A novel approach for determining the flow patterns in centrifuges by means of Laser-Doppler-Anemometry

The flow pattern in process machinery has a significant impact on the product quality, because it influences the residence time, the mixing of components and the stability of chemical reactions. Hence the determination of the residence time and the measurement of the flow patterns have been the emphasis of many studies. The work presented shows a novel approach for the determination of the tangential and axial velocity profiles in a tubular bowl centrifuge. For the first time, flow velocities inside a fast rotating centrifuge have been measured using Laser-Doppler-Anemometry. The rotor of the centrifuge is made of carbon fibre reinforced plastic with an inner diameter of 100 mm and a length of 200 mm. The maximum rotational speed is 20,000 rpm, creating the multiple of 22,400 times the earth gravitational force. No failure of the material was detected at any process parameters. The centrifuge is operated with two different setups. One setup employs an assembly of two coaxial cylinders, in which the void between them is entirely filled with water. In the second arrangement, only the outer rotor is assembled and the centrifuge is operated like an overflow centrifuge. The Laser-Doppler measurements of the axial fluid velocity are confirmed by determining the residence time distribution at various parameters. The results obtained show an effective tangential acceleration; the liquid exhibits a rigid body rotation for rotational speeds up to 8000 rpm for throughputs between 0.5 and 1.8 l/min. The axial flow pattern depend on the volume flux and the rotational speed. The cross-section through which the liquid flows was in most cases between 60% and 100% of the overall area. The influence of the inlet subsides towards the outlet with an inlet zone of 15% of the length of the rotor. No boundary layer flow was detected in the overflow setup, which is due to the plunged inlet and the effective tangential acceleration of the incoming liquid.     

FLOW IN AGITATED THIN FILM HORIZONTAL EVAPORATOR

We made a theoretical analysis for an axial flow of a working liquid of low viscosity without concern for the thermal effects. Variables studied were rotational speed of wiping blades, volumetric flow rate and viscosity.

When the viscosity is low, theoretical values are in proper accord with experimental ones. As a result, we can say that the residence time and the effective area for heat transfer are able to be controlled (when the viscosity is low) by selecting the rotational speed.     

Characterization of Mixing and Size Segregation in a Rotating Drum by a Particle Tracking Method

The mechanisms of segregation in solids mixing, even in simple rotating drums, are not clearly understood. Although most past studies have focused on binary mixtures, this work investigates the effect of polydispersity on granular flow, mixing, and segregation in a rotating drum operated in rolling regime through particle trajectories obtained from the radioactive particle tracking technique. Velocity profiles, radial segregation, and axial dispersion coefficients for monodisperse and polydisperse systems of glass beads are analyzed with respect to rotational speed and particle size. A model is introduced to predict the residence times along streamlines and evaluate the rate at which the material renews at the free surface and within the inner layers of the bed. Our results reveal similar velocity profiles and residence times for monodisperse and polydisperse systems. They also indicate that the particles distribute along the radial direction of the drum, although not necessarily in a core/shell configuration. © 2012 American Institute of Chemical Engineers AIChE J, 59: 1894–1905, 2013     

Comparison of two-phase upflow and downflow fixed bed reactors performance: Catalytic SO2 oxidation

A time- and space-dependent model based on the piston-dispersion-exchange model for liquid flow was developed to analyze the performance of two-phase upflow and downflow fixed bed reactors and was applied to the catalytic SO₂ oxidation. The hydrodynamic parameters were determined from residence time distribution measurements, using an imperfect pulse method for time-domain analysis of nonideal pulse tracer response. A transient diffusion model of the tracer in the porous particle coupled with the PDE model was used to interpret the obtained RTD curves. Gas-liquid mass transfer parameters were determined by a stationary method based on the least square fit of the calculated concentration profiles in gas phase to the experimental values. It is shown that two-phase downflow fixed bed reactor performs better at low liquid flow rates, while two-phase downflow fixed bed reactor performs better at low liquid flow rates, while two-phase upflow performs better at high liquid flow rates.     

Droplet characteristics in the multi-staged high speed disperser with single inlet

Droplet characteristics in the cavity zone of a multi-staged high speed disperser with single inlet were studied in this paper. The influences of both the operating and structural parameters on the mean droplet diameter, size distribution and liquid flux distribution were quantitatively analyzed. The result showed that the mean droplet diameter decreased with the increase of rotational speed and the number of rotors;whilst there is little influence on the inlet flow rate. In the experimental range, the minimum value of mean droplet diameter is 0.57 mm, 0.48 mm, 0.41 mm in the two-staged, three-staged and four-staged rotors, respectively. The Rosin–Rammler(R–R) distribution could describe the droplet size distribution appropriately, and it became uniform with the increase of rotational speed and the number of rotor, while the inlet flow rate had little effect on the droplet size distribution. The liquid flux distribution curves were always unimodal. With the increase of rotational speed, the location of maximum liquid flux ratio moved from zone 3 to zone 4 and this value decreased from 22.1% to 18.1%. Using Coefficient of Variation(CV) to indicate the uniformity of liquid flux distribution, it was found that the CV decreases from 47.5% to 22.7%when the number of rotor increased from 2 to 4.     

FLOW IN AGITATED THIN FILM HORIZONTAL EVAPORATOR

Abstract

We made a theoretical analysis for an axial flow of a working liquid of low viscosity without concern for the thermal effects. Variables studied were rotational speed of wiping blades, volumetric flow rate and viscosity.

When the viscosity is low, theoretical values are in proper accord with experimental ones. As a result, we can say that the residence time and the effective area for heat transfer are able to be controlled (when the viscosity is low) by selecting the rotational speed.     

Process intensification of gas–liquid downflow and upflow packed beds by a new low‐shear rotating reactor concept

In the present work, a new low‐shear rotating reactor concept was introduced for process intensification of heterogeneous catalytic reactions in cocurrent gas–liquid downflow and upflow packed‐bed reactors. To properly assess potential advantages of this new reactor concept, exhaustive hydrodynamic experiments were carried out using embedded low‐intrusive wire mesh sensors. The effect of the rotational velocity on liquid flow patterns in the bed cross‐section, liquid saturation, pressure drop, and regime transition was investigated. Furthermore, liquid residence time and Péclet number estimated by a stimulus‐response technique and a macro‐mixing model were presented and discussed with respect to the prevailing flow patterns. The results revealed that the column rotation induces different flow patterns in the cross‐section of the packed bed operating in a concurrent downflow or upflow mode. Moreover, the new reactor concept exhibits a more flexible adjustment of pressure drop, liquid saturation, liquid residence time, and back‐mixing at constant flow rates. © 2016 American Institute of Chemical Engineers AIChE J, 63: 283–294, 2017     

Cyclic variation of the liquid flow residence time in periodically operated trickle-bed reactors

The cyclic variation of the mean residence time of the liquid phase is investigated in a trickle-bed reactor operated with a liquid feed rate modulated in a periodic square wave pattern. Experiments made using a salt tracer method are compared to a residence time model, based on the concept of continuity shock waves. The model predicts accurately the mean residence times and their cyclic variation in case of a non-zero base liquid flow rate. A particular application of the model is the adjustment of the feed cycle parameters in order to obtain a constant residence time of the liquid, no matter the moment at which it enters the bed. This particular cycle duration depends, among others, on the feed rates, but also on the bed length.     

Residence time distribution in a real single screw extruder

The residence time distribution in an industrial single screw extruder was investigated experimentally in the case of melt and plasticating extrusion. The investigations performed proved that the extrusion parameters influence strongly the residence time distribution in the extruder. It was found that the resistance to flow through the die-head of the extruder is very important from this point of view, as well as other parameters like rotational speed of the screw and the screw channel depth. Variation of these parameters can change the residence time distribution over a broad range between the extreme idealized cases of plug flow and flow with perfect mixing. In order to obtain quantitative dependences three moduli were used and a correlation equation was obtained. This equation enables an estimation of residence time distribution on the basis of experimental characteristics of the extruder and the actual extrusion parameters.     

折流式旋转床持液量的研究

将折流式旋转床分成若干液体流动区,计算流动区内动、静圈壁上液膜及动、静圈之间液滴的运动时间,在此基础上建立折流式旋转床持液量模型. 以空气-水为物系,在直径300 mm、高51 mm的折流式旋转床中进行实验,分别测得不通和通空气时转子的持液量,用实验数据拟合出持液量模型参数. 结果表明,转子持液量随液量和气量增加而增加,随转子转速增加而减小,高转速下气量对持液量的影响明显减弱. 折流式旋转床不通气持液量为2.35%~3.68%,是普通丝网旋转填料床不通气持液量的1.32~2.06倍.     

新型径向叶片式旋转床压降分析及气相流场模拟

针对折流式旋转床压降高、能耗大的问题,提出了一种新型超重力旋转床设备--径向叶片式旋转床。首先,对该旋转床的压降进行了理论分析和建模,并利用水-空气体系进行了实验研究。通过改变气量、转速和液量探究了新型径向叶片式旋转床压降的变化规律,结果表明压降随气量、转速和液量的增加而增加,且随着气量和转速的增加,液量对压降的贡献逐渐减小。压降模型的预测值与实验数据的相对偏差基本在10%以内,表明模型可以较好地预测新型径向叶片式旋转床的压降。另外,通过计算流体力学（CFD）软件的模拟获得了旋转床内气相流场和压力分布的结果,发现转子内压降是总压降的主要部分;气体进入转子后会因叶片作用使得周向速度变大,并在转子外缘处达到最大值;气体的进口流速将会影响旋转床内的气相分布。利用实验数据对CFD模拟结果进行了验证,两者的相对偏差在10%左右。     

气液旋流器内液相平均停留时间

旋流设备内伴有传热、传质或反应过程时,介质停留时间是其关键参数。在冷模实验装置上,采用持液量法,对气液旋流器内液相平均停留时间进行了研究。结果表明,液相停留时间随入口含液率增大明显降低,随入口气速增大降低较小。气液界面剪切力远小于液相重力是入口气速对液相停留时间影响较小的主要原因。基于液膜受力平衡,建立了气液旋流器内液相平均停留时间模型。模型预测停留时间与实测值总体吻合良好,在液膜Reynolds数Re_l< 1200范围内,模型预测停留时间偏大,讨论了模型预测偏差与液膜流型的关系。     

小型气-液-固流化床液相的停留时间分布

采用脉冲示踪技术,研究了3 mm床径的小型气-液-固流化床内液相停留时间分布。以KCl为示踪剂,液相为去离子水,气相为空气,固相为平均粒径0.123~0.222 mm的玻璃微珠和氧化铝颗粒,测量流化床出口液相的电导率,得到其停留时间分布曲线。结果表明,增大表观液速和表观气速,分布曲线变窄,平均停留时间缩短,Peclet数增大;固相的存在使液相的平均停留时间增长。表观液速1.96~15.70 mm×s^-1,表观气速1.18~1.96 mm×s^-1的条件下,流动接近层流;平均停留时间的范围为（19.6±0.34）s~（48.0±0.92）s,建立的Pe经验关联式对实验结果有较好的预测,偏差在±25%以内。研究结果对于小型三相流化床的设计放大具有指导意义。     

分子蒸馏过程的计算流体力学模拟

采用计算流体力学(CFD)方法,分析了蒸发器上液体负荷、刮膜器旋转速度对蒸发器上液膜厚度变化及液膜中速度矢量的影响。将CFD模拟结果与文献报道的计算值和实验值进行比较,发现具有较好的吻合性,同时可以用模拟计算结果解释一些实验现象。采用脉冲注射示踪剂法测定了蒸发器上流体的平均停留时间分布,与CFD模拟的在刮膜器作用下蒸发器上流体平均停留时间分布数据进行比较,二者的偏差在±8%以内,验证了CFD模拟的准确性。     

Performance of a rotating zigzag bed—A new HIGEE

As a new kind of rotating equipment, rotating zigzag bed (RZB) is structurally unique and has many superior features. The RZB is characterized by a rotor coaxially combining a rotating disc with a stationary disk. Compared with a conventional rotating packed bed (RPB), the RZB can function without liquid distributors, eliminate one dynamic-seal, and easily accommodate and accomplish intermediate feeds in continuous distillation processes. The RZB also effectively increases the contact time of gas and liquid phases and thus, enhances the mass transfer capacity. In this work, the principles of the RZB are presented. The hydraulic and mass transfer performance of the RZB was investigated. Experimental results showed that the pressure drop of the RZB increases with the increase of the rotational speed and the gas flow rate, but decreases with the increase of the liquid flow rate. A semi-empirical equation was proposed to correlate the pressure drop data with good agreement. The mass transfer efficiency of the RZB decreases with the increase of the reflux rate at lower reflux rate, but levels off at higher reflux rate. The number of theoretical plates of the RZB increases with the increase of rotational speed of the rotor. However, at a higher rotational speed, this trend is not obvious. In addition, some considerations for further work are discussed.     

流化床稀相区淤浆停留时间和蒸发时间的计算

以Hypol聚丙烯工艺第三反应器为例,计算了淤浆液滴在气相流化床反应器稀相区的平均蒸发时间和平均停留时间,并讨论这2个计算值之间的关系,结果表明,淤浆液滴在流化床稀相区,液相丙烯已完全蒸发,因此适量增加淤浆量,进一步提高反应器产率是可能的,扬子石油化工公司聚丙烯装置B线扩容改造后,丙烯循环量增加,而流化床流化态稳定,本文提供了理论依据。     

化学吸收法测定新型复合转子旋转床气液有效比表面积及液相传质系数

用不同浓度的NaOH溶液吸收CO2,分别测定新型复合转子旋转床的气液有效比表面积和液相传质系数,考察了液量、气量和转速的影响. 结果表明,新型复合转子旋转床的有效比表面积和液相传质系数均随液量、气量和转速增大而增大. 在相同操作条件下,与折流式旋转床相比,新型复合转子旋转床转子的有效比表面积增大7%~159%,液相传质系数降低7.7%~18.2%,最终液相体积传质系数增大4%~132%.     

Longitudinal mixing in horizontal rotary drum reactors

The longitudinal mixing of sodium carbonate (soda) (mean particle size 137 μm) has been investigated in a laboratory horizontal rotary drum reactor 250 mm in diameter and 600 mm long. The distributions of residence times have been estimated by means of a pulse of a small amount of sodium bicarbonate. The concentration of the tracer at the reactor discharge has been evaluated by thermal decomposition of the samples and by measuring their weight loss.The hold-ups, the mean residence times and the variances of the distribution of residence times were evaluated as a function of the rotational speed of the reactor and the feed rate of the particles. By applying a dispersion model, the Peclet numbers were evaluated from the standardized variances and plotted as a function of the feed rate and rotational speed. The mean residence time of the particles was calculated by means of an extended model of Vahl and Kingma. They correspond with the experiments.     

The Relationship Between Hysteresis and Liquid Flow Distribution inTrickle Beds

Experiments were conducted on a trickle bed with 0.283 m ID to eluddate the relation-ship between hysteretic phenomena and liquid distribution. The hysteresis of pressure drop and the variance of radial liquid distribution were observed simultaneously. Residence time dlstribu-tion (KTD), holdup and mean residence time (RT) of liquid phase were also found to demonmtrate hystereels of the same nature. RTD, liquid holdup and mean RT calculated with a simple model from the distribution of liquid flow rate show chaxacteristic consistant with the experlmeataJ data, suggesting that the hyteretic phenomena originate from the multiplicity and nonuniformity of liquid flow distribution.     

Experimental study of residence time,particle movement and bed depth profile in rotary kilns

Experiments were performed in a pilot scale rotary kiln with coal and coke particles to study their mean residence time, residence time distribution, bed depth profile and time spent at the bed surface. The influence of filling ratio on residence time was studied with a uniform bed depth in the kiln. Residence time distribution and bed depth profile measurements were performed in a kiln without end constriction, at different rotational speeds and different solid inputs. The residence time fraction corresponding to the passage of the particles at the bed surface was measured with a photographic study of the movement of a coloured particle. Various equations were tested to represent the experimental results. The equations of Kramers and Croockewit (1952) and Ronco (1965) were adequate to calculate mean residence times, while only the former could represent correctly the bed depth profile. An equation is proposed which turns out to be quite accurate in predicting the fraction of the residence time spent in the upper layer of the bed.