Continuous hydrogenation of vegetable oils in reactors equipped with static mixers

Continuous hydrogenation of industrially refined soybean oil with Harshaw Ni catalyst was achieved in a slurry column equipped with Sulzer SMV motionless mixers. The influence of the operating parameters (temperature, pressure, catalyst concentration and gas velocity) was investigated. The presumption that, in this equipment, the liquid-solid mass transfer limits the rate of the process is in good agreement with the experimental data.     

One-step creation of hierarchical fractal structures

Relatively recently, we advanced a route to create, in a controlled fashion, combined horizontal and vertical stratified structures by simple and energy-efficient processing operations employing static mixing elements. While in state-of-the-art static mixing the focus is on layer multiplication, here the aim is to create hierarchical fractal structures. Therefore, the main question addressed in this article is how structures, rather than layers, can be multiplied. The key aspect is the addition of layers on the sides or in the midplane of the flow during the process; every addition step increases the hierarchy by one level. This article derives the general formalism for forming fractal structures with controlled hierarchy, and we develop the language required to design and construct the dies. The main part of the article addresses this main topic and is based on the splitting serpentine static mixer geometry that can be easily made on the parting surfaces of a mold on both the micro- and the macroscale. The second part of the article addresses the strategy to minimize the number of mirroring steps, eventually avoiding mirroring completely, and is based on the rotation-free multiflux static mixer geometry. With the design language derived, complex hierarchical fractal structures can be generated simply by changing the number and sequence of operators within extrusion dies or molds, providing a one-step solution to produce material structures for potential use in diverse applications ranging from advanced mechanical systems to photovoltaic devices, where controlled assembly of dissimilar materials, and the realization of huge interfaces and genuine cocontinuity throughout the cross section, is critical.     

A continuum model for the segregation of bidisperse particles in a blade mixer

The process of blending powders using stirring blades involves complicated granular flows, particle-scale mechanisms, and blade–particle interactions, which is challenging to predict and control. This article proposes a continuum-based model for such a process by incorporating the flow rheology, isotropic particle diffusion and the percolation of granular materials. A method combining finite element method (FEM), finite difference method (FDM), and immersed boundary method (IBM) is developed to numerically implement the continuum model and applied to a cylindrical blade mixer. The model well describes the tempo-spatial distribution of small/large particles in the stirring process, such as the accumulation of small particles in the vicinity of blades. Remarkably, this model can capture the various intricate effects of blade parameters, including the blade rake angle, rotating speeds, filling level, and the friction coefficient of the mixer wall. It is therefore promising for optimizing the blade mixers in industries.     

Determination of the mixing performance of sulzer SMV static mixers by laser induced fluorescence

Local concentrations are measured at the outlet of different configurations of Sulzer SMV static mixers placed in a tube. Laser Induced Fluorescence is the non intrusive technique used to measure mean and RMS concentrations. The two fluids mixed are miscible and the flow regime is turbulent. The influence of the number of elements, their position and the ratio between the velocities of the two compounds on the mixing is studied. The results show that these parameters are important for the quality of mixing. The velocity ratio influences the radial mixing, while the mixing length depends on the number and position of the elements.     

Computational modelling of industrial pulp stock chests

Agitated pulp stock chests are the most widely used mixers in pulp and paper manufacture. Stock chests are used for a number of purposes, including attenuation of high‐frequency disturbances in pulp properties (such as mixture composition, fibre mass concentration, and suspension freeness) and are designed using semi‐empirical rules based largely on previous experience. Tests made on both laboratory and industrial‐scale pulp chests indicate that they are subject to non‐ideal flows, including channelling and creation of dead zones. In the present work, a commercial computational fluid dynamic (CFD) software (Fluent) is used to model two industrial pulp stock chests. The first chest is rectangular, agitated using a single side‐entering impeller, and feeds a mixture of chemical pulps at 3.5% mass concentration (C_m) to a papermachine. The second chest has rectangular geometry, with a mid‐feather wall used to direct suspension flow through a U‐shaped trajectory past four side‐entering impellers. This chest is used to remove latency from a C_m = 3.5% thermomechanical pulp suspension ahead of stock screening. For CFD computations, pulp rheology was described using a modified Hershel–Buckley model. Steady‐state simulations were made corresponding to process conditions during mill tests. The calculated steady‐state flows were then used to determine the dynamic response of the virtual chests and then compared with experimental measurements and found to agree reasonably well. The computed flow fields provided insight into mixing processes occurring within the chests, showing cavern formation around the impellers (which reduced the agitated volume available for mixing). Mass‐less particle tracking, using the steady‐state flow field, gave insight into the stagnant regions and bypassing zones created in the vessels. This paper discusses difficulties encountered in characterising the mixing (both experimentally and computationally) and the limitations of the industrial data.     

Detailed investigation of active CMOS mixers noise in submicron technology

A unified noise figure expression incorporating the thermal noise and flicker noise has been proposed for active CMOS mixers. Based on the derived conversion functions with output resistance effect, the noise transforming factors for different stages are numerically computed to rigorously describe the noise output. The subthreshold conductance has also been taken into account by utilizing the latest continuous noise model and the simplified MOSFET I-V model. As a result, the frequency-dependent characteristic of noise expression is of competency for explaining the flicker noise mechanism, thus can be directly applied to active CMOS mixers with any IF characteristics. And good agreement is obtained between simulations and measurements.     

Scheduling and sequencing of rubber compounds on banbury mixers in a tyre company

Scheduling and sequencing compounds on banbury mixers is a daily production planning function in a tyre company. The current scheduling procedures are based on experience. A number of factors, such as, capacity, cost, time, speed, set-up of mixers, compound changeovers, density and demand of compound, have to be considered during planning. In this paper, we propose a two-stage approach to this problem. This approach can be easily computerised to aid the personnel in the planning function. An example, considering actual data obtained from the company, is used to illustrate the approach. The current scheduling practice by company personnel, as inferred from past record, is also reported.     

NETmix®, a new type of static mixer: Modeling,simulation, macromixing,and micromixing characterization

NETmix® is a new technology for static mixing based on a network of chambers connected by channels. The NETmix® model is the basis of a flow simulator coupled with chemical reaction used to characterize macro and micromixing in structured porous media. The chambers are modeled as perfectly mixing zones and the channels as plug flow perfect segregation zones. A segregation parameter is introduced as the ratio between the channels volume and the whole network volume. Different kinetics and reactants injection schemes can be implemented. Results show that the number of rows in the flow direction and the segregation parameter control both macro and micromixing, but the degree of micromixing is also controlled by the reactants injection scheme. The NETmix® model enables the systematic study of micromixing and macromixing for different network structures and reaction schemes, enabling the design of network structures to ensure the desired yield and selectivity. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Solid Suspension in Jet Mixers

Experiments have been carried out with jet mixers to study the solid suspension characteristics. The jet velocities required for solid suspension in 0.5 and 1 m ID tanks were measured experimentally. The nozzle diameter was varied from 0.0156 to 0.05 m. The nozzle clearance from the tank bottom was varied from 0.1 to 0.9 m. Tap water and sand of average sizes 100, 300, and 500 µm were used. The solid loading was varied from 1 to 5% (wt.). The effect of nozzle angle was also studied. A semi‐empirical model has been developed to predict the jet velocity needed to achieve a certain degree of suspension.