Using electrical resistance tomography and computational fluid dynamics modeling to study the formation of cavern in the mixing of pseudoplastic fluids possessing yield stress

Investigation of the Role of Impeller Structural Parameters on Liquid-Liquid Mixing Characteristics in Stirred Tanks

Liquid-liquid mixings in stirred tanks are commonly found in many industries. In this study, we performed computational fluid dynamics (CFD) modeling and simulation to investigate the liquid-liquid mixing behavior. Furthermore, the population balance model (PBM) was used to characterize the droplet size distribution. The PBM model parameters were calibrated using the experimental data of droplet sizes at different agitation speeds. Additionally, we employed the steady-state Sauter mean droplet size to validate the developed CFD-PBM coupled model at different dispersion phase holdups. Then, the validated CFD-PBM coupled model was employed to evaluate the role of impeller structural parameters on the liquid-liquid mixing efficiency based on a user-defined mixing index. It was found that the position of impellers significantly affects the mixing efficiency, and an increase in stirring speed and the number of impellers improved the mixing efficiency.

Review of applications of electrical resistance tomography to chemical engineering

In spite of decades of study and investigation, the research on tomography and electrical resistance tomography (ERT) in particular, remains to be focus of immense scientific significance. ERT provides the ability to measure conductivity distribution inside a process plant and delivers time evolving multidimensional information. Such important and otherwise inaccessible information enhances critical process knowledge whilst improving the design and function of the process equipment. ERT has been employed in a variety of fields including chemical engineering. This paper reviews previous research carried out on the application of ERT within the chemical engineering arena. The applications are classified based on the objective of ERT measurements, the unit operations ERT has been utilized on, the media under examination, and also other technologies and data processing techniques used in combination with ERT. The objective of this taxonomy is to offer the reader with a broad insight into the current situation of ERT related research and developed applications in the chemical engineering field and to assist in the identification of research gaps for future investigation.

Gas Dispersion in Non-Newtonian Fluids with Mechanically Agitated Systems: A Review

Gas dispersion in non-Newtonian fluids is encountered in a broad range of chemical, biochemical, and food industries. Mechanically agitated vessels are commonly employed in these processes because they promote high degree of contact between the phases. However, mixing non-Newtonian fluids is a challenging task that requires comprehensive knowledge of the mixing flow to accurately design stirred vessels. Therefore, this review presents the developments accomplished by researchers in this field. The present work describes mixing and mass transfer variables, namely volumetric mass transfer coefficient, power consumption, gas holdup, bubble diameter, and cavern size. It presents empirical correlations for the mixing variables and discusses the effects of operating and design parameters on the mixing and mass transfer process. Furthermore, this paper demonstrates the advantages of employing computational fluid dynamics tools to shed light on the hydrodynamics of this complex flow. The literature review shows that knowledge gaps remain for gas dispersion in yield stress fluids and non-Newtonian fluids with viscoelastic effects. In addition, comprehensive studies accounting for the scale-up of these mixing processes still need to be accomplished. Hence, further investigation of the flow patterns under different process and design conditions are valuable to have an appropriate insight into this complex system.

Evaluation of the mixing quality of high-viscosity yield stress fluids in a tubular reactor

In this study, the mixing quality of high-viscosity yield stress fluid (Carbopol aqueous solution) under laminar and turbulent flow regimes was evaluated through a numerical experimental study. A three-dimensional computational fluid dynamics large-eddy simulation (CFD-LES) model was employed to capture large-scale vortex structures. The proposed CFD model was validated by the experimental data in terms of mean velocity profiles and velocity-time history. Thereafter, the CFD model was applied to simulate the residence time distribution using the tracking technique: tracer pulse method and step method. In addition, the non-ideal flow phenomena caused by molecular diffusion and eddy diffusion were evaluated. The effects of the rheological properties on the mixing performance were also investigated. The presented results can provide useful guidance to enhance mass transfer in reactors with high-viscosity fluids.

Numerical investigation of hydrodynamics and heat transfer for Bingham-pseudoplastic fluids in an industrial coiled stirred tank

Computational fluid dynamics (CFD) was used to investigate the influence of complex rheological properties for Bingham-pseudoplastic fluids on hydrodynamics and heat transfer performance in an industrial polymerization coiled agitated reactor. The fluid rheology was described by the Herschel–Bulkley rheological model. The power consumption obtained by CFD simulation was in good agreement with the plant data. The relationship between the Metzner–Otto constant and power-law index for dual axial flow impellers was investigated. The hydrodynamics strongly depends on the rheological parameters and rotational speed. The flow domain is composed of two parts: the cavern around the impellers, and the stagnant zone adjacent to helical coils and tank wall which resulting in poor mixing and heat transfer performance. With the increase of rotational speed, the stagnant zone could be effectively eliminated, while the heat transfer performance could be significantly improved.

A General Review of the Current Development of Mechanically Agitated Vessels

The mixing process in a mechanically agitated vessel is a widespread phenomenon which plays an important role among industrial processes. In that process, one of the crucial parameters, the mixing efficiency, depends on a large number of geometrical factors, as well as process parameters and complex interactions between the phases which are still not well understood. In the last decade, large progress has been made in optimisation, construction and numerical and experimental analysis of mechanically agitated vessels. In this review, the current state in this field has been presented. It shows that advanced computational fluid dynamic techniques for multiphase flow analysis with reactions and modern experimental techniques can be used with success to analyse in detail mixing features in liquid-liquid, gas-liquid, solid-liquid and in more than two-phase flows. The objective is to show the most important research recently carried out.

Electrical Tomography: A Review of Configurations, and Application to Fibre Flow Suspensions Characterisation

Understanding the behaviour of suspension flows continues to be a subject of great interest considering its industrial relevance, regardless of the long time and effort dedicated to it by the scientific and industrial communities. Information about several flow characteristics, such as flow regimen, relative velocity between phases, and spatial distribution of the phases, are essential for the development of exact models for description of processes involving pulp suspension. Among the diverse non-invasive techniques for flow characterisation that have been reported in the literature for obtaining experimental data about suspension flow in different processes, Electrical Tomography is one of the most interesting, since it presents perhaps the best compromise among cost, portability, and, above all, safety of handling (indeed there is no need to use radiation, which requires special care when using it). In this paper, a brief review and comparison between existing technologies for pulp suspension flow monitoring will be presented, together with their strengths and weaknesses. Emphasis is given to Electrical Tomography, because it offers the above-mentioned compromise and thus was the strategy adopted by the authors to characterise different flow processes (solid–liquid, liquid–liquid, fibres, etc.). The produced portable EIT system is described, and examples of results of its use for pulp suspension flow characterisation are reported and discussed.

Characterization of mixing and yield stress of pretreated wheat straw slurries used for the production of biofuels through tomography technique

Wheat straw is a low-cost feedstock for the production of biofuel. Pretreatment process is an important stage in producing biofuels since it makes the fibers more accessible to enzymatic hydrolysis which is the final step of producing biofuels. Pretreated wheat straw (PWS) slurries are non-Newtonian fluids with yield stress. Mixing of fluids exhibiting yield stress such as the pretreated wheat straw slurry results in the generation of cavern, which is a fully-mixed zone, around the impeller and the stationary regions elsewhere, which causes difficulties in the production of biofuels. In this study, the non-invasive electrical resistance tomography technique was utilized to determine the cavern dimensions as a function of the impeller type and impeller speed. The cavern sizes were then used to measure the yield stress of PWS slurries as a function of fiber size (≤ 2 and ≤ 6 mm) and fiber concentration (6, 8, and 10 wt%).

A new model of cavern diameter based on a validated CFD study on stirring of a highly shear-thinning fluid

Results of numerical simulations of momentum transfer for a highly shear-thinning fluid (0.2% Carbopol) in a stirred tank equipped with a Prochem Maxflo T type impeller are presented. The simulation results were validated using LDA data and both tangential and axial force measurements in the laminar and early transitional flow range. A good agreement between the predicted and experimental results of the local fluid velocity components was found. From the predicted and experimental values of both tangential and axial forces, the power number, Po, and thrust number, Th, were also calculated. Values of the absolute relative deviations were below 4.0 and 10.5%, respectively, for Po and Th, which confirms a satisfactory agreement with experiments. An intensive mixing zone, known as cavern, was observed near the impeller. In this zone, the local values of fluid velocity, strain rate, Metzner–Otto coefficient, shear stress and intensity of energy dissipation were all characterized by strong variability. Based on the results of experimental study a new model using non-dimensional impeller force number was proposed to predict the cavern diameter. Comparative numerical simulations were also carried out for a Newtonian fluid (water) and their results were similarly well verified using LDA measurements, as well as experimental power number values.

Mixing of Shear Thinning Fluids in Cylindrical Tanks: Effect of the Impeller Blade Design and Operating Conditions

The 3D flow fields and power consumption within a cylindrical vessel stirred by a rotating turbine are numerically studied. Simulations are performed to determine the impact of changes in operating parameters on the mixing characteristics. Investigations are focused on effects of the impeller blade curvature, shaft speed and impeller rotational direction. The fluid simulated has a shear thinning behavior. Designing the blade in retreat shape seems very promising in term of power consumption since a reduction of Np is obtained with increasing blade curvature. In the positive rotational direction, the retreat bladed impeller yields highly radial flows with less power consumption than the straight bladed impeller. The 45° retreat blade gave an increase in the radial velocity by 39 %, compared with the straight blade. But, a better axial circulation is obtained with the straight blade. The comparison between the positive rotational direction (+w) and the negative rotational direction (–w) cases revealed that, a reduced mixing time can be obtained with a retreat bladed impeller operating in the negative rotational direction (–w), but with further power consumption.

Super-sensing technology: industrial applications and future challenges of electrical tomography

Electrical tomography is a relatively new imaging technique that can image the distribution of the passive electrical properties of an object. Since electrical tomography technology was proposed in the 1980s, the technique has evolved rapidly because of its low cost, easy scale-up and non-invasive features. The technique itself can be sensitive to all passive electrical properties, such as conductivity, permittivity and permeability. Hence, it has a huge potential to be applied in many applications. Owing to its ill-posed nature and low image resolution, electrical tomography attracts more attention in industrial fields than biomedical fields. In the past decades, there have been many research developments and industrial implementations of electrical tomography; nevertheless, the awareness of this technology in industrial sectors is still one of the biggest limitations for technology implementation. In this paper, the authors have summarized several representative applications that use electrical tomography. Some of the current tomography research activities will also be discussed. This article is part of the themed issue 'Supersensing through industrial process tomography'.