Gas hold‐up in stirred tank reactors

Based on a study of the gas hold‐up data for stirred tank reactor generated in the present work and the data available in the literature for large stirred tank reactors (T = 0.57 m to 2.7 m) equipped with disc turbines and pitched blade downflow turbines a correlation is presented which reliably predicts gas hold‐up data over wide range of system configurations and operating parameters. The parameter used, N/N_cd, relates gas hold‐up at impeller speed N with respect to the gas hold‐up at minimum impeller speed for complete dispersion of the gas, N_cd. It is shown that the gas hold‐up data of different workers when compared on the basis of N/N_cd, shows unanimity.     

搅拌反应器内计算流体力学模拟技术进展

综述了计算流体力学(CFD)技术应用在搅拌反应器的进展情况。重点对搅拌反应器内流动场模拟的各种处理方法,包括"黑箱"模型法、内外迭代法、多重参考系法和滑移网格法,进行了介绍与评价,指出了各种方法所具有的特点及存在的问题。阐述了搅拌反应器内CFD技术的发展方向,并就国内的研究现状进行了简单概述。     

Gas—liauid mass transfer in three-phase stirred tank reagors: Newtonian and non-newtonian fluids

Gas—liquid mass transfer has been investigated in gas—liquid-solid three-phase stirred tank reactors with Newtonian and non-Newtonian liquids. Volumetric mass transfer coefficients and gas hold-ups were measured in a 0.2 m i.d. stirred tank reactor and the effects of low-density polymeric particles (ρ_s, =1030 and 1200 kg/m³; up to 15 vol%) on gas—liquid mass transfer were examined. The volumetric mass transfer coefficients in water were found to decrease due to the presence of solid particles at constant impeller speed and superficial gas velocity. On the other hand, solids loading led to higher mass transfer rates in non-Newtonian carboxymethyl cellulose aqueous solutions. Our previously proposed model for mass transfer in gas—liquid two-phase systems was extended to gas—liquid—solid three-phase systems. Reasonable agreement was found between the predictions of the proposed model and the experimental data.     

Measurement of gas and liquid flows in stirred tank reactors with multiple agitators

The gas flow in a 3:1 aspect ratio vessel agitated by triple Rushton turbines has been measured by an ultrasound Doppler probe and by means of residence time studies. Strong recirculation around each impeller is found which fits in well with the compartmentalisation found in earlier liquid mixing studies. Surprisingly, when two axial A315 impellers above a Rushton turbine were used, gas recirculation around each impeller was still found. Study of the liquid phase mixing by a decolourisation technique confirmed that the gas flow essentially destroyed the strong axial liquid flow expected. Indeed, even under unaerated conditions, compartmentalisation was found between each impeller.     

Backmixing of liquid in horizontal multiple-impeller vessels

The batch mixing model for liquid as the continuous phase of a gas-liquid system in a horizontal multiple-impeller vessel was applied to continuous flow operation. The back flow ratio was determined by measuring the residence time distribution. The relation between back flow ratio and operating variables was found to be similar to that for a vertical multiple-impeller vessel. A method for estimating the back flow ratio in a horizontal multiple-impeller vessel, from the mixing time in a single-impeller vessel, was presented.     

CFD simulations of two stirred tank reactors with stationary catalytic basket

Among the different systems used for laboratory kinetic investigation, stationary catalytic basket stirred tank reactors (SCBSTRs) allow one to study triphasic reactions involving shaped catalyst with large size. The hydrodynamics of these complex reactors is not well known and has been studied experimentally in only a few cases. Despite the difference in the design of two commercial SCBSTRs reported in these works, the local measurements of the liquid-solid mass transfer coefficient inside the catalytic basket revealed the same velocity profile. The aim of the present work is therefore to investigate more accurately the hydrodynamics of the two reactors by means of CFD in order to compare the effect of the blade/baffle hydrodynamic interaction on the flow pattern. Owing to the geometrical complexity of the reactors, the hydrodynamic investigation is based on the k-ε model and the Brinkman-Forsheimer equations. The agreement at the local level with the experimental data (PIV and mass transfer measurements) validates this preliminary work performed with the standard values of the parameters present in the turbulent model and the Brinkman-Forsheimer equations. The simulations reveal in both reactors a ring-shaped vortex around the impeller in the agitation region. The high axial location of its centre induces a reverse flow at the tips of the basket. Owing to the fluid friction in the porous medium, the azimuthal flow in the core region is transformed into a radial flow in the basket where the flow decreases abruptly. Vertical vortices are located at the blade tips and at the downstream face of the baffles or they are located in the basket on both sides of the baffles, depending on the design and the location of the baffles. At the inner radius interface of the basket, the vertical blade impeller induces a rather homogeneous velocity profile, but the pitched blade impeller imposes a high velocity at the plane of symmetry. Therefore the simulations demonstrate that two different local velocity patterns and two different porous media may induce the same mass transfer properties.     

Investigations of fluid dynamics in mechanically stirred aerated slurry reactors

The fluid dynamics of stirred aerated slurry reactors with A-310® propeller, 4-blade 45° pitch turbine and 6-blade Rushton disc turbine were studied over a wide range of gas flow rates. With respect to power consumption, gas hold-up, and fluid dynamically limiting cases, viz., suspension and flooding, the Rushton disc turbine was found to be the best in stirred aerated slurry reactors. The influence of particle density, shape and mass fraction and of liquid properties on gassed critical stirrer speed, N_jsg, and of gassed power input per unit volume, P_jsg, on particle suspension and gas dispersion, were investigated. Empircal correlations in combination with that of Zwietering were established for scale-up design in three-phase slurry reactors.     

Suspension of solid particles in multi‐impeller three‐phase stirred tank reactors

Solids suspension characteristics in gas—liquid–solid three‐phase stirred tanks with multi‐impellers were experimentally examined. Minimum impeller speeds for ultimately homogeneous solid suspension have been measured stirred tank reactors. Three impellers were installed: two four‐pitched blade downflow disk turbines and one Pfaudler type impeller chosen to provide good gas dispersion and to accomplish off‐bottom suspension of solid particles, respectively. Gas dispersion causes an increase in particle sedimentation associated with a decrease in power consumption and as a result, minimum impeller speeds for ultimately homogeneous solid suspension increase with increasing gas flow rates. A correlation was developed to predict minimum impeller speeds for ultimately homogeneous solid suspension. The proposed correlation, which agrees satisfactorily with the experimental results, is expected to be useful in design and scale‐up.     

在搅拌槽中含惰性颗粒的液液固三相体系的液液传质特性

在化工、石油、冶金等工业中普遍涉及多相体系,近年来新的化学反应不断应用于工业生产,出现不少新的复杂多相体系,如液液固、气液液等．在己内酰胺生产、浸取一萃取耦合操作、纳米颗粒制备等过程中都涉及液液固体系,但有关的化学工程研究似乎仍是空白．     

Experimental and CFD investigation of power consumption in a dual Rushton turbine stirred tank

Power consumption of a mixing system is a key variable in chemical and bioprocess engineering, the determination of which is of interest of many processes. Besides, prediction of the flooding-loading transition in an aerated stirred tank is crucial for the correct design of aerated stirred tank reactors. In this research, laboratory investigation has been carried out on local and total power consumption of a single phase as well as gas-liquid phase systems in a fully baffled stirred tank equipped with dual six-blade Rushton turbines; moreover, the flow regime behavior of a gas-liquid system was investigated. Results have been compared with data obtained from CFD simulation of experimental setup and the data available in the literature. Reasonable agreement between the experimental and simulation results indicates the validity of the CFD model. Using predicted data some empirical correlations have been derived which present new relations in estimation of power consumption and flow regime transitions in stirred tanks with dual Rushton impellers.     

搅拌釜三维流场的雷诺应力模型数值模拟

引言 近年来,雷诺平均Navier-Stokes方程及其封闭方程组成的湍流模型在应用于搅拌釜复杂湍流现象的模拟上取得了成功,主要是采用标准k-ε[1]、RNG k-ε[2]等模型.     

搅拌槽内非牛顿流体的微观混合特性

在直径为0·476m的搅拌槽内,分别选用三窄叶翼型搅拌桨和标准六直叶涡轮搅拌桨,采用羟乙基纤维素(HEC)水溶液非牛顿流体作为工作体系,以改进的硫酸铜沉降反应与氯乙酸乙酯水解反应的平行竞争反应作为研究微观混合的反应工作体系,在质量分数为0·1%~0·5%的HEC水溶液中,排除硫酸铜副反应的影响,利用铜离子质量浓度与可见光吸光度的线性关系,考察了进料时间、搅拌转速、溶液黏度、流体的非牛顿性以及搅拌桨类型等因素对副产物收率(XQ)的影响规律。结果表明,当进料时间超过临界进料时间3500s后,X_Q不再改变;随着搅拌转速的增加,X_Q减小,但其减小的趋势逐渐变缓;在相同转速下,X_Q随着流体黏度的增加而增加,但增加的趋势有所减缓;对于黏性流体不能仅仅采用雷诺数作为放大准则;在相同的能量耗散速率及桨叶区进料的情况下,Damkohler准数较大的标准六直叶涡轮搅拌桨的X_Q较小。     

Fischer-tropsch synthesis in a stirred tank slurry reactorndashreaction rates

The effect of process variables (temperature, pressure, space velocity, and H₂/CO feed ratio) on the Fischer-Tropsch synthesis on a promoted fused iron catalyst was studied in a slurry phase stirred tank reactor (STR). Operating conditions were chosen such that some of the data could be compared with previously reported results, but experiments were also performed at more extreme conditions (temperatures up to 280°C and pressures up to 2.86 MPa) than previously studied in a slurry phase STR. The catalyst activity compares well with previous studies at an H₂/CO feed ratio of 1.0 and 1.8, but the activity is lower than previously reported values in the 0.64-0.72 range of H₂/CO feed ratios. Spacetime-yield increases with pressure, and reactor productivity is best increased by increasing pressure at a constant pressure to space velocity ratio. The water-gas-shift reaction is near equilibrium at high conversions, and always proceeds at a slower rate than the Fischer-Tropsch synthesis in a STR.     

非标准釜中双层桨的搅拌功率和气含率

在装有单层或双层蛇管换热器的搅拌釜中，分别以六直叶圆盘涡轮（ＤＴ）、四叶（４５°）折叶桨（４ＩＢＴ）或六叶（４５°）折叶桨（６ＩＢＴ）为上层桨，ＤＴ为下层桨，测定了不同双层桨的搅拌功率和气含率。结果表明，搅拌功率随蛇管层数、液位高度和桨间距的增加而增大，但气含率随液位的上升而下降。在装有双层蛇管换热器的搅拌釜中，ＤＴ与６ＩＢＴ双层桨的通气搅拌功率Ｐａ和气含率α的关联式为Ｐａ＝２．４９（Ｐ０２ＮＤ３／ＱＧ（０．５６））（０．３７）及α＝０．０２９Ｐ＿ｖ￣（０．４８）ｕ＿ｓ￣（０．４７）。     

Scalar mixing measurements in a continuously operated stirred tank

An LIF (Laser induced flourescence) line scan system was used to obtain unobtrusive scalar concentration measurements in a continuously operated stirred tank agitated by a radial flow Rushton turbine and an axial flow 60°‐pitched blade impeller. A better blending process was generally achieved in the axial flow field, with macro‐ and micromixing in the radial flow field being most complete with fluid injected into the radial discharge jet, and in the axial flow field with fluid injected from above into the rotating impeller. Local concentration levels and fluctuations scaled with the feed pipe flow rate, and the degree of concentration uniformity throughout the tank scaled with the impeller speed and increased with the cube of the power input.     

The simplest stirred tank for laminar mixing: Mixing in a vessel agitated by an off‐centered angled disc

We study the mixing structure, mixing performance, and short term dynamics in round bottomed laminar tanks agitated by an eccentrically located angled disc. We define eccentricity (E = e/R) as the ratio of the distance of the axis of rotation from the center line of the tank (e) and the tank radius (R). The structural and dynamic features observed at different eccentricity values were compared using planar laser‐induced fluorescence techniques and computational fluid dynamics calculations. A Poincaré analysis demonstrates the chaotic nature of the flow induced by eccentricity. Practically globally chaotic conditions are observed for E = 0.42 and E = 0.50, with mixing times of 5–8 min at Re = 416. We study the effect of different injection points on the short‐term mixing dynamics and we calculate axial flow rates and Power numbers. Stirred tanks agitated by an eccentrically located angled disc are a simple and cost effective system for laminar mixing applications. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3092–3108, 2013     

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.     

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。     

Transitional flow in a Rushton turbine stirred tank

The way in which the single phase flow of Newtonian liquids in the vicinity of the impeller in a Rushton turbine stirred tank goes through a laminar‐turbulent transition has been studied in detail experimentally (with Particle Image Velocimetry) as well as computationally. For Reynolds numbers equal to or higher than 6000, the average velocities and velocity fluctuation levels scale well with the impeller tip speed, that is, show Reynolds independent behavior. Surprising flow structures were measured—and confirmed through independent experimental repetitions—at Reynolds numbers around 1300. Upon reducing the Reynolds number from values in the fully turbulent regime, the trailing vortex system behind the impeller blades weakens with the upper vortex weakening much stronger than the lower vortex. Simulations with a variety of methods (direct numerical simulations, transitional turbulence modeling) and software implementations (ANSYS‐Fluent commercial software, lattice‐Boltzmann in‐house software) have only partial success in representing the experimentally observed laminar‐turbulent transition. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3610–3623, 2017