Improving the dynamic performance of continuous-flow mixing of pseudoplastic fluids possessing yield stress using Maxblend impeller

The strategic approach of this article is to characterize the continuous-flow mixing of pseudoplastic fluids possessing yield stress in a stirred reactor with the Maxblend impeller. Dynamic experiments were carried out through the frequency-modulated random binary input of a brine solution to determine the extent of non-ideal flows. Mixing quality was determined on the basis of the extent of channeling and fully mixed volume. The effects of important parameters such as impeller speed (25–500 rpm), absence of baffles, fluid rheology (0.5–1.5%), fluid flow rate (3.20–14.17 L min⁻¹), and the locations of inlet/outlet on the dynamic performance of the continuous-flow mixing vessel were explored. The performance of the Maxblend impeller was then compared to the performances of various types of impellers such as close-clearance (an anchor), axial-flow (a Lightnin A320), and radial-flow (a Scaba 6SRGT) impellers. It was found when the channeling approached zero and the fully mixed volume approached the total fluid volume in the vessel, the power drawn by the A320 impeller and the Scaba impeller were about 2.9 and 4.3 times greater than that of the Maxblend impeller. Thus, the Maxblend impeller was able to drastically improve the performance of continuous-flow mixing with huge power savings. The mixing quality was further improved by optimizing the impeller speed, decreasing the fluid flow rate, decreasing the fluid concentration, and using bottom inlet- top outlet configuration. The flow non-ideality of the mixing system increased in the absence of the baffles. Thus, better mixing quality and more energy savings can be achieved by employing the findings of this study.     

GAS-LIQUID MASS TRANSFER CHARACTERISTICS OF LARGE-SCALE IMPELLERS: EMPIRICAL CORRELATIONS OF GAS HOLDUPS AND VOLUMETRIC MASS TRANSFER COEFFICIENTS IN STIRRED TANKS

Gas dispersion with large-scale impellers consisting of modified large paddle impellers in stirred tanks, with rather large ratios of both impeller diameter and impeller height to tank diameter, was experimentally examined in transition and turbulent mixing ranges. Gas holdups and volumetric gas-liquid mass transfer coefficients with large-scale impellers, i.e., Maxblend and Fullzone impellers, were measured in 0.31 and 0.6 m I.D. stirred tanks, and the gas dispersion performance of large-scale impellers was compared with that of double conventional small-scale high-speed impeller systems, i.e., double four-flat blade disk turbine impellers and double four-flat paddle impellers.

The gas holdups of the large-scale impellers were comparable with those of the small-scale impeller systems at a given rotational speed. The volumetric gas-liquid mass transfer coefficients for large-scale impellers were also similar to those of the small-scale impeller systems. It was found that the large-scale impellers are not more energy efficient than the small-scale impellers in obtaining good gas dispersion.

Empirical correlations for gas holdups and volumetric gas-liquid mass transfer coefficients were developed. They fit the experimental data in transition and turbulent mixing ranges reasonably well, with correlation factors greater than 0.84.     

最大叶片式桨在假塑性流体中的搅拌流场模拟

为研究最大叶片式桨在高黏假塑性流体中的搅拌流动行为,以黄原胶溶液为研究体系,采用计算流体力学方法重点研究了釜内流体的功耗特性、速率分布、剪切速率、表观黏度分布和总体流动状况。结果表明:最大叶片式桨具有与大多数径流桨相似的"双循环"流型结构,且预测的功耗特性与实验数据一致性良好。最大叶片式桨适用于高黏假塑性流体的混合,而对于高黏牛顿流体的混合则效果不佳。釜内的剪切速率分布较宽泛,且受转速影响较大。转速可作为该桨改善黄原胶体系混合效率的重要参数之一。     

GAS-LIQUID MASS TRANSFER CHARACTERISTICS OF LARGE-SCALE IMPELLERS: EMPIRICAL CORRELATIONS OF GAS HOLDUPS AND VOLUMETRIC MASS TRANSFER COEFFICIENTS IN STIRRED TANKS

Gas dispersion with large-scale impellers consisting of modified large paddle impellers in stirred tanks, with rather large ratios of both impeller diameter and impeller height to tank diameter, was experimentally examined in transition and turbulent mixing ranges. Gas holdups and volumetric gas-liquid mass transfer coefficients with large-scale impellers, i.e., Maxblend and Fullzone impellers, were measured in 0.31 and 0.6 m I.D. stirred tanks, and the gas dispersion performance of large-scale impellers was compared with that of double conventional small-scale high-speed impeller systems, i.e., double four-flat blade disk turbine impellers and double four-flat paddle impellers.

The gas holdups of the large-scale impellers were comparable with those of the small-scale impeller systems at a given rotational speed. The volumetric gas-liquid mass transfer coefficients for large-scale impellers were also similar to those of the small-scale impeller systems. It was found that the large-scale impellers are not more energy efficient than the small-scale impellers in obtaining good gas dispersion.

Empirical correlations for gas holdups and volumetric gas-liquid mass transfer coefficients were developed. They fit the experimental data in transition and turbulent mixing ranges reasonably well, with correlation factors greater than 0.84.     

Effect of Impeller Spacing on the Flow Field of Yield-Pseudoplastic Fluids Generated by a Coaxial Mixing System Composed of Two Central Impellers and an Anchor

The three-dimensional flow field generated by a coaxial mixer composed of double Scaba impellers and an anchor in the mixing of the xanthan gum solution, a non-Newtonian yield-pseudoplastic fluid was investigated using the computational fluid dynamics (CFD) technique. The mixing time measurements were performed by a non-intrusive flow visualization technique called electrical resistance tomography (ERT). To evaluate the influence of the impeller spacing on the hydrodynamics of the double Scaba-anchor coaxial mixer, the upper impeller submergence was set to 0.140?m while the lower impeller clearance and the spacing between two central impellers were changed within a wide range. The experiments and simulations were conducted for both co-rotating and counter-rotating regimes at different impeller spacing. The analysis of the collected data with respect to the power number, flow number, mixing time, and pumping effectiveness proved that the co-rotating mode had superiority over the counter-rotating regime. Furthermore, the impact of the impeller spacing in the co-rotating mode was assessed with respect to the mixing time, power number, and mixing energy. The results demonstrated that a coaxial mixer with the impeller spacing of almost equal to the central impeller diameter (C₂?=?0.175?m) and the impeller clearance of C₃?=?0.185?m was the most efficient configuration compared to the other cases. Additionally, the influence of the impeller spacing on the flow pattern was assessed in terms of the radial velocity, tangential velocity, axial velocity, shear rate, and apparent viscosity profiles. When the impeller spacing (C₂) was varied, the merging flow and parallel flow patterns were observed.     

Experimental investigation of the flow dynamics of rheologically complex fluids in a Maxblend impeller system using PIV

The Maxblend^® mixer is used in processes involving Newtonian, shear-thinning or viscoelastic fluids and, as for many impellers, little is known regarding the relationship between the rheological behavior and the flow and mixing properties. An experimental study of the hydrodynamics in the Maxblend was carried out using Newtonian and non-Newtonian fluids in laminar and early transitional regimes. Flow fields were measured by two-dimensional particle image velocimetry (PIV) to evaluate the effect of highly shear-thinning and viscoelastic behavior on the performance of the mixer. The experimental setup consisted of a 35-L tank equipped with two baffles. A total of 100 measurements were proven to be sufficient in order to attain convergence of the velocity components for all studied regimes. Isolated zones in the highly shear-thinning case were observed by means of a decolorization technique. Elasticity in the laminar regime produced a reversal of the flow and a solid body rotation in the bottom region of the tank. Fluid velocity magnitude and spread were observed to be reduced by the presence of elastic forces.     

Gas-liquid mass transfer studies: The influence of single- and double-impeller configurations in stirred tanks

The influence of impeller structure on the mass transfer characteristics was studied with the steady-state method for gas-liquid volumetric mass transfer coefficient (k _L a). The single-impeller configurations included eight impeller types (three radial flow impellers, four axial flow impellers and one mixed flow impeller), and the doubleimpeller included three configurations (RT+RT, RT+WH _D , WH _D +WH _D ). For single-impeller, the gas-liquid mass transfer rates of radial flow impellers were better than those of axial flow impellers under the same rotation speed and gas flow rate. The mass transfer performance (defined as the volumetric mass transfer coefficient per unit power input) of radial flow impellers were also better than that of axial flow impellers. With the same kLa value under a certain gas flow rate, the local bubble size distribution between radial flow impeller and axial flow impeller was similar. As for double impellers, RT+RT provided the highest mass transfer rate under certain rotation speed and gas flow rate, while WH _D +WH _D gave the highest values of gas-liquid mass transfer coefficient with the same power consumption.     

Flow and Turbulence in the Discharge of Radial Pumping Turbines: Influence of the Turbine Type

Velocity measurements were made in the impeller discharge of 6SRGT‐ and Rushton‐type impellers in a 0.6 m³ tank using constant temperature anemometry with a direction sensitive split‐film probe. The reproducibility error of the measurement system was found to be greater than 5 % for all measured properties. The main flow and turbulent parameters measured at three agitation rates in the impeller discharge are compared for the two turbines with respect to both agitation rate and the measured power input. For comparison of the flow properties in the centerline of the two turbines having different diameter and blade height, a uniform representation was used treating the impeller stream as a special kind of free jet. Using this representation, we obtained similar results for both turbines on all measured parameters. The profile measurements showed a similar main flow field for both turbines, but significant differences were found in the axial distribution of turbulent kinetic energy and the energy dissipation rate.     

刚柔组合搅拌桨强化搅拌槽中流体混沌混合

搅拌槽内普遍存在着两种不同类型的混合区域：混沌混合区和规则区。增大混沌混合区,是提高流体混合效率、降低搅拌过程能耗的重要途径。而合理设计搅拌桨有助于流体形成适宜的流动状态,实现混沌混合。柔性体与刚性体组合,可设计出具有多体运动行为的刚柔组合搅拌桨,可强化流体混沌混合行为。结合Matlab 软件,实验研究了双层桨搅拌槽内自来水体系的最大Lyapunov指数（LLE）和多尺度熵（MSE）的变化规律,对比分析了刚性桨和刚柔组合桨两种桨叶对流体混沌混合的影响。结果表明,刚柔组合桨强化流体的运动特性,使更多流体进入混沌混合状态。在转速为210 r·min^-1时,流体的混沌混合达到最佳状态,刚性桨体系的LLE为0.041,而刚柔组合桨体系的LLE为0.048;刚柔组合桨可有效耗散能量,使整个槽体的能量分布均匀,刚柔组合桨在150 r·min^-1时的多尺度熵率与刚性桨在210 r·min^-1时基本相近;刚柔组合桨体系的混合时间均低于刚性桨体系,在转速为120 r·min^-1时,刚柔组合桨使流体的混合时间缩短了26%左右。刚柔组合桨可改变流场结构和能量耗散方式,强化流体混沌混合,实现高效节能操作。     

Design of multiple impeller stirred tanks for the mixing of highly viscous fluids using CFD

The effect of multiple Intermig impeller configuration on hydrodynamics and mixing performance in a stirred tank has been investigated using computational fluid dynamics. Connection between impeller stages and compartmentalisation has been assessed using Lagrangian particle tracking. The results show that by a rotating the Intermig impeller by 45^° with respect to its neighbours, instead of a 90^° rotation as recommended by manufacturers, enables a wider range of operating conditions, i.e., lower Reynolds number flows, can be handled. Furthermore by slightly decreasing the distance between the lower two impellers, fluid exchange between the impellers is ensured down to Re=27.     

Effect of impeller type on continuous‐flow mixing of non‐Newtonian fluids in stirred vessels through dynamic tests

Mixing of non‐Newtonian fluids with axial and radial flow impellers is prone to a significant extent of nonideal flows (e.g., dead zones and channelling) within the stirred reactors. To enhance the performance of the continuous‐flow mixing of pseudoplastic fluids with yield stress, close‐clearance impellers were utilised in this study. We explored the effects of various parameters such as the type of close‐clearance impeller (i.e., the double helical ribbon (DHR) and anchor impellers), impeller speed (25–500 rpm), impeller pumping direction, fluid rheology (0.5–1.5% xanthan gum solution), fluid flow rate (3.20–14.17 L min^?1) and the locations of outlet (configurations: top inlet–top outlet, top inlet–bottom outlet) on the dynamic performance of the mixing vessel. The performance of the DHR impeller was then compared to the performance of various types of impellers such as axial‐flow (Lightnin A320) and radial‐flow (Scaba 6SRGT) impellers. The dynamic tests showed that the DHR impeller was the most efficient impeller for reducing the extent of nonideal flows in the continuous‐flow mixer among the impellers employed in this study. In addition, the mixing quality was further improved by optimising the power input, increasing the mean residence time, decreasing the fluid yield stress, using the up‐pumping impeller mode and using the top inlet–bottom outlet configuration. © 2011 Canadian Society for Chemical Engineering     

Improved power and mass transfer correlations for design and scale-up of multi-impeller gas-liquid contactors

The impeller power and volumetric mass transfer coefficient were measured in a pilot-plant single-, double- and triple-impeller vessels of inner diameter 0.6 m. The experimental conditions corresponded with those used earlier in geometrically similar laboratory scale vessel of inner diameter 0.29 m [Fujasová et al., 2007, Chem. Eng. Sci. 62, 1650-1669]. The same impeller types and their combinations were used as well as the experimental techniques and forms of the data treatment/correlations, which distinguish bottom and upper section behaviour. Concretely, 23 combinations of the following impeller types were used: Rushton turbine (RT), six-pitched-blade impeller pumping upwards (PBU) and downwards (PBD), Lightnin A315 (LTN) impeller, and Techmix 335 pumping upwards (TXU) and downwards (TXD). Distilled water, representing a low-viscosity coalescent batch, was used as the liquid phase.It was found that the correlations established on the basis of the laboratory scale data might be used to describe the transport characteristics in the pilot-plant vessel. The more precise correlations, based on the data from both the laboratory and the pilot-plant scale vessels have also been established. The specific powers dissipated by impellers under gassed conditions (P_g) were within the interval from 10 to 8500 W m⁻³ in the experiments. General correlations of the relative power down under aeration (P_g/P₀) are presented separately for the bottom and upper sections of the vessel. k_La were measured by dynamic pressure method in the individual vessel sections simultaneously. Their values moved within the interval from 0.002 to 0.21 s⁻¹. The best fit provided correlating the single- and the multi-impeller (double and triple) vessels data separately. Correlation of the k_La data measured in the middle height of the triple-impeller vessel, the method often used in literature, is also included.Of the triple-impeller configurations, 3RT gave the best mass transfer performance. The configurations utilizing the same impeller type have shown that the radial flow impellers provide higher (20 up to 50%) mass transfer coefficients than the axial flow impellers. The combined configurations (i.e., those with an RT impeller in the bottom section) do not achieve the mass transfer performance of 3RT. The k_La values produced by RT+2PBD and RT+2PBU were only 15-20% lower than those achieved using 3RT at the same power input. The 3LTN and RT+2LTN configurations provided the poorest mass transfer coefficients at the same power input, both being up to 40% lower than those of 3RT.     

Impact of the fluid flow conditions on the formation rate of carbon dioxide hydrates in a semi‐batch stirred tank reactor

CO₂ hydrate formation experiments are performed in a 20 L semi‐batch stirred tank reactor using three different impellers (a down‐pumping pitched blade turbine, a Maxblend?, and a Dispersimax?) at various rotational speeds to examine the impact of the flow conditions on the CO₂ hydrate formation rate. An original mathematical model of the CO₂ hydrate formation process that assigns a resistance to each of its constitutive steps is established. For each experimental condition, the formation rate is measured and the rate‐limiting step is determined on the basis of the respective values of the resistances. The efficiencies of the three considered impellers are compared and, for each impeller, the influence of the rotational speed on the rate‐limiting step is discussed. For instance, it is shown that a formation rate limitation due to heat transfer can occur at the relatively small scale used to perform our experiments. © 2015 American Institute of Chemical Engineers AIChE J, 61: 4387–4401, 2015     

Investigating the impact of multi-piped impellers design on the efficiency of rotodynamic pumps operating at ultra-low specific speed

Multi-piped impellers (name proposed by the author) represent an innovative approach to the design of rotodynamic pumps operating at the specific speed of n_q < 10. In such a construction the energy increase is caused by the flow of liquid through the internal impeller passages as well as by an external flow around the passages, and sensible designing of such a construction is extremely difficult. The study investigates the impact of the basic construction parameters of a multi-pipe impeller on the efficiency of the process of energy transfer into liquid. The main research method involves computational fluid dynamics (CFD) simulations. The selected impeller constructions are made with the SLS (rapid prototyping) method and tested with a measurement stand. The paper presents the comparison of numerical and experimental results. Based on the obtained results the author makes recommendations on the construction of multi-piped impellers.     

Enhancement of liquid–liquid mixing in a mixer-settler by a double rigid-flexible combination impeller

Mixing is crucial in the dispersion of two immiscible fluids. The rational design of an impeller is necessary to form suitable flow conditions and improve fluid mixing efficiency. A double rigid-flexible combination impeller was designed by connecting the upper and lower rigid impeller blades with flexible pieces. Experimental measurements were performed in a laboratory-scale mixer-settler under different impeller types. The largest Lyapunov exponent (LLE) and multi-scale entropy (MSE) were investigated using Matlab. Results showed that the double rigid-flexible combination impeller enhanced liquid–liquid mixing in the mixer-settler through the multiple-body motion behavior triggered by the swings of flexible pieces. At the optimum mixing point of each impeller, the LLEs of the double impeller, double rigid combination impeller, and double rigid-flexible combination impeller were 0.018, 0.055, and 0.057, respectively. At 75 rpm, the MSE of the combination impellers was obviously greater than that of the double impeller, and the rigid-flexible combination impeller had larger MSE than the double rigid combination impeller. The mixing efficiency of the rigid-flexible combination impeller increased with increasing width and quantity of the flexible piece. The quantity of rigid blade slice also influenced the enhancement of mixing ability. The double rigid-flexible combination impeller intensified the chaotic mixing of the two-phase fluid by changing the flow field structure and energy dissipation mode, ultimately achieving an efficient-mixing operation.     

Influence of impeller type on hydrodynamics and gas‐liquid mass‐transfer in stirred airlift bioreactor

The influence of impeller type in a mechanically stirred airlift bioreactor was analyzed in relation to the non‐Newtonian viscous fluids. The agitation was carried out through a marine impeller (axial impeller) and a paddle impeller (radial impeller) located along with the gas sparger in the region comprised by the riser. The bioreactor was sparged with air under different velocities (0.036–0.060 m s^?1). Carboxymethylcellulose 1.94% and xanthan 1.80% were used as a fluid model. The gas holdup and volumetric mass‐transfer coefficient increased in up to five and three times, respectively, when compared to a conventional airlift bioreactor; however, better results were obtained when the straight paddle impeller type was used. The results suggest that the studied bioreactor can be used successfully in viscous fluid, and it can be more efficient than conventional airlift bioreactors. The results obtained suggest the use of radial impellers. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3159–3171, 2015     

Use of novel permeable membrane and air cathodes in acetate microbial fuel cells

In the existing microbial fuel cells (MFCs), the use of platinized electrodes and Nafion^® as proton exchange membrane (PEM) leads to high costs leading to a burden for wastewater treatment. In the present study, two different novel electrode materials are reported which can replace conventional platinized electrodes and can be used as very efficient oxygen reducing cathodes. Further, a novel membrane which can be used as an ion permeable membrane (Zirfon^®) can replace Nafion^® as the membrane of choice in MFCs. The above mentioned gas porous electrodes were first tested in an electrochemical half cell configuration for their ability to reduce oxygen and later in a full MFC set up. It was observed that these non-platinized air electrodes perform very well in the presence of acetate under MFC conditions (pH 7, room temperature) for oxygen reduction. Current densities of −0.43 mA cm⁻² for a non-platinized graphite electrode and −0.6 mA cm⁻² for a non-platinized activated charcoal electrode at −200 mV vs. Ag/AgCl of applied potential were obtained. The proposed ion permeable membrane, Zirfon^® was tested for its oxygen mass transfer coefficient, K₀ which was compared with Nafion^®. The K₀ for Zirfon^® was calculated as 1.9 × 10⁻³ cm s⁻¹.     

Gassed and ungassed power draw in a pilot scale 550 litre fermentor retrofitted with up-pumping hydrofoil B2 impellers in media of different viscosity and with very high power draw

A number of modern impellers have been designed in the pursuit of an alternative to the traditional Rushton turbine, which has a number of well recognized deficiencies. A dual up-pumping combination of the Hayward Tyler B2 (former APV-B2 or simply B2), a high solidity ratio hydrofoil impeller, was retrofitted using traditional methods to a pilot scale fermentor based on cited reference studies of the impeller performance. Using water as a media and comparatively low power draws, the B2 impeller has previously been shown to have good gas handling properties and a low ungassed power number allowing for use at high impeller-to-tank diameter ratio. In the present study a power characterization of the B2 impeller was undertaken in order to extend the available data to viscous media resembling fermentation broths and to very high power draws. Power characterizations were carried out with specific energy input rates up to 12.9 kW/m³ using different shear-thinning media.The ungassed power number of the B2 impeller was determined (3.3 for power draws in the range 0-11.6 kW/m³) and our findings confirm those of previous studies and extend the trends to media of high viscosity. Upon aeration the B2 impellers loose little power compared to the traditional impeller even when applying a very high power draw (10-20% power loss at 450 rpm and 1.28 vvm corresponding to 11.6 kW/m³). Torque fluctuations are found to be small (<5%) for this impeller at high power draw and high viscosity media. Finally it is shown that the B2 impeller can be retrofitted to pilot scale fermentors using traditional methods with a high degree of confidence.     

Which impeller should be chosen for efficient solid–liquid mixing in the laminar and transitional regime?

The vast majority of solid–liquid mixing studies have focused on high Reynolds number applications with configurations and impeller geometries adapted to this type of regime. However, the mixing of particles in a viscous fluid is an essential element of many contemporary industries. We used the computational fluid dynamics-discrete element method model previously developed in our group to investigate solid–liquid mixing with close-clearance impellers in the laminar regime of operation. We compared different geometries, that is, the double helical ribbon, anchor, Paravisc™, and Maxblend™ impellers. We investigated the impact of fluid viscosity and compared the results with those obtained with the pitched blade turbine, a more commonly used impeller, based on power consumption for equivalent mixing states. This study highlights that the higher the viscosity of the fluid, the more interesting it is to use close-clearance impellers for their ability to generate a strong shear stress and a strong bulk flow in the entire vessel.     

Recycling and regeneration of used perfluorosulfonic membranes for polymer electrolyte fuel cells

This paper describes a method for the recycling and regeneration of used perfluorosulfonic Nafion^® (Dupont) membranes by dissolution and recasting. The dissolution of the used Nafion^® membranes from polymer electrolyte fuel cells is realized using dimethyl sulfoxide as a solvent under atmospheric pressure and 190 °C. A mechanically robust membrane can be reproduced by a recast process of the dissolved Nafion^® solution at 170 °C. The recycled membrane has shown a good crystalline structure and high mechanical strength. Membrane properties, including water uptake, exchange capacity and resistance are similar to that of the as-received Nafion^® 115 membrane. Fuel cells prepared by the recycled membrane demonstrate a comparable performance to that of the fresh fuel cell.