An analytical model for the prediction of power consumption for shear-thinning fluids with helical ribbon and helical screw ribbon impellers

An approximate analytical model has been developed to predict power consumption for the mixing of shear-thinning fluids with helical ribbon and helical screw ribbon impellers in the laminar flow regime. Extensive data on power input measurements embracing a wide range of flow behaviour index, with strong (n<0.4) and weak (0.4<n<1) shear-thinning fluid characteristics, available in the literature have been used to demonstrate the applicability of the present model for a wide range of helical ribbon mixer configurations. The model is able to explain the differences in the data reported in the existing literature and to successfully predict the complex dependence of power consumption on the fluid properties and the system geometry. Finally, the proposed correlation only requires a knowledge of the flow behaviour index of the fluid and of the geometrical parameters of the mixing systems (wall clearance, number of ribbons, pitch and width of the ribbons) and one characteristic parameter K_p of the mixing system which can be obtained from a single measurement of power for Newtonian liquids in the laminar regime.     

Cavern formation in pulp suspensions using side-entering axial-flow impellers

Pulp fibre suspensions display non-Newtonian rheology, including a yield stress. In mixing operations, this creates regions of active motion around the impellers with the cavern size affecting the quality of mixing attained. Due to the opacity of the suspensions, two non-invasive techniques were evaluated for determining cavern dimensions: electrical resistance tomography (ERT) and ultrasonic Doppler velocimetry (UDV), with ERT chosen for most tests due to the speed of data acquisition. Cavern volume as a function of impeller speed is reported for a range of mixing conditions (hardwood and softwood pulp, suspension mass concentrations from one to five percent, two impeller offsets from the wall, and three suspension height-to-chest diameter ratios). A scaled version of a commercial axial flow impeller was used in a standard side-entering configuration. Measured cavern diameters were compared against model predictions available in the literature. The discrepancy between experimental data and model predictions were significant and were attributed to interaction between the developing cavern and the vessel walls. An alternative model was developed for predicting cavern volume taking this interaction into account.     

Shear and skin friction on particles in power-law fluids agitated by flat-blade and fluid foil impellers

The shear rates that exert angular deformation on spherical particles have been measured. The particles are mimiced by a spherical probe. The probe has been immersed in various impeller-agitated power law fluids. The fluids are aqueous dispersions of polymers, e.g. CMC, xanthan gum and starch. The probe has been positioned in various points of a stirred vessel and at various angles. Angle-averaged shear rate distributions were produced. The distributions obtained are characteristic for the specific impeller flow patterns. The flow patterns have been identified by computational fluid dynamics (CFD). Two types of impellers representative for the flat and the fluid-foil blade design, i.e., a Rushton flat-blade turbine (RT) and a Narcissus impeller (NS) are studied. The effects of rheological properties and blade design on the ‘shear-rate-on-particles’ distribution are examined. The local shear field non-uniformity has been uncovered and compared in terms of the CFD-generated time-averaged velocity and deformation rate profiles. The ‘shear-rate-on-particles’ distribution apart from the impeller is found to follow qualitatively the time-averaged inner flow shear rate distribution. Referring to impeller speed 5-12.5 Hz, the dimensionless wall shear rate varied between 200 and 1000. In power law fluids, the shear rate on particles decreased up to 50%. The fluid-foil NS-generated shear field was found comparable to the shear field induced by conventional flat-blade turbines and appeared in cases less sensitive to polymer presence. The shear rate produced by the fluid-foil impeller in the highly shear-thinning model solution (n∼0.4) exceeded the flat-blade RT-imposed shear rate. The analysis has been extended to skin friction drag on particles. It is shown that, while exerting an undoubtedly greater angular deformation in water-like fluids, in polymer presence the conventional flat-blade turbine introduces a flow geometry that imposes particle drag that is close or in some cases even less than the one generated by the fluid-foil impeller. The fact implies a weak shape effect of radial turbines on shear-sensitive particles or particle dispersions in power law liquids.     

Forced convection in cross flow of power law fluids over a tube bank

The forced convective heat transfer characteristics for incompressible power-law fluids past a bundle of circular cylinders have been investigated numerically. The cylinder-to-cylinder hydrodynamic interactions have been approximated via a simple cell model. The momentum and energy equations have been solved using a finite difference based numerical method for a range of physical and kinematic conditions. The role of the two commonly used thermal boundary conditions, namely, constant temperature or constant heat flux, on heat transfer characteristics has also been studied. Extensive numerical results elucidating the effect of shear-thinning viscosity on the values of Nusselt number have been obtained for Peclet numbers ranging from 1 to 5000, Reynolds number in the range 1-500, flow behaviour index 1?n?0.5 and three values of voidages, namely, 0.4, 0.5 and 0.6, typical of tubular heat exchangers and tube banks. Under all conditions, varying levels of enhancement in Nusselt number are observed due to shear-thinning behaviour. The surface averaged Nusselt number shows strong dependence on the values of voidage, power-law index, Reynolds and Peclet numbers. The paper is concluded by presenting comparisons with the scant experimental results available in the literature.     

Studies on frictional pressure drop of gas-non-Newtonian two-phase flow in a cocurrent downflow bubble column

An exclusive study has been done on experimental investigation of the two-phase frictional pressure drop with air-non-Newtonian liquid (CMC solutions) system in cocurrent downflow bubble column. The effects of gas and liquid flowrate on two-phase frictional pressure drop have been illustrated. An attempt has been made to fit the experimental two-phase frictional pressure drop data by modified Lockhart and Martinelli correlation and Aoki correlation. In another approach, friction factor method was adopted to correlate the experimental results in terms of dimensionless groups of the operating and system variables and the predicted values were found to be in good agreement with the experimental result. The experiments were performed in the bubbly flow regime because of its stability and uniformity.     

CFD investigation of the pipe transport of coarse solids in laminar power law fluids

A numerical parametric study of the laminar pipe transport of coarse particles in non-Newtonian carrier fluids of the power law type has been conducted using an Eulerian-Eulerian computational fluid dynamics (CFD) model. The predicted flow fields have been successfully validated by experimental measurements of particle velocity profiles obtained using a positron emission particle tracking technique, whilst solid-liquid pressure drop has been validated using relevant correlations gleaned from the literature. The study is concerned with nearly-neutrally buoyant particles flowing in a horizontal or vertical pipe. The effects of various parameters on the flow properties of such mixtures have been investigated over a wide range of conditions. The variables studied are: particle diameter (2-9 mm), mean solids concentration (5-40% v/v), mean mixture velocity (25-125 mm s⁻¹), and rheological properties of the carrier fluid (k=0.15-20 Pa sⁿ; n=0.6-0.9). A few additional runs have been conducted for shear thickening fluids, i.e. n>1. Whilst the effects of varying the power law parameters and the mixture flowrate for shear thinning fluids are relatively small over the range of values considered, particle size and solids concentration have a significant bearing on the flow regime, the uniformity of the normalised particle radial distribution and of the normalised velocity profiles of both phases, and the magnitude of the solid-liquid pressure drop. The maximum particle velocity is always significantly less than twice the mean flow velocity for shear thinning fluids, but it can exceed this value in shear thickening fluids. In vertical down-flow, particles are uniformly distributed over the pipe cross-section, and particle diameter and concentration have little effect on the normalised velocity and concentration profiles. Pressure drop, however, is greatly influenced by particle concentration.     

Characterization of the continuous-flow mixing of non-Newtonian fluids using the ratio of residence time to batch mixing time

Continuous-flow mixing of pseudoplastic fluids possessing yield stress is a complex phenomenon exhibiting non-ideal flows within the stirred vessels. Electrical resistance tomography (ERT), a non-intrusive technique, was employed to measure the mixing time in the batch mode while dynamic tests were performed to study the mixing system in the continuous mode. This study attempts to explore the effects of the operating conditions and design parameters on the ratio of the residence time (τ) to the mixing time (θ) for the continuous-flow mixing of non-Newtonian fluids. To achieve these objectives, the effects of impeller types (four axial-flow impellers: A310, A315, 3AH, and 3AM; and three radial-flow impellers: RSB, RT, and Scaba), impeller speed (290–754 rpm), fluid rheology (0.5–1.5%, w/v), impeller off-bottom clearance (H/2.7–H/2.1, where H is the fluid height in the vessel), locations of inlet and outlet (configurations: top inlet-bottom outlet and bottom inlet-top outlet), pumping directions of an axial-flow impeller (up-pumping and down-pumping), fluid height in the vessel (T/1.06–T/0.83, where T is the tank diameter), residence time (257–328 s), and jet velocity (0.317–1.66 ms⁻¹) on the ratio of τ to θ were investigated. The results showed that the extent of the non-ideal flows (channeling and dead volume) in the continuous-flow mixing approached zero when the value of τ/θ varied from 8.2 to 24.5 depending on the operating conditions and design parameters. Thus, to design an efficient continuous-flow mixing system for non-Newtonian fluids, the ratio of the residence time to the mixing time should be at least 8.2 or higher.     

Effect of the shaft eccentricity and rotational direction on the mixing characteristics in cylindrical tank reactors

Strategy of the shaft eccentricity is introduced to enhance the mixing characteristics in a flat bottomed cylindrical vessel without baffles. The mixing is ensured by a six-curved blade impel er. Three solutions which are models of food emulsions are used as working fluids. These solutions have a shear thinning behavior modeled by the power-law. The effects of fluid properties, stirring rates, impeller rotational direction and impeller eccentricity on the 3D flow fields and power consumption are investigated. Three values of impeller eccentricity are consid-ered, namely 0%, 24%and 48%of the vessel diameter. It is found that the opposite clockwise rotational direction reduces the power consumption, compared with the clockwise rotational direction. Also, the obtained results show that an impeller placed at an eccentric position between 24%and 48%of the vessel diameter and at the third of the vessel height may ensure the best mixing characteristics.     

Using electrical resistance tomography and computational fluid dynamics modeling to study the formation of cavern in the mixing of pseudoplastic fluids possessing yield stress

Electrical resistance tomography (ERT) provides a non-intrusive technique to examine, in three dimensions, the homogeneity and flow pattern inside the mixing tank. In this study, a 4-plane 16-sensor ring ERT system was employed to study the shape and the size of cavern generated around a radial-flow Scaba 6SRGT impeller in the mixing of xanthan gum solution, which is a pseudoplastic fluid possessing yield stress. The size of cavern measured using ERT was in good agreement with that calculated using Elson's model (cylindrical model). The 3D flow field generated by the impeller in the agitation of xanthan gum was also simulated using the commercial computational fluid dynamics (CFD) package (Fluent). The CFD model provided useful information regarding the impeller pumping capacity, flow pattern, and the formation of cavern around the impeller. CFD results showed good agreement with the experimental data and theory.     

Power-draw analysis of a coaxial mixer with Newtonian and non-Newtonian fluids in the laminar regime

The power consumption of a new coaxial mixer composed of a wall scraping arm and a series of rods and a pitched-blade turbine mounted on the same axis of revolution and operated in a contra-rotating mode has been characterized. The work is based on experimental measurements and 3D numerical simulations in the case of homogeneous Newtonian and non-Newtonian fluids in the laminar regime. Very good agreements between experimental and numerical results have been obtained. It has been shown that the Metzner-Otto concept can be extended to account for the speed ratio between the impellers, which allows to represent the power consumption results of the coaxial mixer on a single power master curve like with a single agitator mixer.     

A mechanistic model to determine the critical flow velocity required to initiate the movement of spherical bed particles in inclined channels

This study presents a mechanistic model that predicts the critical velocity, which is required to initiate the movement of solid bed particles. The model is developed by considering fluid flow over a stationary bed of solid particles of uniform thickness, which is resting on an inclined pipe wall. Sets of sand bed critical velocity tests were performed to verify the predictions of the model. An flow loop with recirculation facilities was constructed to measure the critical velocities of the sand beds. The tests were carried out by observing the movement of the bed particles in a transparent pipe while regulating the flowrate of the fluid. Water and aqueous solutions of PolyAnoinic Cellulose were used as a test fluid. The critical velocities of four sand beds with different particle size ranges were measured. The model was used to predict the critical velocities of the beds. The model predictions and experimentally measured data show satisfactory agreement. The results also indicated that the critical velocity is influenced by the properties of the fluid, flow parameters, and particle size.     

Explicit calculation of the friction factor in pipeline flow of Bingham plastic fluids: a neural network approach

An artificial neural network (ANN) approach was used in this paper to develop an explicit procedure for calculating the friction factor, f, under both laminar and turbulent flow conditions of Bingham plastic fluids in closed conduits and pipe networks. The procedure aims at reducing the computational efforts as well as eliminating the need for conducting complex and time-consuming iterative solutions of the governing implicit equations for calculating the friction factor, f. The ANN approach involved the establishment of an explicit relationship among the Reynolds number, Re, Hedstrom number, He, and the friction factor, f, under both laminar and turbulent flow conditions. Although, an analytical solution of the governing equation under the laminar flow regime was also feasible (such an equation is also provided in this paper), the ANN model is applicable under both laminar and turbulent flow conditions where the analytical approach will have major limitations (especially when considering the implicit equation that govern the turbulent flow regime).     

Laminar flow of power-law fluids in the entrance region of a pipe

The study is concerned with developing laminar flow of a power-law fluid in a circular tube. The analysis extends the filled-region concept, used previously to study Newtonian fluid flow, to the more general class of power-law fluids. Flow is analyzed in both the inlet and filled regions using an integral boundary layer method. Results obtained provide the lengths of the entrance, inlet and filled regions as a function of the generalized Reynolds number and the power-law fluid index. In addition, the variations of the local friction factor, the pressure drop and the centerline velocity along the axial coordinate are also provided. The available models are compared with the present one on the basis of experimental data. The present results are found to reach asymptotically the fully developed values, and also to be in good agreement with all available experimental data.     

Investigation by laser Doppler velocimetry of the effects of liquid flow rates and feed positions on the flow patterns induced in a stirred tank by an axial-flow impeller

The flow patterns established in a continuously-fed stirred tank, equipped with a Mixel TT axial-flow impeller, have been investigated by laser Doppler velocimetry, for a high and a low value of mean residence time—mixing time ratio. The pseudo-two-dimensional axial-radial-velocity vector plots, as well as the spatial distributions of the tangential velocity component and the velocity profiles around the impeller, show that the interaction between the incoming liquid and the liquid entrained by the agitator rotation cause the flow pattern in the vessel to become strongly three-dimensional, especially in the region between the plane, where the feeding tube lies, and the 180°-downstream plane. The increase in the liquid flow rate and the location of the feed entry both affect the flow pattern, with the latter having a more pronounced effect. The overall process, in this mode of operation, depends upon the appropriate configuration and choice of parameters: for conditions corresponding to high liquid flow rates, the flow patterns indicate the possibility of short-circuiting, when the liquid is fed into the stream being drawn by the agitator and when the outlet is located at the bottom of the vessel.     

Convective heat transfer for power law fluids in packed and fluidised beds of spheres

The forced convection heat transfer characteristics for an incompressible and steady flow of power law liquids in fixed and extended beds of spherical particles has been studied numerically. The sphere-sphere hydrodynamic interactions have been accounted for by using a simple cell model. Within the framework of such a cell model, the momentum and energy equations have been solved using a finite difference method to obtain the velocity and temperature fields. Extensive numerical estimates of the local and average Nusselt numbers as functions of the physical, rheological and kinematic variables have been presented and discussed for the two commonly employed thermal boundary conditions. In broad terms, the Nusselt number for power law fluids (both shear-thinning and shear-thickening conditions) normalized with respect to the corresponding value for a Newtonian fluid shows weak additional dependence on the power law flow behaviour index. The shear-thinning behaviour is seen to promote heat transfer and as expected the shear-thickening behaviour impedes heat transfer in fixed and fluidised beds. All in all, the present results encompass wide ranges of conditions as follows: Reynolds number: 1-500; Peclet number: 1-500; bed voidage: 0.4-0.8 and the flow behaviour index: 0.5-1.8 thereby covering extremely shear-thinning and shear-thickening types of fluid behaviours. The paper is concluded by presenting detailed comparisons with the limited analytical and/or experimental results available for liquid-solid mass transfer in such systems.     

Predictions of heat transfer and pressure drop for a modified power law fluid flow in a square duct

Numerical Solutions for the Nusselt Numbers (CHF and CWT) and the Friction Factor times Reynolds Number have been obtained for fully developed laminar flow of a MPL (Modified Power Law) fluid within a square duct. The solutions are applicable to pseudoplastic fluids over a wide shear rate range from Newtonian at low shear rates through a transition region to power law behavior at higher shear rates. A shear rate parameter is identified, which allows the prediction of the shear rate range for a specified set of operating conditions. Numerical results of the Nusselt numbers (CHF and CWT) and the Friction factors times Reynolds number for the Newtonian and power law regions are compared with previous published results, showing agreement with 0.02% in Newtonian region and 4.0% in power law region.     

Characterization of the granular-to-fluid state process during mixing by power evolution in a planetary concrete mixer

Adding product into the mixer exerts a strong and rapid impact during concrete mixing. Experimental data obtained from a planetary mixer in a full-scale concrete plant under laboratory conditions show that the state of mixture progress with mixing time is well described by the mixing power evolution. More specifically, a reliable method for detecting the time corresponding to the transformation of a mixture from a cohesive granular material into a granular paste (i.e. the so-called “transition time”), through use of a mixing power measurement, will be presented herein. Moreover, once this transition has been achieved, mixing power consumption will be related to mixture rheology and then to mixer geometry by means of a simplified hypothesis. This equation can also be obtained via a dimensionless analysis. Lastly, it will be shown that mixture behavior beyond the transition point is well fitted by a hyperbolic equation. The corresponding mixing power evolution can then be predicted by the level of power at this transition time. These results are suitable for application to online process monitoring.     

Conduction and dissipation in the shearing flow of granular materials modeled as non-Newtonian fluids

After providing a brief review of the constitutive modeling of the stress tensor for granular materials using non-Newtonian fluid models, we study the flow between two horizontal flat plates. It is assumed that the granular media behaves as a non-Newtonian fluid (of the Reiner-Rivlin type); we use the constitutive relation derived by Rajagopal and Massoudi [Rajagopal, K. R. and M. Massoudi, “A Method for measuring material moduli of granular materials: flow in an orthogonal rheometer,” Topical Report, DOE/PETC/TR-90/3, 1990] which can predict the normal stress differences. The lower plate is fixed and heated, and the upper plate (which is at a lower temperature than the lower plate) is set into motion with a constant velocity. The steady fully developed flow and the heat transfer equations are made dimensionless and are solved numerically; the effects of different dimensionless numbers and viscous dissipation are discussed.     

Using computational fluid dynamics modeling to study the mixing of pseudoplastic fluids with a Scaba 6SRGT impeller

The 3D flow field generated by a Scaba 6SRGT impeller in the agitation of xanthan gum, a pseudoplastic fluid with yield stress, was simulated using the commercial CFD package. The flow was modeled as laminar and a multiple reference frame (MRF) approach was used to solve the discretized equations of motion. The velocity profiles predicted by the simulation agreed well with those measured using ultrasonic Doppler velocimetry, a non-invasive fluid flow measurement technique for opaque systems. Using computed velocity profiles across the impeller, the effect of fluid rheology on the impeller flow number was investigated. The validated CFD model provided useful information regarding the formation of cavern around the impeller in the mixing of yield stress fluids and the size of cavern predicted by the CFD model was in good agreement with that calculated using Elson's model.