Finite element modeling of the laminar and transition flow of the Superblend dual shaft coaxial mixer on parallel computers

The macro-mixing mechanisms of the Superblend coaxial mixer consisting of a Maxblend impeller and a double helical ribbon agitator mounted on two independent coaxial shafts rotating at different speeds are numerically investigated. The simulations are based on the resolution of the Navier-Stokes equations with help of a parallel three-dimensional finite element solver exploiting the capabilities of high performance computers. To model the rotation of agitators a hybrid approach based on a novel finite element sliding mesh and fictitious domain method is used. The power consumption, the flow patterns, the shear rate distribution, the pumping capacity and the mixing time of the Superblend mixer are calculated from the simulated hydrodynamics. The simulations allow observing the flow as it evolves from deep laminar (Re=0.1) to transition (Re=520) regime. As Reynolds number increases, several recirculation zones above and below the middle of the tank are formed. It is found that operating the agitators in co-rotation mode requires less power consumption and exhibits equal or shorter mixing time than counter-rotation mode. The larger power consumption in counter-rotating mode is caused by the presence of high shear vortices generated between the two coaxial agitators. Furthermore it is shown that the shear distribution throughout the Superblend coaxial mixer operating in co-rotation mode is almost homogenous, which is highly desirable for shear sensitive products. In view of the results obtained in this work, the Superblend coaxial mixer is found as a good alternative for tough mixing applications.     

Experimental and CFD simulation studies on power consumption in mixing using energy saving turbine agitator

Experimental and simulation investigation on power consumption in new energy saving turbine agitator has been presented here. Modification was done by introducing single and double rectangular and V cuts in the conventional turbine agitator. The power consumption for new energy-saving turbine agitator has been found to be less than that of the conventional turbine agitator. Also, the power consumption for V cut has been found to be less than that of rectangular cut in turbine agitator. Power characteristics for different geometrical parameters of energy saving turbine agitators were obtained for both the transition and turbulent regimes of the flow in agitated vessel. CFD simulations have been used to predict power consumption. The simulation results have been compared with the experimental data obtained on a pilot-scale set up.     

An analysis of the use of electrical power measurements for process control in large‐scale stirred vessels

The mechanical power that is transferred to a liquid via the shaft of an agitator is obtained from a measurement of the electrical power flowing into the electric motor within an accuracy of less than 5%. The accuracy obtained is limited by the calibration procedure. As the implementation of an electric power measurement is both simple and comparatively inexpensive, the technique is suitable for a continuous monitoring of the power used by agitators in the process industries.     

计算多轴拌器的轴功率

对三种搅拌器：锚式、螺旋式、锯齿式，在不同的转速配比下进行了轴功率测试，搅拌雷诺数为０．８～３０００００，液体的粘度为０．００１～８４Ｐａ．ｓ。液体的性质属牛顿型流体，试验过程用计算机控制．通过测量轴的扭矩来确定搅拌器的轴功率。实验测定了不同情况下搅拌器相互之间的影响。实验数据由马跨特计算方法确定模型参数并给出层流至湍流范围内三种搅拌器轴功率的计算公式．     

Power consumption scale-up in agitating non-newtonian fluids

A method for the determination of power consumption of industrial agitators in non-Newtonian fluids on the basis of measurements on a model device is presented. The applicability of this method for purely viscous, time dependent and viscoelastic fluids is discussed. The method was tested experimentally using agitators of two different sizes and results of measurements confirmed the applicability of the present method for engineering calculations.     

组合桨搅拌器的宏观混合特性

分别以浓度为１％，２％，３％，３．５％的羧甲基纤维素溶液为实验，采用测温法，测定了正交双层三角桨－单螺带桨，正交双层三角桨－内外单螺带桨．锚式桨－三叶推进器．锚式桨－内外单螺带４种组合桨拌器的宏观混合时间，无量钢数Ｃ１，Ｃ２，Ｃ３，Ｃ４综合评判了它们的宏观混合性能，实验证明，前２种组合桨搅拌器在不同流域内都使搅拌介质达到良好的宏观混合，且功率消耗低，混合效率高，具有明显的节能优势，对搅拌变粘度体系     

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.     

Studies on transfer processes in mixing vessels: hydrodynamic of the modified Rushton turbine agitators in gas—liquid dispersions

The modified blade turbines are attractive alternatives to the standard Rushton turbine as they do not require any modification in the electrical engine motor and drive assemblies, are simple to manufacture, have a reduced power consumption and have a greatly increased gas-handling capacity before flooding.The modified blades were obtained through increase in the blade height of the Rushton turbine simultaneously with perforation of the blade surface. The filled surface of the modified blade is equal to the blade surface of the standard Rushton turbine.Power dissipation and hydrodynamic regimes using standard and modified Rushton turbine agitators positioned singly or doubly on the same shaft, in a gas—liquid system, were investigated.The TP3 modified turbine with the surface fraction S_G/S_C of the perforation equal to 0.353 is optimum on the basis of the power consumption and of the gas-handling and dispersing capacity.     

圆盘涡轮式搅拌器的搅拌性能比较分析

在椭圆封头搅拌槽中根据行业标准建立了4种圆盘涡轮式搅拌器的几何模型,利用标准k-ε湍流模型和多参考系(MRF)方法,研究了叶片形状、搅拌速度、旋转方向和流型转变对搅拌功率、排出流量、泵出效率和剪切速率的影响。结果表明：叶片形状对功率、排出流量、泵出效率和流型转变的临界安装高度均有影响;径向流条件下,泵出效率排序为圆弧叶(反)>弯叶(正)>箭叶(反)>圆弧叶(正)>平直叶>箭叶(正)>弯叶(反);流型由径向流转变为轴向流后,搅拌功率及径向排出流量均下降。对标准搅拌器的性能评估为工业搅拌设备的选型和设计提供了参考依据。     

行星轮式搅拌器及其性能分析

介绍了行星轮式搅拌器的结构特征和工作原理,并且应用fluent软件模拟其流场。对锚式、推进式及行星轮式3种搅拌器的功率准数和相对混合效率数进行了对比分析。结果表明,在相同的工作条件下,行星轮式搅拌器的功率准数与锚式、推进式搅拌器的基本相等,而行星轮式搅拌器的相对搅拌混合效率远大于锚式和推进式搅拌器的。     

组合式搅拌器对疏水缔合聚合物溶解特性的影响

机械搅拌是目前加速疏水缔合聚合物溶解熟化所广泛采用的一种方法。然而,聚合物溶解是一个从多相到单相、从低黏到高黏的变化过程,单一搅拌器用于聚合物的溶解过程存在诸多的问题。本文采用适用中低黏度的翼型搅拌器（KCX）和适用高黏度的锚框式搅拌器（MS）的组合,通过实验研究了翼型搅拌器不同操作方式（上翻或下压）和锚框式搅拌器不同转速等操作工况对聚合物溶解熟化过程中的作用,并将翼型搅拌器功率的实验数据与数值模拟的结果进行了比较。研究结果表明：翼型和锚框式搅拌器在聚合物不同的溶解熟化过程中其作用是不一样的;双搅拌器的同向运行可以促进罐内的流动和整体循环,加速聚合物的溶解和熟化;采用翼型搅拌器下压操作（KCXD）与MS搅拌器同向运转操作方式最利于聚合物的溶解和熟化。     

单槽单桨磷酸萃取槽

讨论湿法磷酸采用单槽单桨萃取槽的工程投资 ,并与单槽多桨对比其经济效益     

Mixing energy investigations in a liquid vessel that is mixed by using a rotating magnetic field

The purpose of the present report is, first, to develop the basic equations and similarity criteria governing the mixing system with the magnetic particles under the effect of a rotating magnetic field (RMF); second, to carry out the experimental investigations dealt with the power consumption and mixing time under the action of RMF. Dimensionless correlations are proposed to predict power consumption and the mixing time in the analyzed mixing system. The study relates to the mixing energy defined as the product of the power input and the mixing time in a tested experimental set-up. The data obtained for mixing efficiency was correlated in terms of the modified Reynolds number which can be used for predictions of mixing process in systems with the magnetic particles. The magnetic particle may be treated as a miniaturized mixer and it may offer a unique alternative approach to mixing. The satisfactory comparison indicates that the mixing process under the action RMF has the significantly higher of the energy consumption than the classical agitators.     

筒式搅拌器性能试验研究

介绍了获得实用新型专利的筒式搅拌器的结构和工作原理,对筒式搅拌器的搅拌性能进行了试验研究和分析,并与推进式搅拌器和涡轮式搅拌器进行了比较。试验结果表明,3种搅拌器在同等条件下,筒式搅拌器的能耗最小,且其排液量和循环流量最大。     

立式钻铣床动力头设计与三维造型

多工位钻铣床实现了一台机床对一个零件做不同加工的功能,节省了机床,也缩小了占地面积,同时提高了加工精度和生产率,对工人劳动强度也降低很多。本设计中,钻头的固定采用拉杆式楔形固定,钻头采用套筒及主轴轴面为拉杆的结构,套筒外侧用绝缘胶固定了一个支撑架,钻头的动力由同步齿形带传递到钻头,比起万向轴传递动力要准确且刚性好。动力采用行星轮的传递方式,保证了各工位的同步工作,节省空间,本机构紧凑,各啮合齿轮之间中心距不超过100 mm,因而,用齿轮传动可以满足要求,这样可以用标准件对机床快速装配完工,对缩短加工周期有很大好处。     

用于腈纶废丝溶解的往复回转式搅拌器的研究

介绍往复回转式搅拌器的特性 ,研究三角形截面往复回转式搅拌器的桨叶尺寸、釜体尺寸、桨间距、搅拌转速和搅拌功率之间的关系 ,通过对单向回转扭矩法测得的功率与日本扭矩法比较 ,验证了往复回转功率表法的可靠性 ,并进行了模拟腈纶长丝搅拌实验 ,长丝长度达釜径的 18倍 ,仍不缠结 ,当加入的长丝束质量比为 11.8%时 ,搅拌功率约增加 1.2倍     

微燃机冷热电三联供系统运行策略优化分析

用单纯形法对冷热电三联供系统用于办公楼宇时冬夏季典型日负荷下的运行策略进行优化, 优化目标分别为系统的一次能源消耗量最小、运行成本最小和二氧化碳排放量最小, 并对冷热电联产系统和分产系统进行了比较。结果表明:不同优化目标下, 系统的运行策略不同。冬季工况下, 以一次能源消耗量最小为优化目标时, 系统多采用以热定电的运行模式;在以运行成本最小或以二氧化碳排放量最小为优化目标时, 系统全天采用以电定热的运行模式;以三者加权最小为优化目标时, 系统多采用以热定电的运行模式。夏季工况下, 以一次能源消耗量最小为优化目标时, 分产系统的运行策略要优于联产系统;在以运行成本最小或以二氧化碳排放量最小为优化目标时, 系统全天采用以电定热的运行模式;以三者加权最小为优化目标时, 系统多采用以热定电的运行模式。     

聚合物溶解槽内双搅拌器流场特性的数值模拟

搅拌设备是目前海上油田实施聚合物驱油的配注系统的关键设备之一。利用计算流体力学方法对聚合物溶解过程采用翼型上推式搅拌器KCXU和锚式搅拌器MS的内外3种组合槽内流场进行了数值模拟,获得了搅拌器槽内的流场特性、循环流量及搅拌器的功率消耗。结果表明:在第1种混合状态时,KCXU搅拌器与转动的MS搅拌器组合时的流场变得更为复杂、无序。在第2,3种混合状态时,KCXU搅拌器与正转的MS搅拌器的组合形成的流场速度较大,加强了KCXU搅拌器的流动范围,并,且形成了最大的循环流量,其功率居中。     

Scaling factors in granular flow—analysis of experimental and simulations results

The relationship between the design of powder mixers and their performance is of crucial importance for many industrial processes and yet is not well understood. Here the flow patterns generated by an agitator carrying a long flat blade were compared to those generated by a single ploughshare using positron emission particle tracking and DEM. The performances of these agitators were also assessed against those of multi-blade and multi-plough agitators. The powder flows created by the different designs had some qualitative similarities. Indeed, all the agitators were shown to generate a loop of circulation below the free surface of the bed. The radial support of each mixing element was also observed to act as a separatrix for the axial flow, leading to the formation of a loop of circulation on each side of the mixing elements, thus inhibiting axial convection of material. The single-blade agitators, be the flat blade or the plough, were found to induce a pulsing regime, this feature being also observe with the multi-blade agitators but with a lesser amplitude. For moderate agitator frequencies of rotation where inertial effects are negligible, fundamental characteristics of the flow patterns extracted from power spectra of axial displacements could be scaled with the number of blade passes.     

Mixing analysis in a coaxial mixer

The performance of a coaxial mixer in the laminar-transitional flow regime was numerically investigated with Newtonian and non-Newtonian fluids. These mixers comprised two shafts: a central fast speed shaft mounted with an open turbine, and a slow speed shaft fitted with a wall scraping anchor arm. To model the complex hydrodynamics inside the vessel, the virtual finite element method (POLY3D^TM software) coupled with a Lagrange multiplier approach to cope with the non-linearity coming from the rheological model was employed. Co-rotation and counter-rotation mode were compared, based on several numerical criteria, namely, mixing time, power consumption and pumping rate. It was found that co-rotating mode is more efficient than counter-rotating mode in terms of energy, pumping rate and homogenization time.