller types and improving the shear rate environment in the large-scale stirred tank.     

Konzept zur Maßstabsübertragung beim Suspendieren im Rührbehälter

Concept for Scale-up on Suspension in a Stirred Tank. The relationships derived for the suspension of solids in a propeller loop can be applied to corresponding processes in a stirred tank by means of analogy considerations. Accordingly, the ratio of stirrer power to slip power of laminar flow state is inversely proportional to the vessel diameter. In contrast, the power ratio remains constant in turbulent flow. There is a pronounced transition range between these two limiting states. The author's own experimental studies performed over a wide range of Re numbers for the recycling flow confirm this relationship. The observations presented explain why numerous authors have determined scale-up rules lying between these two extremes. The experiments shows that the power input for suspension is always significantly greater than the slip power. Under otherwise identical conditions, the necessary stirrer power is smaller by a factor of three for a propeller stirrer than for a disk impeller. The suspension of small solids concentrations can also be approximated by the flow model presented. The somewhat different physical relations valid in this case are substantiated by the author's experiments. The model also provided information relevant to scale-up when the particle properties are unknown. This is demontrated for an example in a 21 m³ vessel.     

Effect of scale of operation on granule strength in high shear granulators

Results of a study on the influence of operation scale and impeller speed of high shear mixer granulators on the strength of granlues are reported in this paper. Calcium carbonate particles have been granulated in four scales of a geometrically similar high shear granulator (Cyclomix) with 1, 5, 50 and 250 L capacities. For the smallest scale, the effect of a small deviation from geometric similarity was also investigated. An aqueous solution of polyethylene glycol was used as the binder. Three scaling rules of constant tip speed, constant shear stress and constant Froude number have been used to determine the impeller speed for the different scales of the granulators. The granules produced in these experiments have been dried and tested for strength using side crushing test method. The data have then been analysed and compared. Operation of granulators according to the constant tip speed rule produces granules with a similar strength for all four scales, followed by a similar trend for the constant shear stress rule, albeit to the less extent. The constant Froude number rule produces a heterogeneous strength distribution and is not a suitable criterion for scaling-up of high shear granulators. The distribution of granule strength has been fitted to the normal, log-normal and Weibull distributions. Weibull distribution fits the data well for the constant tip speed operations.     

搅拌槽中酯化反应热失控的CFD模拟

热失控是化工过程中常见的安全风险之一。在间歇釜式反应器中,桨叶的机械转动可以增强流体的循环流动、湍流强度、混合程度以及传热,进而有效防范热失控。防控效果与反应器结构和搅拌桨型密切相关。针对丙酸异丙酯酯化反应,采用计算流体力学模拟研究了桨型(Rushton桨、30o PBT桨及60o PBT桨)、转动方向和挡板对釜式反应器内温度演化的影响,从流动结构方面分析了原因。基于散度的失控判据比较了三种搅拌桨抑制热失控的能力,抑制能力为Rushton桨＞30° PBTD桨＞60° PBTD桨。本研究可为搅拌反应器热失控的优化设计提供一定的理论依据。     

搅拌槽中气泡大小分布规律的研究

运用改进后的光电毛细管探头技术测量了搅拌槽中较宽操作条件范围内的气泡大小分布,由湍流理论分析了叶轮区和循环区影响气泡大小的主要因素,得到了气泡大小空间分布的初步规律及不同区域内的气泡平均直径与操作条件之间的定量关系.     

POWER CONSUMPTION AND SOLID SUSPENSION IN COMPLETELY FILLED VESSELS

Mixing in a completely filled vessel, designed as a pressure vessel, has been investigated. The power demand of two pitched blade turbines of different sizes, and one high flow impeller was studied. The influence of side-mounted and bottom-mounted baffles, as well as the clearance between the bottom and the impeller was investigated. The experiments were carried out in a plexiglass vessel with a diameter of 288 mm. The Power number was calculated from measured data on the power demand and the impeller speed. Furthermore, preliminary studies on the critical impeller speed and power demand at the off-bottom suspension point for one set of glass particles were carried out. The Power number was mainly influenced by the impeller type, while the power demand at the off-bottom suspension point was more dependent of the impeller size and clearance. For bottom-mounted baffles a minimum in the Power number was noticed with increased clearance. It was found the minimum was located at the transition point between two different How patterns. This study shows that the configuration with the lowest Power number is not necessary the most efficient for suspending solid particles.     

An LDA study of the turbulent flow field in a baffled vessel agitated by an axial,down-pumping hydrofoil impeller

The turbulent flow of water in a cylindrical, baffled vessel with an axial flow hydrofoil impeller, either a Chemineer HE3 (CHE3) or a Prochem Maxflo T (PMT), has been studied using a laser Doppler anemometer. Using ensemble averaging, the mean axial and radial flow and the associated fluctuating components were obtained for the whole of the vessel; plus similar data for the tangential component close to the impeller. Assuming axial symmetry, flow rates were calculated as were flow numbers and circulation flow numbers. Power numbers were also determined. All the data obtained were used to compare the circulation efficiency of the two hydrofoils plus a pitched blade and a Rushton turbine. This comparison showed that the CHE3 required a power input of about 2/3 of that for the PMT and about 1/3 of that for the pitched blade and Rushton turbine to obtain the same axial-radial circulation in the tankz.     

Perturbed turbulent stirred tank flows with amplitude and mode-shape variations

Stirred tank (STR) flows at low and moderate Reynolds numbers show poor mixing behavior due to formation of segregated zones inside which both magnitude and fluctuation level of velocity components show lower values compared to the active fluid regime (i.e., impeller jet stream, circulation loops). Active perturbation of the STR flow using a time-dependent impeller rotational speed can potentially enhance mixing by breaking up these segregated unmixed zones and enhancing the turbulence level throughout the tank volume. In the present study, the effect of different perturbation cycles on an unbaffled turbulent stirred tank flow at a moderate Reynolds number (rotational speed N=3 rps) is studied using a large-eddy simulation (LES) technique coupled with immersed boundary method (IBM). The perturbation frequency (f) is chosen to correspond to a dominant macro-instability in the flow (f/N=0.022). Two different perturbation amplitudes (20% and 66%) and two perturbation shapes (square-wave and sine-wave) are investigated, and changes in the mean flow field, turbulence level and impeller jet spreading are examined. Large-scale periodic velocity fluctuations due to perturbations are noticed to produce large strain rates favoring higher turbulence levels inside the tank. Production of turbulent kinetic energy due to both the mean and periodic component of the velocity field is presented. Fluctuations in power consumption due to perturbation are also calculated, and shown to correlate with the perturbation amplitude.     

Zur Maßstabsübertragung beim Suspendieren im Rührgefäß

Scale-up of agitated vessels in the case of suspensions . In the scale-up of agitated vessels a decrease of specific power input ε is recommended in the case of suspensions. Up to now it has been assumed that turbulence is the reason for this decrease. This paper shows that there may also be a contribution due to decreasing wall areas causing less wall shear stresses and moreover a reduction of circulation due to lower cross-sectional areas per unit volume of the threads of flow. In the case of so-called ?complete suspension”? according to the ?1-s criterion”?, two mechanisms can be distinguished: On the one hand we have a lifting of solid particles without, and on the other hand such a lifting with formation of bulk accumulations of solids on the bottom of the vessel. In the first case, scale-up can be done as for a homogeneous distribution of the solid material. The specific power input ε is ～ μ⁰ up to ε ～ μ^?1 with the scale-up factor μ. In the second case (formation of dense solids clouds) a relationship ε ～ μ^m with m > 0 was found.     

Solids motion in a conical frustum-shaped high shear mixer granulator

An experimental study has been carried out on the solids motion in a conical frustum-shaped vertical high shear mixer granulator by using the positron emission particle tracking (PEPT) technique. The mixer granulator has a vertical shaft attached to which are 4 sets of impellers at different elevations. The shaft is operated at 3, 6 and 12 Hz, which correspond to the top impeller tip speed of 2.1, 4.1 and 8.3 m/s. Particles are observed to circulate in both the horizontal and vertical directions. The period of horizontal circulation is short and is in the order of seconds, whereas that of the vertical circulation takes tens of seconds and often consists of lots of higher frequency fluctuations. There is a dominant solids motion in the tangential direction at all impeller speeds with the maximum tangential velocity 2.2-5.3 times that of the maximum axial and radial velocities. The maximum values of the three velocity components increase with increasing impeller speed, but the ratios of the maximum velocity to the tip speed decreases with increasing impeller speed, suggesting a rate-dependent behaviour. The particle flow pattern shows the presence of swirling flows at a position depending on the impeller speed. The results also suggest the existence of an optimal impeller speed that gives the best macroscopic mixing characterised by the vertical solids circulation.     

Continued self-similar breakup of drops in viscous continuous phase in agitated vessels

Drop breakup in viscous liquids in agitated vessels occurs in elongational flow around impeller blade edges. The drop size distributions measured over extended periods for impellers of different sizes show that breakup process continues up to 15–20 h, before a steady state is reached. The size distributions evolve in a self-similar way till the steady state is reached. The scaled size distributions vary with impeller size and impeller speed, in contrast with the near universal scaling known for drop breakup in turbulent flows. The steady state size of the largest drop follows inverse scaling with impeller tip velocity. The breadth of the scaled size distributions also shows a monotonic relationship with impeller tip velocity only.     

轴流式搅拌器湍流运动特性

引言 搅拌混合是化工工业过程中最常见,也是最重要的单元操作之一,其主要目的是加速体系中传质或传热过程.     

Characterisation of three different impellers using the LDV-technique

A characterisation of three commonly used impellers was made in this study by measuring local mean velocities and the fluctuations of these velocities with the LDV technique. The data was used to estimate volumetric flow, velocity fluctuations and turbulent intensity in the impeller region of the tank. The impellers investigated were a high flow impeller, a pitched blade turbine and a Rushton turbine. The cylindrical vessel used was made of Perspex, had a dished bottom (DIN 28013), was equipped with four baffles and had an inner diameter of 0.45 m. It was found that the bulk velocities could be scaled with the tip-speed of the impeller (ND). The flow rate at constant impeller speed increased in the order high flow impeller — Rushton turbine — pitched blade turbine. The corresponding order for the turbulence fluctuation is: high flow impeller — pitched blade turbine — Rushton turbine. The velocity profile of the flow out from the high flow impeller was furthermore, not as smooth as could be expected.     

最大叶片式桨在假塑性流体中的搅拌流场模拟

为研究最大叶片式桨在高黏假塑性流体中的搅拌流动行为,以黄原胶溶液为研究体系,采用计算流体力学方法重点研究了釜内流体的功耗特性、速率分布、剪切速率、表观黏度分布和总体流动状况。结果表明:最大叶片式桨具有与大多数径流桨相似的"双循环"流型结构,且预测的功耗特性与实验数据一致性良好。最大叶片式桨适用于高黏假塑性流体的混合,而对于高黏牛顿流体的混合则效果不佳。釜内的剪切速率分布较宽泛,且受转速影响较大。转速可作为该桨改善黄原胶体系混合效率的重要参数之一。     

Scalar mixing measurements in batch operated stirred tanks

An LIF technique was used to obtain unobtrusive measurements of scalar concentration as a function of time and mixing times in a fully baffled batch operated mixing vessel agitated by five forms of impeller (Rushton, ‘bucket’, six bladed 45°-and 60°-pitched blade, hyperboloid). The mixing time was comparable to the time required for the dye/scalar to be transported from the top of the vessel to the bottom part plus the time required for a further two rotations of the bulk flow in the circumferential direction. At constant power input the mixing times for similar impellers were similar, although different for different types.     

Effect of scale on the draw down of floating solids

In this study, the draw down of floating solids from the liquid surface has been investigated using vessels of 0.61 and 2.67 m diameter. The importance of impeller type (mixed flow pitched blade turbine (PBT) and the narrow blade hydrofoil LE-20), pumping mode and position and the effect of varying liquid height have also been studied. Impeller speed and power consumption at which no solids remain at the surface for more than 2-4 s are determined by visual observations.Results from different scales are discussed in relation to the way in which solids are drawn down from the liquid surface. It has been shown that over a wide range of conditions the power required for drawing down solids can be reduced by operating in the upward rather than downward pumping mode and using an axial flow narrow blade hydrofoil rather than a mixed flow pitched blade turbine. Different scale up criteria, power per unit volume, tip speed and Froude number, are discussed for these systems. For scale up, specific power input is shown to be the most appropriate criterion for upward pumping impellers.