Radial gas mixing characteristics in a downer reactor

In a downer reactor (0.1 m-I.D.x3.5 m-high), the effects of gas velocity (1.6-4.5 m/s), solids circulation rate (0–40kg/m²s) and particle size (84, 164 Μm) on the gas mixing coefficient have been determined. The radial dispersion coefficient(D _r ) decreases and the radial Peclet number (Pe_r) increases as gas velocity increases. At lower gas velocities, D_r in the bed of particles is lower than that of gas flow only, but the reverse trend is observed at higher gas velocities. Gas mixing in the reactor of smaller particle size varies significantly with gas velocity, whereas gas mixing varies smoothly in the reactor of larger particle size. At lower gas velocities, D_r increases with increasing solids circulation rate (G_s), however, D_r decreases with increasing G_s at higher gas velocities. Based on the obtained D_r values, the downer reactor is found to be a good gas-solids contacting reactor having good radial gas mixing.     

Axial mixing of particles in batch ball mills

An experimental study of the axial mixing of dry, powders in batch ball mills has been carried out. For a system of silicon carbide and garnet particles in a laboratory mill containing small plastic balls, the observed mixing is in good agreement with a simple diffusion model. Empirical expressions are presented which relate the diffusion coefficient to the ball and particle loading in the mill. The expressions seem to be valid over most of the practical range of operating conditions except when the filing of either particles or balls is very low. Under these conditions, segregation of balls and particles occurs, apparently leading to anomalous values of the diffusion coefficient.     

Energy efficiency of cement finish grinding in a dry batch ball mill

Dry grinding experiments on cement clinker were carried out using a laboratory batch ball mill equipped with torque measurement. The specific energy was found to be dependent on operating parameters and clinker environment. Additional compounds such as gypsum and pozzolanic tuff improve energy efficiency. The optimal parameters allowing maximising the energy efficiency factor were determined. Energy efficiency factors were obtained both on the crude material (size minus 2.8 mm) and on a sieved fraction (1-0.71 mm). They demonstrate that a low initial rate of breakage implies higher energy efficiency. On the contrary, conditions ensuring an initial maximal rate of breakage lead to an increase of the energy consumption.     

Radial gas mixing in a fluidized bed using response surface methodology

Radial gas mixing in a fluidized bed was studied using response surface methodology (RSM), which enables effect examinations of parameters with a moderate number of experiments. All experiments were conducted in a 0.29-m ID fluidized-bed cold model. The gas dispersion process within the bed is described using the dispersed plug flow model. Pure carbon dioxide was used as the tracer gas, continuously injected into the center of the bed by a point source. The downstream radial tracer concentration profile was measured using a gas chromatograph.The radial gas dispersion coefficient, D_r, was well correlated with operating parameters and the particle and gas properties: (U−U_mf)/U_mf, H_s/d_b, φ_d, and Ar, with a determination coefficient R² of 0.966. Effect test indicates that the dimensionless characteristic velocity, (U−U_mf)/U_mf, has the most significant influence on D_r, while the static bed height to bed diameter ratio, H_s/d_b, is less remarkable. The interactions of (U−U_mf)/U_mf with the distributor open-area ratio, φ_d, and with the Archimedes number, Ar, both play important roles. An evolutive response surface model was proposed to describe the radial gas mixing in the bubbling/slugging fluidization regimes.     

Numerical simulation on mixing kinetics of slender particles in a rotary dryer

The mixing processes of slender particles in a rotary dryer fitted with lifters were simulated in three dimensions. Particle motion was modeled by the Discrete Element Method (DEM) and a three dimensional collision model for slender particles was developed. Contact force, friction force and gravitational force acting on an individual slender particle were considered when establishing mathematics models. The influences of rotational velocity on the mixing of slender particles were discussed and compared with those of spherical particles under identical operating conditions. It was found that the mixing characteristics of slender particles and spherical particles all followed a constant rate until a completely mixed state was encountered. But there were still certain differences between these two kinds of particles. The influences of the lifters with different shapes were further discussed for slender particles. Selected stimulation results were obtained and would provide consults for the further study of slender particles.     

A comparison of dry and wet grinding of a quartzite ground in a small batch ball mill

Classical grinding models involve the selection function (S), which gives the rates of breakage of particles of each screen size fraction, and the breakage function (B), which describes the instantaneous size distributions of fragments produced when the particles of each fraction are broken. In order to investigate the differences between dry and wet grinding as far as the selection and breakage functions are concerned, batch grinding experiments were performed on both dry and wet bases, on the same material, a quartzite, in a small ball mill under similar experimental conditions.On a dry basis, the rates of breakage were found to be time invariant and independent of the size environment in the mill. It is logical to postulate a similar behavior for the breakage function. On a wet basis (65% solids), an increase of the rates of breakage was observed as grinding proceeds. This behavior is essentially due to the variation of the size environment within the mill. This increase in breakage rates was, however, less and less important as the particle size decreased and was not observed for the smallest particles tested. These points were confirmed by considering the disappearance kinetics of samples of different screen size fractions of quartzite injected in the mill during the batch grinding of a limestone. Moreover, it is not impossible that the breakage function could also vary with grinding time, giving rise to finer instantaneous size distributions of fragments as the size environment in the mill becomes finer. As an overall result, wet grinding has appeared more selective than dry grinding for coarse material, while it did not produce more schlamms.     

Experimental study of the mixing kinetics of binary pharmaceutical powder mixtures in a laboratory hoop mixer

As increasingly commented by the literature during the last 5 years, estimating the homogeneity of a powder mixture and following powder mixing processes is not a simple task. In this paper, we present the development and statistical validation of a sampling methodology for defining the number of samples required to provide a reasonable estimation of the homogeneity attained in a laboratory scale tumbler mixer. This method is then used to follow the mixing kinetics of a dilute binary powder mixture in a hoop mixer. Special attention is paid to the statistical meaning of the values obtained and the influence of the physical characteristics such as particle size and shape. The role of the particle shape of the majority powder is particularly emphasised and it is quantitatively demonstrated that spherical particles are harder to mix and more ready to segregate than particles with irregular shapes. The different mixing mechanisms at play are identified; the practical limits of use of such tumbler mixers with pharmaceutical powders are discussed.     

DEM simulation on particle mixing in dry and wet particles spouted bed

In this paper, the mixing characteristics of the dry and wet particles in a rectangular spouted bed are simulated using a three-dimensional discrete element method (DEM). In particular, the influence of turbulence and liquid bridge force is investigated using the standard k-ε two-equation model and the Mikami model. The Ashton mixing index is adopted to evaluate the dynamic mixing process of the particle system. The geometry of the simulated bed is the same as that of the experimental bed by Liu et al. [G. Q. Liu, S. Q. Li, X. L. Zhao, Q. Yao. Chem. Eng. Sci. 63 (2008) 1131-1141]. The effect of the spouting gas velocity on the mixing process is discussed for the mixing of dry particles (without the liquid bridge force), while the effect of the moisture content is discussed for the mixing of wet particles (with the liquid bridge force).     

Effect of eccentricity on transitional mixing in vessel equipped with turbine impellers

In this paper, the results of the experimental studies of the mixing time, as well as the power consumption and baffle presence in the stirred tank with dual eccentrically located impellers are presented. The experiments were carried out in an unbaffled flat-bottomed cylindrical vessel. Three types of impellers were used: Rushton turbine, six pitched blade turbine and six flat blade turbine. The obtained data show that eccentricity of dual impeller systems leads to reduction of mixing time. Moreover, the experimental data confirmed the enlargement of power consumption in such systems. In the paper the analysis of relation between eccentricity ratio and mixing time has been performed.     

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.     

干式球磨机尾气除尘系统的改造

为重钙生产提供磷矿粉的干式球磨机除尘净化系统,由湿式水沫除尘代替原电除尘,在第二级旋风除尘器到尾端排气筒的气体管道内及尾端排气筒内分别安装3个和2个水沫除尘喷头,详细介绍水沫除尘喷头的结构尺寸与安装。使用3年,效果很好,既净化了尾气,又回收了磷矿粉,而改造投资甚少。     

Calibration of the perfect mixing model to a dry grinding mill

The perfect mixing model is calibrated to a dry grinding mill used to prepare iron powder for powder metallurgy applications. The calibration procedure was modified to account for possible error on both the mill feed and discharge size distributions, while the usual calibration criterion is based on the estimation error of the mill product size distribution. The calibration criterion was also modified to allow the simultaneous processing of several sampling campaigns to estimate common appearance, breakage and discharge rate functions. Calibration results are analysed in terms of reproducibility of model estimates and model capacity to predict the mill powder content as a function of the mill throughput and power drawn.     

A rapid mixing process in continuous operation under periodic forcing

We introduce a simple and powerful new process for mixing two fluid streams introduced into a pipe via a splitter plate. We demonstrate that the fluids can be thoroughly mixed (at least on large scale) within one pipe diameter downstream of the splitter. Mixing is controlled via periodic velocity forcing of one of the input streams, and is due to amplification of the perturbation as described by instability and receptivity theory. The effectiveness of the mixing depends strongly and non-trivially on the perturbation frequency and amplitude, which distinguishes this method from simple mechanical stirring. The method is effective even at relatively low Reynolds numbers, where laminar flow is observed in the absence of the forcing. Fast mixing can be obtained for different initial velocity ratios of the two inlet streams, rendering the mixing process relatively versatile. Here the mixing method is demonstrated, and potential issues for industrial application are discussed.     

An electrical resistance tomography method for determining mixing in batch addition with a level change

For the first time, the capability of three-dimensional ERT to monitor systems with a significant level change under realistic process conditions and scales has been demonstrated. Level change within a 600 l vessel has been investigated with the addition of a brine tracer. Using the new method of a moving reference, the three-dimensional images can be reconstructed without level artifacting, allowing un-obstructed viewing of the mixing patterns. A moving finite element model has also been used to show the images with the actual level change.     

Axial dispersion in the three-dimensional mixing of particles in a rotating drum reactor

Horizontal drum reactors are widely used in industry for the processing of granular material. They are ideally suited for chemical processes that require high temperatures at near-atmospheric pressure. However, the complexities of these reactors have resulted in empirical design procedures that lead to very conservative and costly reactors. This study first reviews critically the extensive literature on experimental results obtained on rotary kilns (without flights) and proposes new design equations for the axial-dispersion coefficient in terms of rotational speed, degree of fill, drum diameter, and particle diameter. A total of 179 data points from the literature, encompassing both the batch and the continuous operational modes, yielded design correlations for slumping, rolling/cascading and cataracting bed behaviours. Additionally, new measurements were made on a pilot-scale rotary drum by tracking a single radioactive particle (emitting gamma-rays) using a battery of nine scintillation counters; these data confirmed the correctness of the proposed design correlations.     

A combined active/passive scheme for enhancing the mixing efficiency of microfluidic devices

The straight microchannels used in conventional microfluidic devices yield a poor mixing performance because the fluid flow is restricted to the low Reynolds number regime, and hence mixing takes place primarily as a result of diffusion. In an attempt to improve the mixing efficiency of pressure-driven microfluidic flows, the current study applies periodic velocity perturbations to the species flows at the microchannel inlet and incorporates a wavy-wall section within the mixing channel. Numerical simulations are performed to analyze the respective effects on the mixing efficiency of the geometric amplitude of the wavy surface, the length of the wavy-wall section, and the Strouhal number of the periodic velocity perturbations. Overall, the results reveal that the mixing performance is improved by increasing the geometric wave amplitude or length of the wavy-wall section and by applying a Strouhal number in the range 0.33-0.67.     

An experimental analysis on mixing and stoking of monodisperse spheres on a grate

A better understanding of the mixing and stoking process is crucial for an optimization of the combustion process on grate firing systems. Thus experimental studies were carried out to analyse the response of a particle assembly on varying grate operational parameters. To reduce the number of variables which affect the system a generic grate design was chosen and a material of monodisperse spheres was selected. The grate system applied uses vertically moving parallel bars to induce mixing. Different patterns of bar motion were created by linking the bars in groups of uniform movement. A transparent polycarbonate side wall gives optical access to front layer of spheres. The mixing process was measured and quantified by image analysis of this visible layer. When applying a constant number of bar strokes it is found that the mixing performance is independent of the bar velocity. However, mixing performance increases nearly linearly with the stroke length. It turned out that specific “movement patterns” could be identified which show improved mixing behaviour. The results provided here may also be used for comparison with simulations of the particle mixing with the Discrete Element Method (DEM).     

Effect of louver baffles on hydrodynamics and gas mixing in a fluidized bed of FCC particles

The effect of louver baffles on the particle concentration profiles, pressure fluctuations, bed expansion, and gas mixing of a fluidized bed was investigated in a transparent 2-D column of cross-section 500×30 mm and height 6 m over a broad range of operating conditions covering both the bubbling and turbulent flow regimes. Visual observations, pressure fluctuations and steady gas tracer experiments showed that louver baffles can break bubbles, as indicted by the lower amplitudes and higher mean frequencies of differential pressure fluctuations, but they were only effective for superficial gas velocities <∼0.7 m/s for the FCC particles considered in this study. The ability of louver baffles to break bubbles reached a maximum near the onset of the turbulent flow regime. A gas cushion of low particle concentration appeared below the louver baffle, and its height increased with increasing superficial gas velocity, indicating increasing suppression of solids backmixing. Internal emulsion circulation was promoted above the louver baffle, causing an uneven distribution of gas flow. The addition of louver baffles reduced the upstream tracer gas concentrations by 80-90%, indicating a significant decrease in the backmixing fluxes of both gas and solids across the baffle layer. The tracer gas concentrations above the louver baffles increased resulting from the promoted emulsion circulation by louver baffles.