Prediction of gas cavities size and structure and their effect on the power consumption in a gas-liquid stirred tank by means of a two-fluid RANS model

Aerated cavities behind the impeller blades in stirred tanks affect the power transferred to the liquid that in turns affects heat and mass transfer, thus the development of fully predictive simulation methods to detect the formation of cavities, their size and structures is of paramount importance for an effective simulation of aerated reactors and bioreactors. In this work, operating conditions corresponding to different cavity structures are investigated by means of a Reynolds averaged two-fluid model without adjustable parameters. Based on the comparison with previous experiments and correlations, the method proved to be reliable in the prediction of the transition between vortex-clinging and small '3-3′ cavities, cavity size and power drawn reduction. For the first time, small '3-3′ cavities with volume fractions close to unity are obtained with a steady approach. The power reduction mechanism is observed and a novel interpretation of the formation of the asymmetrical cavities is proposed

A PBM-Based Procedure for the CFD Simulation of Gas–Liquid Mixing with Compact Inline Static Mixers in Pipelines

A compact static mixer for gas–liquid dispersion in pipelines is studied in this paper with a Reynolds averaged two fluid model approach. A procedure based on the lumped parameter solution of a population balance model is applied to obtain the bubble Sauter mean diameter needed to model the interphase forces. The gas distribution in the pipe is analyzed in two different operative conditions and the efficiency of the static mixer is assessed in terms of the gas homogeneity in the pipe section, with low coefficients of variations being obtained. A computational model to obtain the volumetric mass transfer coefficient, kLa, developed for partially segregated systems is applied finding kLa values comparable to those typically obtained with other static mixers. The proposed computational model allows us to locally analyze the oxygen transfer rate by observing the limitations due to gas accumulation behind the body of the static mixer, which leads to the local depletion of the driving force. Geometrical optimization of the static element is proposed, based on the analysis of gas–liquid fluid dynamics and of the interphase mass transfer phenomena

In-line monitoring of mixing performance for smart processes in tubular reactors

This work is focused on the experimental analysis of the fluid dynamics characteristics of a tubular reactor equipped with Kenics static mixers working under turbulent flow con-ditions, with the specific aim of demonstrating the advantages of in-line monitoring tools for continuous process applications. Electrical Resistance Tomography, pressure trans-ducers and Particle Image Velocimetry are employed to evaluate the mixing performance, the pressure drop and the flow field, respectively, considering the standard configuration of the mixers, consisting in mixing elements with alternating orientation, a single mixing element or multiple elements with the same orientation. The applicability of Electrical Resistance Tomography for offering insight into continuous reactors is assessed and the potential of monitoring the mixing performance inside the static mixers is shown. The experimental data suggest that alternatives to the standard element configurations might be adopted for optimizing the fluid mixing process, taking into account the mixing per-formances and the pressure drop, for which a novel correlation based on distributed and concentrated contributions is proposed

Axial Force at the Vessel Bottom Induced by Axial Impellers

This paper deals with the axial force affecting the flat bottom of a cylindrical stirred vessel. The vessel is equipped with four radial baffles and is stirred with a four 45° pitched blade impeller pumping downwards. The set of pressure transducers is located along the whole radius of the flat bottom between two radial baffles. The radial distribution of the dynamic pressures indicated by the transducers is measured in dependence on the impeller off-bottom clearance and impeller speed.It follows from the results of the experiments that under a turbulent regime of flow of an agitated liquid the mean time values of the dynamic pressures affecting the bottom depend not on the impeller speed but on the impeller off-bottom clearance. According to the model of the flow pattern of an agitated liquid along the flat bottom of a mixing vessel with a pitched blade impeller, three subregions can be considered in this region: the liquid jet streaming downwards from the impeller deviates from its vertical (axial) direction to the horizontal direction,  the subregion of the liquid flowing horizontally along the bottom and, finally, the subregion of the liquid changing direction from the bottom upwards (vertically) along the wall of the cylindrical vessel, when the volumetric flow rates of the liquid taking place in the downward and upward flows are the same.

A New Approach to Evaluate 3D Flow Fields Using an Off-Axis 2D PIV System: Investigation of a Tubular Reactor Equipped with Kenics Static Mixers

In this work, an off-axis 2D Particle Image Velocimetry system is used to obtain the 3D flow field at the outlet of a tubular reactor equipped with Kenics static mixers. The 3D flow fields are obtained exploiting the out-of-plane velocity component and considering the symmetrical features of the flow generated by the static mixers. The raw results show that the velocity vectors, measured on a cross section perpendicular to the tube axis by 2D-PIV with the camera located at 24° from the measurement plane, are affected by the axial component of the flow. However, taking into account the symmetry of the flow f ield with respect to the tubular reactor axis and evaluating the effect of the out of plane velocity component, the correct 2D velocity vectors on the plane and also the velocity component in the axial direction can be calculated from the raw 2D PIV data. The consistency of the methodology is demonstrated by comparison of the results with the flow field measured in a smaller tubular reactor of similar geometry and Reynolds number with a symmetrical 2D-PIV system, with the camera located perpendicularly to the laser plane. Then, the 3D features of the flow are analyzed to characterize the effects of the different combinations of static mixer configurations on the fluid dynamics of the system in turbulent conditions. The results show that, as the pressure drop increases, a more uniform velocity distribution is achieved

Hydrodynamics, power consumption and bubble size distribution in gas-liquid stirred tanks

In this work, we present the results collected in a gas-liquid stirred tank by a combination of experimental and computational methods, with the aim of presenting original data on the bubbles size distribution and contributing to the development of fully predictive methods for the design and the scale-up of chemical and biochemical gas-liquid reactors. Basic variables which affect mass transfer and consequently the performances of industrial aerobic fermentations are discussed, with special focus on the bubble size distribution, the gassed power consumption and the gas cavities. The current developments of Two Fluid and Population Balance models for obtaining fully predictive results on gas-liquid mixing in stirred tanks are discussed. The results confirm that the correct prediction of the bubble size in the impeller zone is a crucial prerequisite for obtaining reliable results of the hydrodynamics of aerated stirred tanks

Liquid mixing time and gas distribution in aerated multiple-impeller stirred tanks

Gas-liquid fluid dynamics and mass transfer are crucial aspects of aerobic fermentation and robust methodologies for their determination in industrial bioreactors are expected to provide significant improvements in many production processes. In this work, a gas-liquid stirred tank of high aspect ratio, that replicates the geometry of typical industrial aerated fermenters, is investigated. In particular, the liquid phase homogenization dynamics and the gas phase spatial distribution are determined. The selected methodology is based on the analysis of the conductivity measurements obtained by Electrical Resistance Tomography. The gas-liquid flow regimes and the mixing time are identified at various gas flow rates and impeller speeds, thus covering different gas-liquid regimes. Data col lected with vertical and horizontal arrangements of the electrodes allow to obtain a tailed picture of the equipment working mode and to gain insight into the gas-liquid flow dynamics under optically inaccessible conditions. Quantitative evaluation of the bility of the collected data is attempted by comparing the results obtained with the tical and horizontal arrangements in the same locations

Numerical and Experimental Analysis of the Daughter Distribution in Liquid-Liquid Stirred Tanks

The drop size distributions (DSDs) of a dilute immiscible liquid-liquid mixture were measured in a fully turbulent stirred tank operating at different impeller speeds. The results were used to infer the best daughter distribution function (DDF) leading to the best reproduction of the shape of the DSD. Bell-shaped, U-shaped, M-shaped, and uniform statistical DDFs were studied, producing from two to four daughters from each breakup event. A simplified approach from the literature was adopted to solve the population balance equation that considers the spectrum of the turbulence inside the tank obtained from computational fluid dynamics simulations. The U-shaped distribution producing four fragments better reproduces the shape of the experimental DSD in the studied system

Large blade impeller application for turbulent liquid–liquid and solid–liquid mixing

Application of large blade impellers to turbulent single-phase and two-phase mixing is investigated in this work in order to provide a quantitative basis for estimating the possible advantages in industrial mixing operations with respect to fast impeller types. The analysis is based on the discussion of three-dimensional velocity fields collected in a single-phase vessel stirred by a Maxblend impeller by stereoscopic particle image velocimetry and of dispersed phase distribution and liquid mixing time obtained in solid–liquid and liquid–liquid systems by electrical resistance tomography. The results highlight that turbulent two-phase mixing can be efficiently performed in baffled vessels stirred by large blade impellers both in shear-rate controlled and bulk-motion controlled processes