Scale-up in laminar and transient regimes of a multi-stage stirrer, a CFD approach

A multi-stage industrial agitator system adapted to the mixing of a mixture whose viscosity varies during the process has been characterized by using CFD. In the entire study the mixture is supposed to have a Newtonian behavior even though it is rarely the case. It is shown that the well-adapted propeller is able to e7ciently blend high viscous media provided the Reynolds number is not too low. A scale-up study of the agitated system has also been carried out by respecting the classical scale-up rules such as the geometrical similarity and the conservation of the power per volume in the particular case of viscous media. Using an Eulerian approach, the hydrodynamics of three di9erent scales with geometrical similarity have been numerically characterized by the energy curve (power number versus Reynolds number) and by the Metzner and Otto constant in which both are required for scale-up procedure. Experimental power measurements have been carried out at the smaller scale so that simulations have been partially validated. New hydrodynamic criteria have also been introduced in order to quantify the =ows in the case of a multi-stage stirrer running at low Reynolds number. It has been shown how this hydrodynamic di9ers dramatically from one scale to another when scale-up at constant energy per volume is applied. From the CFD results, recommendations about the widely used scale-up rules have been suggested and modi>cations of stirring geometry have been proposed in order to reduce the =ow pattern variations during scale-up. ? 2002 Elsevier Science Ltd. All rights reserved

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 (ow patterns established in a continuously-fed stirred tank, equipped with a Mixel TT axial-(ow impeller, have been investigated bylaser Doppler velocimetry, for a high and a low value of mean residence time—mixing time ratio. The pseudo-two-dimensional axial– radial-velocityvector plots, as well as the spatial distributions of the tangential velocitycomponent and the velocitypro;les around the impeller, show that the interaction between the incoming liquid and the liquid entrained bythe agitator rotation cause the (ow pattern in the vessel to become stronglythree-dimensional, especiallyin the region between the plane, where the feeding tube lies, and the 180◦-downstream plane. The increase in the liquid (ow rate and the location of the feed entryboth a$ect the (ow pattern, with the latter having a more pronounced e$ect. The overall process, in this mode of operation, depends upon the appropriate con;guration and choice of parameters: for conditions corresponding to high liquid (ow rates, the (ow patterns indicate the possibilityof short-circuiting, when the liquid is fed into the stream being drawn bythe agitator and when the outlet is located at the bottom of the vessel

Modelling thermal effects in agitated vessel and reactor design consideration

The knowledge of the heat transfer coefficient on the inner side of a heated vessel wall is of utmost importance for the design of agitated vessels. The present contribution deals with heat transfer in an agitated vessel containing non-Newtonian liquid. The impellers used are six-blade Turbine (TPD) and a Propeller (TPI). The following aspects are discussed: description of the heat transfer process with the aid of dimensional analysis, heat transfer correlations for agitated liquid and influence of impeller speed on heat transfer

Alternate operating methods for improving the performance of a continuous stirred tank reactor

The effect of the pumping direction of an axial flow impeller, the feeding rate and the number of feed inlets on the operation of a continuously-fed stirred tank has been studied using CFD. The flow patterns generated by the up-pumping and down-pumping impeller, under both ‘typical’ and ‘intensified’ operating conditions, are compared. The effect of various tank configurations on the performance of the vessel is assessed by analysing the flow and power numbers, as well as the concentration field of a non-reactive tracer. Furthermore, the inlet feed jets are reduced using traditional jet similarity analysis and are compared with that of a typical round jet. The results show that up-pumping impellers improve circulation in the upper part of the tank and reduce shortcircuiting of the feed stream with only a small increase in power consumption. Furthermore, by using multiple feed inlets to increase the total throughput capacity, the amplitude of torque fluctuations is decreased and impeller bypassing is also decreased. The ensemble of conclusions suggest that the throughput capacity and mixing quality of a CSTR can be improved, without problems of short-circuiting, by employing up-pumping impellers coupled with multiple surface feed points

PIV measurements in an aerated tank stirred by a down- and up-pumping axial flow impeller

Liquid phase hydrodynamics in an aerated tank stirred by a down- and an up-pumping pitched blade turbine have been investigated using Particle Image Velocimetry. The effect of agitator configuration and the gas phase on the mean velocity fields and turbulent quantities in the vessel have been investigated. The global mean gas holdup has also been evaluated for the two pumping conditions. For the gas flow rate used, the presence of gas only slightly alters the liquid flow patterns produced by both the down- and up-pumping configurations and causes a general decrease in the mean liquid velocities. The turbulent kinetic energy in the impeller discharge region was not affected by the presence of gas, but in the bulk of the tank, aeration caused a decrease in this value. Global gas holdup was found to be ~36% greater for the up-pumping impeller and a large amount of gas was found to be entrained by the primary circulation loop

Flow Induced by Dual-Turbine of Different Diameters in a Gas-Liquid Agitation System: the Agitation and Turbulence Indices

Flow induced by a dual turbine stirred tank was characterized measuring local velocities with a LDV and drawing the main velocity fields and the maps of turbulence intensities. The hydrodynamic regime studied in all the experiments was the so-called merging flow regime. Two impeller configurations were studied. In the first one, two disk style turbine of the same dimensions (configuration A) were used, while in the second one, the dimensions of the upper turbine were 20 % proportionally smaller than those of the lower turbine (configuration B). The agitation and turbulence indices were used to evaluate, as a first order approximation, the power consumption distribution between convective and turbulent flows. The comparison of the two-phase agitation systems studied showed that configuration B seems to be more efficient than configuration A, since both induce a similar global convective flow, but the first one assures a significant reduction of power consumption. The distribution of power consumption between convective and turbulent flows was evaluated using the agitation index and a new global parameter: turbulence ind

Agitation de fluides visqueux. Cas de mobiles à pales, d'ancres et de barrières.

L'agitation mécanique de fluides visqueux est étudiée dans le cas de mobiles à pales, d'ancres et de barrières. Deux techniques sont utilisées : une technique numérique qui repose sur l'intégration des équations de Navier Stokes en régime laminaire et pour des fluides newtoniens et non-newtoniens ; une technique expérimentale, l'anémométrie à film chaud. La confrontation entre ces deux techniques est satisfaisante. Les résultats concernant les fonctions courant et rotationnel, les composantes de la vitesse, les contraintes, la viscosité apparente, la dissipation visqueuse et la puissance consommée permettent de conclure que l'indice de comportement du fluide, le nombre de Reynolds auront peu d'influence sur les schémas d'écoulement. Une application pratique, l'agitation du fromage fondu, est développée en fin de mémoire

Evaluation of the Physical Stability of Zinc Oxide Suspensions Containing Sodium Poly-(acrylate) and Sodium Dodecylsulfate.

The physical stability of zinc oxide (ZnO) aqueous suspensions has been monitored during two months by different methods of investigation. The suspensions were formulated with ZnO at a fixed concentration (5 wt%), sodium poly-(acrylate), as a viscosifier, and sodium dodecylsulfate (SDS), as a wetting agent. The rheological study shows that the suspensions exhibit a non-Newtonian, most often shear-thinning behavior and their apparent viscosity increases with polymer concentration. The rheograms of most of the ZnO suspensions do not vary during the experimental period. The viscoelastic properties of these suspensions, such as elastic or storage modulus (G′), viscous or loss modulus (G″) and phase angle (δ) were also examined. For% strains lower than 10%, all the formulations show strong elastic properties (G′ > G″, δ varies between 5 and 15°). Beyond 10% strain, the rheological behavior changes progressively from elastic to viscous (G″ > G′ for % strain >80%). Consistently, δ increases and reaches the 50–70° zone. Multiple light scattering (back-scattered intensity), measured with the Turbiscan ags, was used to characterize suspension physical stability (early detection of particle or aggregate size variations and particle/aggregate migration phenomena). Suspensions containing 0.4 and 0.6 wt% polymer remain stable and macroscopically homogeneous, without being affected by the change of particle size observed with a laser particle sizer. Sedimentation tests, pH, and ζ potential measurements versus time, also confirmed these findings

Blending of Newtonian and Shear-Thinning Fluids in a Tank Stirred with a Helical Screw Agitator

Newtonian and non-Newtonian laminar fluid flow has been simulated using Computational Fluid Dynamics for a cylindrical vessel stirred by a helical screw agitator. Simulations have been performed for a vessel geometry with and without a draft tube. Simulated flow patterns in the vessel have been examined and compared with the experimental work of previous authors. The power number and the circulation number have been evaluated, and interpreted in a similar manner to other works. The PO.Re constant, A, has been determined to be 295 for the geometry with the draft tube and 150 for that without the draft tube. These results are in the same range as previously reported values. The Metzner and Otto constant, k, has been evaluated to be 16.23 which is in excellent agreement with experimental results reported in the literature

Flow generated by radial flow impellers: PIV measurements and CFD simulations

Particle image velocimetry (PIV) and computational fluid dynamics (CFD) have been used to investigate the single phase and gas-liquid flow generated by a Scaba SRGT turbine. The key details of the trailing vortices, the turbulent flow around the impeller blades and the accumulation of gas have been studied by using PIV measurements and CFD simulations. Both the experimental and numerical results show that the flow and the trailing vortices are not altered significantly upon gassing. The simulated results are generally in good agreement with the experimental findings. The CFD simulations also show that only small low-pressure regions exist behind the blades of the Scaba turbine compared with the very large lowpressure zones formed by the Rushton turbine. These results enable better understanding of the improved performance of the Scaba turbine for gas-liquid dispersions compared with the Rushton turbine