错位刚柔桨强化搅拌槽内流体混合实验及数值模拟

为消除搅拌反应器中混合隔离区,对标准刚性桨（R-RT）、错位刚性桨（PR-RT）和错位刚柔桨（PRF-RT）三种桨叶体系的流体混沌特性参数、流场结构以及流体运动速度进行了探讨。采用Matlab软件编程计算最大Lyapunov指数（LLE）和多尺度熵（MSE）,通过计算流体力学研究了三种桨叶体系流场结构和流体运动速度的差异。实验及计算结果表明,错位刚柔桨通过柔性桨叶的随机扰动破坏了隔离区介稳态流场边界,较大程度地消除了混合隔离区。PRF-RT的LLE相比于R-RT和PR-RT分别提高了13.29%和7.25%,MSE也较PR-RT和R-RT大;PRF-RT增强了流场不稳定性,形成了不对称性流场结构,减少了隔离区分布范围;PRF-RT强化桨叶能量耗散,提高了搅拌槽底部、顶部液面以及搅拌槽壁区域流体运动速度,减小了流体混合时间。     

弹性搅拌桨强化液-液两相混沌混合及液滴分散特性的研究

传统的混合澄清槽一般采用刚性搅拌桨来实现液-液两相的混合萃取,普遍存在效率低、能耗高等问题。将一种弹性搅拌桨应用在混合澄清槽中,以强化液-液两相混沌混合及分散特性。以最大Lyapunov指数（LLE）和多尺度熵（MSE）表征体系混沌状态,以分散相液滴粒径分布、Sauter平均粒径（D₃₂）等表征分散效果,分别研究了桨叶类型（弹性搅拌桨、刚柔组合桨及刚性桨）、弹簧长度、线径、外径等因素对混沌混合效果和分散特性的影响。结果表明,相比较刚性搅拌桨和刚柔组合搅拌桨,弹性搅拌桨通过弹簧的形变和储能作用,强化了搅拌能量的传递方式,提高了分散相的分散效果,有利于液液两相的混沌混合,在搅拌转速N=200 r/min、弹簧线径为0.6 mm、弹簧相对长度为1.2、弹簧外径为7 mm时,弹性搅拌桨体系的LLE和MSE更大,且MSE值波动最强;同时,各搅拌体系内分散相平均粒径D₃₂与转速呈对数线性关系,弹性搅拌桨体系内分散相液滴尺寸更小且数量更多。     

穿流式刚-柔组合搅拌桨强化混合澄清槽内油-水两相混沌混合

运用LabView和Matlab软件分别采集和处理穿流式刚-柔组合搅拌桨扰动澄清槽中油-水两相流体内部的压力脉动信号,得出的最大Lyapunov指数（LLE）和多尺度熵（MSE）,反映流体内部的混沌程度;同时采用流场可视化技术观测流体混合状态。结果表明,相比于刚性组合桨,穿流式刚-柔组合搅拌桨通过穿流孔与柔性部分的共同作用改变流场的结构和能量耗散方式,使流体的混沌程度和混合状态都优于刚性组合桨。当转速为88 r·min^-1时,流体的混沌混合都达到最佳状态,各实验条件下的LLE均大于零,表明流场混合体系已进入混沌状态,且穿流式刚-柔组合搅拌桨体系的MSE明显高于刚性组合桨体系,说明穿流式刚-柔组合搅拌桨的混合效果优于刚性组合桨。另外,柔性片上穿流孔的数目和柔性桨叶的厚度对流场的混沌特性也有明显的影响。     

刚柔组合搅拌桨强化搅拌槽中流体混沌混合

搅拌槽内普遍存在着两种不同类型的混合区域：混沌混合区和规则区。增大混沌混合区,是提高流体混合效率、降低搅拌过程能耗的重要途径。而合理设计搅拌桨有助于流体形成适宜的流动状态,实现混沌混合。柔性体与刚性体组合,可设计出具有多体运动行为的刚柔组合搅拌桨,可强化流体混沌混合行为。结合Matlab 软件,实验研究了双层桨搅拌槽内自来水体系的最大Lyapunov指数（LLE）和多尺度熵（MSE）的变化规律,对比分析了刚性桨和刚柔组合桨两种桨叶对流体混沌混合的影响。结果表明,刚柔组合桨强化流体的运动特性,使更多流体进入混沌混合状态。在转速为210 r·min^-1时,流体的混沌混合达到最佳状态,刚性桨体系的LLE为0.041,而刚柔组合桨体系的LLE为0.048;刚柔组合桨可有效耗散能量,使整个槽体的能量分布均匀,刚柔组合桨在150 r·min^-1时的多尺度熵率与刚性桨在210 r·min^-1时基本相近;刚柔组合桨体系的混合时间均低于刚性桨体系,在转速为120 r·min^-1时,刚柔组合桨使流体的混合时间缩短了26%左右。刚柔组合桨可改变流场结构和能量耗散方式,强化流体混沌混合,实现高效节能操作。     

柔性桨与自浮颗粒协同强化高黏度流体混沌混合

高黏度流体混合处于层流状态,存在混沌混合区和隔离区,混沌混合是提高其混合效率的有效方法。为增强高黏度流体的混沌混合,在甘油体系中采用柔性搅拌桨并加入自浮颗粒,实验研究了最大Lyapunov指数(LE_max)随单位体积功耗(P_v)的变化规律。结果表明,只加入固体颗粒对原体系LE_max的影响不大,当P_v=2000 W·m^-3时,使用柔性桨后体系LE_max增加10.29%;柔性桨与固体颗粒协同作用时,可使体系LE_max增加30.86%。在P_v≤2000 W·m^-3时,柔性桨和自浮颗粒协同强化高黏度流体混沌混合的效果最好。     

偏心射流-刚柔组合桨搅拌器内混沌混合行为研究

搅拌反应器内普遍存在混合隔离区,是实现高效混合的一大障碍。流场耦合诱发流体的混沌现象,可减少混合隔离区,提高流体混合效率。结合Matlab软件,探究偏心空气射流-单层刚柔组合桨体系的混合行为演变规律,对比分析了不同偏心率下桨叶类型、桨叶离底高度、空气射流量以及转速对流体混沌混合的影响。结果表明,刚柔组合桨通过其自身刚-柔-流的多体运动与偏心空气射流的流场耦合,破坏了流体混合过程中出现的对称性流场,使更多的流体进入混沌状态。刚-柔组合桨（RF-RDT、RF-IRDT）比刚性桨（RDT、IRDT）的LLE值大,其中RF-RDT相比于其他3种类型的搅拌桨（IRDT、RDT、RF-IRDT）,其LLE值分别提高了约42.8%,27.0%、6.9%;空气射流的偏心率等于0.6时,其最大LLE值相比于其他偏心率（0.8、0.4、0.2、0）,依次提高了6.5%、2.4%、17.6%、25.1%。该研究结果可为刚柔组合桨的优化设计提供理论依据。     

Chaotic mixing performance enhanced by rigid-flexible impeller with long-short blades in stirred tank

The presence of a mixing isolation regions in a stirred reactor is a major obstacle to enhancing fluid mixing. Breaking the symmetrical flow field structure in the stirred tank and destroying the mixing isolation area can improve the fluid mixing efficiency. The Matlab software was used to calculate the maximum Lyapunov exponent (LLE) and multi-scale entropy (MSE). The effects of different blade types, flexible blade length, flexible blade number, blade height from bottom and rotation speed on fluid mixing were compared. The results show that the rigid-flexible impeller with long-short blades (RF-LSB) can enhance the flow field structure more unstable and asymmetric with deformation and random vibration of flexible pieces, destroy the symmetry flow in the process of fluid mixing, induce the asymmetric flow field, and make more fluid into the chaotic state. When at 90 r/min and three pieces of flexible, the LLE of the RF-LSB is larger than that of rigid impeller and rigid-flexible impeller RF-LSB with increase of 20.22% and 7.98% respectively. The mixing time (θ_m) of the three systems [RF-LSB (three pieces), rigid impeller, rigid-flexible impeller] has an exponential relationship with the power consumption per unit volume (P_v). When P_v is constant, θ_m of the RF-LSB system is the smallest. Results showed that the RF-LSB (three pieces) is superior to rigid impeller and rigid-flexible impeller, which is more conducive to fluid chaotic mixing.     

长短叶片复合型刚柔桨强化搅拌槽内流体混沌混合行为

搅拌反应器中混合隔离区的存在是强化流体混合的主要障碍。打破搅拌槽中的对称性流场结构,破坏混合隔离区,可以提高流体混合效率。采用Matlab软件编程计算最大Lyapunov指数(LLE)和多尺度熵(MSE),比较了不同桨叶类型、柔性片长度、柔性片数量和桨叶离底高度以及转速对流体混合的影响。结果表明,长短叶片复合型刚柔桨(RF-LSB)桨叶通过刚柔耦合错位连接,柔性片的形变与随机振动对流体的非稳态扰动,使流场结构不稳定性和不对称性增强,强化了流体混合效果。当柔性片数量为3,搅拌转速为90 r/min时,RF-LSB体系比刚性桨和刚柔桨体系的LLE值分别提高了20.22%和7.98%;三种体系[RF-LSB(柔性片数量为3)、刚性桨和刚柔桨体系]的混合时间(θm)与单位体积功耗(Pv)呈指数型关系,当Pv相同时,RF-LSB(柔性片数量为3)的θm最小,表明RF-LSB(柔性片数量为3)更有利于流体混沌混合。     

刚柔组合桨强化粉煤灰酸浸搅拌槽内固液混沌混合

传统粉煤灰提铝工艺中酸浸搅拌槽均采用刚性搅拌桨。因刚性桨卷吸能力有限，导致固体颗粒易沉槽、流体混沌混合效率低。提出刚柔组合桨强化酸浸搅拌槽中固液混沌混合行为。实验基于固含率为30%的粉煤灰-自来水体系，研究了刚柔组合酸浸搅拌槽内混沌混合特性及能量耗散规律。采用扭矩传感器采集扭矩时间序列信号，借助Matlab软件编译计算混合过程中最大Lyapunov指数和多尺度熵等混沌特性参数，以单位体积功耗表征搅拌反应器的功率特性。实验考察了搅拌桨安装离底高度、柔性片长度、柔性片宽度等因素对酸浸槽内粉煤灰混沌混合的影响，对比了刚性桨与刚柔组合桨体系的能耗差异。研究结果表明：刚柔组合桨通过柔性片的作用，能增大搅拌桨的卷吸力，进而减少固体颗粒沉槽现象，促进全槽混沌混合；在最优化条件（120 r/min，搅拌桨安装离底高度为T/4，柔性片长度为1.2H ₁、柔性片宽度为D/8）下，体系最大Lyapunov指数达到最大值0.0645，各尺度下的MSE均比其他条件更大，表明刚柔组合桨能够通过柔性片的多体运动，强化体系混沌混合，均化体系能量分布；刚性桨与刚柔组合桨的单位体积功耗随着转速的增加呈现指数规律增长。     

Chaotic mixing performance and mass transfer enhanced by rigid-flexible impeller with pulse jet

Conventional stirred reactors generally use rigid impeller for mechanical stirring, which leads to the easy creation of isolation mixing regions in the reactor and reduces the efficiency of fluid mixing. The use of multi-flow field coupling to induce chaos and promote more fluids into a chaotic state is one of the effective ways to improve fluid mixing efficiency. In this work, the largest Lyapunov exponent(LLE) and multi-scale entropy(MSE) are investigated with the Matlab compile pressure pulsation signals. The effects of duty ratio, paddle type, flexible paddle thickness, paddle height from the bottom and pulsed air jet flow rate on the chaotic mixing of fluids in a stirred reactor under different pulse periods are explored. In addition, the effects of different impeller types, jet types and air jet flow rate on the volume oxygen mass transfer coefficient K_La are compared and analyzed. When T=0.4 s and D=80%, the results show that the LLE of the rigid-flexible RT impeller compared with the rigid RT impeller increases 11.58% and the MSE of the rigid-flexible RT impeller is also larger than that of rigid RT impeller. It was showed that the pulsed jet rigid-flexible impeller system can better enhance fluid chaos, increase the fluid mixing efficiency and homogenize the system energy distribution. In addition, pulse jet coupling RF-RT impeller system enhances the turbulent characteristics of the fluid, promotes the reduction of the thickness of the liquid film, strengthens the mass transfer and increases the K_La value of the system. When power consumption per unit volume is 360 W/m³, the K_La of the PJ-RF-RT system compared with the PT-R-RT system increases 13.46%, and the K_La of the PJ-R-RT system compared with the SJ-R-RT system increases 11.86%.     

脉冲射流-刚柔组合桨强化流体混沌混合及传质性能研究

传统搅拌反应器普遍使用刚性桨进行机械搅拌,导致反应器内容易产生混合隔离区而降低流体混合效率。采用多流场耦合诱发混沌现象,促使更多流体进入混沌状态,是提高流体混合效率的有效途径之一。结合Matlab软件编译PJ-RF-RT体系中的压力脉动信号得到最大Lyapunov指数(LLE)与多尺度熵(MSE),探究不同脉冲周期下占空比、桨型、柔性桨叶厚度、桨离底高度及脉冲空气射流量对搅拌反应器内流体混沌混合的影响,同时,对比分析了桨型、射流类型、气流量对体积氧传质系数KLa的影响。研究结果表明,在脉冲周期T=0.4 s,占空比D=80%时,RF-RT桨体系较R-RT桨体系的LLE增大了11.58%,且RF-RT体系的MSE显著高于R-RT桨体系,表明脉冲射流刚柔组合桨体系能更好地诱发流体混沌,增大流体混合效率,均化体系能量分布。此外,脉冲射流耦合RF-RT桨体系增强了流体的湍流特性,促使液膜厚度减小,强化了传质,在单位体积功耗Pv=360 W/m3时,PJ-RF-RT体系的KLa较PJ-R-RT提高了13.46%,PJ-R-RT体系的KLa较SJ-R-RT提高了11.86%。     

Chaotic characteristics of pseudoplastic fluid induced by 6PBT impeller in a stirred vessel

Xanthan gum solutions with different mass concentrations were used to study the chaotic characteristics induced by the impeller of perturbed six-bent-blade turbine(6 PBT) in a stirred vessel. Based on the velocity time series obtained by the experiment of particle image velocimetry(PIV), with the software MATLAB(R2016a), the distributions of the largest Lyapunov exponent(LLE) and Kolmogorov entropy(K entropy) of the system, as two important parameters for characterizing the chaotic degree, were investigated respectively. Results showed that both of the LLE and K entropy increased with the increasing speed at the beginning. As the speed was up to 200 r·min-1, the two parameters reached the maximal values meanwhile, corresponding to 0.535 and 0.834, respectively, which indicated that the chaotic degree of the flow field was up to the highest level. When the speed was increased further, both of the LLE and K entropy decreased on the contrary, which meant that the chaotic degree was decreasing. It was also observed that the chaotic characteristics of flow field were hardly affected by the fluid rheology and the detecting positions. The research results will enhance the understanding of the chaotic mixing mechanism and provide a theoretical reference for optimizing impeller structure.     

Chaotic mixing behavior of non-Newtonian fluid intensified by multilayer rigid-flexible impeller induced flow field interface instability

The traditional multilayer rigid impeller has large dead zone for the mixing of pseudoplastic non-Newtonian fluid, stable flow field interface and low mixing efficiency. A method for enhancing the chaotic mixing of non-Newtonian fluid by multilayer rigid-flexible impeller induced flow field interface instability was proposed. In the experiment, sodium carboxymethylcellulose was used as the non-Newtonian fluid system. The power characteristics were measured by the torque sensor. The mixing time was determined by the acid-base neutralization and decolorization method. The largest Lyapunov exponents were calculated by using Matlab software programming. The chaotic characteristics and mixing performance in the mixing process are analyzed. The results show that when the combination mode was RF-(PBTD+PBTD+DT), the impeller arrangement mode θ=60°, and the flexible sheet length installation ratio r=0.8, 1.2, the degree of chaos was higher and the mixing performance was better. Multilayer rigid-flexible impeller can generate multiple spiral flows, and realize the flow field interface instability under the disturbance frequency difference of the flexible sheet between the layers, the stirring dead zone was reduced, and the system enters a chaotic state at a lower speed (when the multilayer rigid-flexible impeller system N>88 r/min, LLE>0; when the multilayer rigid impeller system N>125 r/min, LLE>0). At the same speed, the mixing rate and power per unit volume of the multilayer rigid-flexible combined impeller are higher than that of the multilayer rigid impeller, but the mixing energy per unit volume is approximately the same.     

多层刚柔组合桨诱发流场界面失稳强化非牛顿流体混沌混合行为

传统多层刚性桨用于假塑性非牛顿流体混合搅拌死区较大,流场界面稳定,混合效率低。提出多层刚柔组合桨诱发流场界面失稳强化非牛顿流体混沌混合的方法。实验以羧甲基纤维素钠为非牛顿流体体系,通过扭矩传感器测量功率特性,酸碱中和脱色法测定混合时间,并利用Matlab软件编程计算最大Lyapunov指数,分析了非牛顿流体混合过程中的混沌特性及其混合性能。结果表明,组合方式为RF-(PBTD+PBTD+DT)、桨叶排列方式θ=60°、柔性片长度安装比例r=0.8、1.2时,混沌程度较高,混合性能较好。多层刚柔组合桨可以产生多股螺旋流,并在层间柔性片扰动频率差下实现流场界面失稳,搅拌死区减小,在较低转速下使体系进入混沌状态(多层刚柔组合桨体系N>88 r/min时LLE>0,多层刚性桨体系N>125 r/min时LLE>0);在相同转速下,多层刚柔组合桨混合速率、单位体积功率高于多层刚性桨,而单位体积混合能大致相同。     

Experiment and numerical simulation of chaotic mixing performance enhanced by perturbed rigid-flexible impeller in stirred tank

To eliminate the isolated mixing regions in the stirred tank, factors associated with chaotic mixing performance were studied, including flow field structure and fluid velocity of rigid RT impeller (R-RT), perturbed rigid RT impeller (PR-RT) and perturbed rigid-flexible RT impeller (PRF-RT). The maximum Lyapunov exponent (LLE) and multi-scale entropy (MSE) were calculated by using Matlab software programming, and the differences in flow field structure and fluid velocity of the three blade systems were studied through computational fluid mechanics. The experimental and computational results showed that perturbed rigid-flexible RT impeller could destroy the boundary of the mesostatic flow field in the isolated mixing regions and the symmetry flow in the process of fluid mixing through the random disturbance of the flexible blade, eliminating the isolated mixing regions. At 90 r/min, the LLE of the perturbed rigid-flexible RT impeller is larger than that of rigid RT impeller and perturbed rigid RT impeller. The LLE of the rigid-flexible RT impeller compared with the rigid RT impeller and perturbed rigid RT impeller increases 13.29% and 7.25% respectively and the MSE of the perturbed rigid-flexible RT impeller is also larger than that of rigid RT impeller and perturbed rigid RT impeller. The perturbed rigid-flexible RT impeller enhances the flow field instability, forms an asymmetric flow field structure, and reduces the distribution range of isolated mixing regions. The perturbed rigid-flexible RT impeller enhances the energy dissipation of the blade, improves the fluid velocity at the bottom and top of the tank and the wall of the tank, and reduces the mixing time.     

新型大双叶片搅拌器功率与混合特性的数值模拟

针对过程工业体系特性复杂多变的特点,开发了新型大双叶片宽适应性搅拌器,并建立了描述其流动、混合过程的综合数学模型,模拟分析了搅拌釜内的功率特性、流场特性和混合特性。模拟结果表明:新型大双叶片搅拌器所形成流场中存在着上部叶片区域循环流、下部叶片区域循环流以及纵贯全釜的整体循环流;随体系黏度增加,新型大双叶片搅拌器所产生流场的轴向速度、径向速度和切向速度均波动趋缓,且仍保持良好的功率与混合特性,对流态和黏度具有宽适应性;对新型大双叶片搅拌器而言,近液面加料方式不利于整体混合,适宜的加料点应在上下叶片之间,以缩短混合时间;在消耗相同单位体积功率的前提下,新型大双叶片搅拌器较同尺寸规格的FZ搅拌器的混合效率更高,具有高效节能的竞争优势。模拟结果对改进和优化新型大双叶片搅拌器的结构与运行具有参考价值。     

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.     

搅拌槽内气液两相混沌混合及分散特性

传统Rushton刚性桨常应用于过程工业中搅拌反应器内的气液分散过程,但由于桨叶背后易形成较大的气穴,气液混合效果较差。为了提高搅拌槽内气液两相的混合效果,提出了一种刚柔组合桨强化气液两相的分散过程。利用LabVIEW软件处理刚性桨和刚柔组合桨体系中气液混合过程的压力脉动信号,通过Matlab软件编程计算最大Lyapunov指数（LLE）,分析气液混合体系的混沌混合行为,同时,对刚性桨和刚柔组合桨体系中的相对搅拌功耗、整体气含率、局部气含率进行测量。结果表明,在功耗为170 W,通气量为10 m³·h^-1条件下,与刚性桨相比,刚柔组合桨能够通过刚-柔-流的耦合作用促进桨叶能量的传递过程,提高搅拌体系的混沌混合程度,刚柔组合桨体系的LLE提高了8.89%。同时,在相同操作条件下,与刚性桨相比,刚柔组合桨能够有效提高相对搅拌功耗以及搅拌槽内的整体气含率和局部气含率,且搅拌槽内气体分散更为均匀。     

几种框式桨搅拌槽内流动特性的比较研究

用粒子成像测速（PIV）技术对传统框式桨、传统框式组合桨和新型框式组合桨的流动特性进行研究,对比了三种框式桨在相同工况下搅拌槽内的速度、流型和湍动能。结果表明：传统框式桨搅拌槽内流体流动以水平环流为主,在框式桨上方和框式桨中间区域流体流动不充分;传统框式组合桨搅拌槽内框式桨上方由于二折叶桨的作用使得框式桨上部流体流速变大,槽内流体上下部的流动得到加强,但在框式桨中心区域依旧存在流动死区;新型框式组合桨搅拌槽内两层桨叶间的连接流得到了加强,框式桨底部和中间区域物质和能量的交换更加充分。在考察的三种框式桨中,新型框式组合桨的混合效果更好。研究结果可为新型框式组合桨应用于化工合成工业中提供参考。     

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。