Effect of Viscosity on the Hydrodynamics of Liquid Processes in Microchannels

The hydrodynamics of single‐phase liquid flow with relatively high fluid viscosities in a microchannel was investigated experimentally. The results showed that the conventional theory could predict the single‐phase flow with high fluid viscosities in microchannels. Furthermore, the effect of viscosity on the slug flow of two immiscible liquid phases in a microchannel was studied with high‐speed imaging techniques. It was found that a higher dispersed‐phase viscosity quickened the flow pattern transition from slug flow to parallel flow and resulted in smaller slugs. A modified capillary number representing the mutual effects of the viscosities of the continuous phase and the dispersed phase was proposed for predicting the slug sizes in microchannels.     

Hydrodynamic and mass transfer characteristics of external-loop airlift reactors without an extension tube above the downcomer

The effects of the horizontal connection length (0.1≤L_c≤0.5 m), the downcomer-to-riser cross-sectional area ratio (0.11≤A_d/A_r≤0.53) and the superficial gas velocity (0.02≤U_G≤0.18 ms^-1) on gas holdups in the riser and downcomer, the circulation liquid velocity, the mixing time, and the overall volumetric mass transfer coefficient were determined in external-loop airlift reactors without an extension tube above the downcomer [configuration (a)]. For otherwise fixed conditions, the absence of the extension tube strongly affected the hydrodynamic and mass transfer characteristics of external-loop airlift reactors. In contrast with the external-loop airlift reactor with the extension tube [configuration (b)], a large air pocket formed in the top horizontal connection and the surface aeration took place in the external-loop airlift reactor without the extension tube [configuration (a)]. As a result, the riser circulation liquid velocity in configuration (a) was slower than that in configuration (b). The riser and downcomer gas holdups, the mixing time and the overall volumetric mass transfer coefficient in configuration (a) were larger than those in configuration (b), respectively.     

Experiment and calculation of filtration processes in an external-loop airlift ceramic membrane bioreactor

Air sparging is recognized as an effective way to increase permeate flux in membrane filtration processes. The application of air sparging with an external-loop airlift ceramic membrane bioreactor was studied at different gas flow rates, biomass concentrations and suction pressures. A 180% increase in permeate flux was obtained while filtering a 2 g/L activated sludge wastewater suspension with the airlift cross-flow operation for U_g=0.21 m/s. The mechanism of flux enhancement in the case of slug flow in tubular membrane was discussed. The region near the gas slug was divided into three different zones: falling film zone, wake zone and remaining liquid slug zone. Air sparging significantly lowered cake thickness and consequently cake resistances for the wake region and the falling film region. A novel model combining hydrodynamic of gas-liquid two-phase flow and cake resistance was developed to simulate the process. The model was validated with experimental data with an error of 8.3%.     

Numerical simulation of mass transport in a filter press type electrochemical reactor FM01-LC: Comparison of predicted and experimental mass transfer coefficient

This paper studies flow characteristics and their effect on local mass transfer rate to a flat plate electrode in a FM01-LC electrochemical reactor. 3D reactor simulations under limiting current and turbulent flow conditions were performed using potassium ferro-ferricyanide electrochemical system with sodium sulfate as supporting electrolyte. The model consists of mass-transport equations coupled to hydrodynamic solution obtained from Reynolds-averaged Navier–Stokes equations using standard k–? turbulence model, where the average velocity field, the turbulence level given by the eddy kinetic energy and the turbulent viscosity of the hydrodynamic calculation were used to evaluate the convection, turbulent diffusion and the concentration wall function. The turbulent mass diffusivity was evaluated by Kays–Crawford equation using heat and mass transfer analogies, while wall functions, for mass transport, were adapted from Launder–Spalding equations. Simulation results describe main flow properties, concentration profiles throughout the entire volume of the reactor and local diffusion flux over the electrode. Overall mass transfer coefficients estimated by simulation, without fitting parameters, agree closely with experimental coefficients determined from limiting current measurements (1.85% average error) for Re between 187 and 1407.     

Influences of top clearance and liquid throughput on the performances of an external loop airlift slurry reactor integrated mixing and separation

A new developed external loop airlift slurry reactor, which was integrated with gas–liquid–solid three-phase mixing, mass transfer, and liquid–solid separation simultaneously, was deemed to be a promising slurry reactor due to its prominent advantages such as achieving continuous separation of clear liquid from slurry and cyclic utilization of solid particles without any extra energy, energy-saving, and intrinsic safety design. The principal operating parameters, including gas separator volume, handling capacity, and superficial gas velocity, are systematically investigated here to promote the capabilities of mixing, mass transfer, and yield in the pilot external loop airlift slurry reactor. The influences of top clearance and throughput of the clear liquid on flow regime and gas holdup in the riser, liquid circulating velocity, and volumetric mass transfer coefficient with a typical high solid holdup and free of particles are examined experimentally. It was found that increasing the gas separator volume could promote the liquid circulating velocity by about 14.0% at most. Increasing the handling capacity of the clear liquid from 0.9 m~3·h~(-1) to 3.0 m~3·h~(-1) not only could increase the output without any adverse consequences, but also could enhance the liquid circulating velocity as much as 97.3%. Typical operating conditions investigated here can provide some necessary data and guidelines for this new external loop airlift slurry reactor to upgrade its performances.     

Measurement of fluid flow in the downcomer of an internal loop airlift reactor using an optical trajectory-tracking system

A low cost optical trajectory tracking system (OTTS) for flow studies has been developed in our laboratory. The system was developed with the purpose of identifying flow trajectories, which are required for the mathematical formulation of photosynthetic processes in airlift reactors. It consists of two cameras, which are connected to a PC computer via an Image Process Card. The system is used for the study of fluid trajectories in the downcomer of an airlift reactor. The motion of a single neutrally buoyant fluorescent particle is logged by the system, and the vectors of the trajectories are reconstructed into 3D coordinates. The flow in the downcomer of the airlift reactor was studied using two different draft tube diameters. The superficial gas velocities varied from 0.005 to . Analysis of the experimental results shows that plug flow exists in this region. Shear stress was also analyzed and was found homogeneous. Preliminary results of the measurement of fluid flow in the downcomer of the ALR with helical flow promoters (HFP) are also presented.     

On the main flow features and instabilities in an unbaffled vessel agitated with an eccentrically located impeller

The hydrodynamics of an unbaffled vessel stirred by an eccentrically located Rushton turbine is investigated with both Laser Doppler Anemometry and flow visualisation techniques. The flow field is shown to be characterised by a strong circumferential motion which develops itself around two main vortices, one above and one below the impeller, both inclined with respect to the vertical plane. Such vortices are not steady but move periodically very slowly in comparison to the impeller rotational timescale. Accordingly, two low frequency components, whose values are linearly dependent on the impeller rotational speed, are identified across the vessel. The energetic contribution to the turbulent kinetic energy of such flow instabilities is significant so that they should be taken into account when evaluating micro-mixing information from turbulence quantities. Besides, an additional low frequency component is observed and related to vortex shedding phenomena from the flow-shaft interaction which occur in eccentric agitation operation. The flow discharged from the impeller is also measured and discussed.     

Digital Image Processing Technique to Investigate the Hydrodynamics of an Airlift Reactor with Double Downcomer

Digital image processing, an innovative cost‐effective technique, was employed to investigate the hydrodynamics of a rectangular internal loop airlift reactor with double downcomer. The whole reactor was divided into two downcomers and a riser by means of two vertical blades to achieve a new geometry. Air and water served as gas and liquid media. Experimental measurements were performed by visualizing the concentration of a colored tracer by a digital camera. The captured successive images at specified time intervals were analyzed by the ImageJ software to turn images into quantifiable data. For four reactor geometries, the residence time distribution curves in individual sections and the liquid mixing performance were determined by this noninvasive method. The speed of this technique to capture real‐time data of flow patterns may be one of the most important concerns for imaging multiphase flows in process industries.     

Influence of Longitudinal Vortex Generator Configuration on the Hydrodynamics in a Novel Spouted Bed

The gas‐solid flow in a cylindrical spouted bed with a pair of spherical longitudinal vortex generators (LVGs) was numerically investigated by a two‐fluid model with kinetic theory for granular flow. Simulations and analyses were conducted on five types of spouted beds: a conventional spouted bed without disturbance units as well as spouted beds with a pair of LVGs in which the radius of spheres installed on the LVGs had four different dimensions. Results of the computational fluid dynamics demonstrate that the fountain height decreases with larger radius, and the influence range of the longitudinal vortex increases with the greater radius, both for the gas phase and particle phase. The turbulent kinetic energy of the gas phase along the radial and axial directions in the spouted bed was also promoted significantly by the longitudinal vortex and increased with larger radius, which is due to the higher LVG volume.     

Kinetics and Modeling of Fatty Alcohol Ethoxylation in an Industrial Spray Loop Reactor

The kinetics of the ethoxylation of fatty alcohols catalyzed by potassium hydroxide was studied to obtain the rate constants for modeling of the industrial process. Experimental data obtained in a lab‐scale semibatch autoclave reactor were used to evaluate kinetic and equilibrium parameters. The kinetic model was employed to model the performance of an industrial‐scale spray tower reactor for fatty alcohol ethoxylation. The reactor model considers that mass transfer and reaction occur independently in two distinct zones of the reactor. Good agreement between the model predictions and real data was found. These findings confirm the reliability of the kinetic and reactor model for simulating fatty alcohol ethoxylation processes under industrial conditions.     

Study of an air-lift system. Part I: Hydrodynamics of the atara piston bubble cannon mixer

Hydrodynamic studies of the two-phase flow of air-water mixtures were carried out in an innovative air-lift system called the “Atara Piston Bubble Cannon Mixer”. Slug and churn flows were observed in the discharge tube. The bubble velocity in the slug flow regime and the pressure drop were measured. Bubble entrance effects, found to affect the pressure drop particular to this configuration, are explained The air-lift pump performance is analysed and a hydrodynamic model is developed to predict the pumping capacity as a function of the gas flow rate.     

Studies on the Hydrodynamics of Chaotic Bubbling in a Gas‐Liquid Bubble Column with a Single Nozzle

In this work, the chaotic bubbling mechanism in a gas‐liquid bubble column with a single nozzle was investigated. The signal for the analysis was the time series of pressure fluctuations measured from a pressure transducer probe placed in the bubble column close to the nozzle. In order to study the bubbling process, statistical analysis, qualitative and quantitative nonlinear analyses were carried out for the pressure fluctuations. Power spectra used as standard statistical measures provided preliminary evidence that bubbling in the middle values of gas flow rates may be chaotic in nature. Phase plots provided a qualitative means of analyzing the fine geometry structure of the attractor reconstructed from the bubbling time signal. Positive finite estimates of the Kolmogorov entropy provided a quantitative evidence of behavior consistent with chaos. Besides previous diagnostic tools, the local nonlinear short‐term prediction was also used as a supplement method. It was found that the bubbling process exhibits a deterministic chaotic behavior in a certain range of the gas flow rate. When increasing the gas flow rate, the sequence of periodic bubbling, primary and advanced chaotic bubbling, and jetting or random bubbling were successively observed. However, no clear period doubling sequence leading to chaotic behavior was observed. The sharp loss of the ability to predict the pressure signal successfully with the nonlinear prediction method provides the strongest evidence of the presence of the chaotic bubbling. The variations of the nonlinear invariants, such as the Kolmogorov entropy and the correlation dimension together with the plot of the correlation integral with the operation conditions, might be developed as potential and effective quantitative tools for flow regime identification of the bubbling process.     

Simulation of the Hydrodynamics and Drying in a Spouted Bed Dryer

Gas-particle flow behavior in a spouted bed of spherical particles was simulated using the Eulerian-Eulerian two-fluid modeling approach, incorporating a kinetic-frictional constitutive model for dense assemblies of the particulate solid. The interaction between gas and particles was modeled using the Gidaspow drag model and the predicted hydrodynamics is compared with published experimental data. To investigate drying characteristics of particulate solids in axisymmetric spouted beds, a heat and mass transfer model was developed and incorporated into the commercial computational fluid dynamics (CFD) code FLUENT 6.2. The kinetics of drying was described using the classical and diffusional models for surface drying and internal moisture drying, respectively. The overall flow patterns within the spouted bed were predicted well by the model; i.e., a stable spout region, a fountain region, and an annular downcomer region were obtained. Calculated particle velocities and concentrations in the axisymmetric spouted bed were in reasonable agreement with the experimental data of He et al. (Can. J. Chem. Eng. 1994a, 72:229; 1994b, 72:561). Such predictions can provide important information on the flow field, temperature, and species distributions inside the spouted bed for process design and scale-up.     

Consequences of an asymmetrical confinement in the transfer phenomena for a cylinder at low Reynolds numbers

In most of the systems where heat or mass transfer occur geometrical symmetries are often present. In this paper, we wish to know if the global flux transferred to cylindrical particles in motion (sedimentation, etc.) could be influenced when introducing some geometrical disturbance breaking the general symmetry of the system. To answer this question, we numerically investigate the simple configuration of a single cylindrical particle moving at constant speed between two parallel walls when the particle is off the symmetry plane and when the thermal boundary conditions are of the Dirichlet or Neumann type. When the geometrical disturbance of the system increases, the results show that the backflow that appears in such confined situations yields a non-intuitive evolution of the transfer in convective regimes. In this case a minimum of the flux appears off the symmetry plane. However, in purely diffusive regimes, we find a monotonical evolution of the transfer.     

根据物料特性确定闭路磨矿循环负荷

只要利用闭路磨矿流程给料和产品的粒度分布，通过非线性最优化方法估计出模型参数，就可以求出磨矿回路的循环负荷，因而从理论上省略了测定循环负荷的工作量，具有一定的实际意义。     

Numerical Simulation of the Hydrodynamics of Gas/Solid Two‐Phase Flow in a Circulating Fluidized Bed with Different Inlet Configurations

The gas/solid flow characteristics in a circulating fluidized bed with two different inlet configurations were investigated by numerical simulation based on an Eulerian approach. In order to describe the interaction between the gas phase and the solid phase and the influence of the solid phase on the gas turbulence, a source term formulation with a more reasonable physical meaning was introduced. The simulation results were validated by the experimental data; then, the model was employed to examine the effect of the inlet configuration on the gas and solid feeding. The simulation results showed that, using the side feeding system, the distributions of solid flow and concentration were highly variable both over the column cross‐section and along the column height. However, such variations can be improved by using the elbow inlet system where the gas and solid are fed from the bottom.