Experimentally Validated Computational Fluid Dynamics Simulations of Multicomponent Hydrodynamics and Phase Distribution in Agitated High Solid Fraction Binary Suspensions

Effect of Retrofit Design Modifications on the Macroturbulence of a Three-Phase Flotation Tank-Flow Characterization Using Positron Emission Particle Tracking (PEPT)

Turbulence in stirred tank flotation tanks impacts the bulk transport of particles and has an important role in particle-bubble collisions. These collisions are necessary for attachment, which is the main physicochemical mechanism enabling the separation of valuable minerals from ore in froth flotation. Modifications to the turbulence profile in a flotation tank, therefore, can result in improvements in flotation performance. This work characterized the effect of two retrofit design modifications, a stator system and a horizontal baffle, on the particle dynamics of a laboratory-scale flotation tank. The flow profiles, residence time distributions, and macroturbulent kinetic energy distributions were derived from positron emission particle tracking (PEPT) measurements of tracer particles representing valuable (hydrophobic) mineral particles in flotation. The results show that the use of both retrofit design modifications together improves recovery by increasing the rise velocity of valuable particles and decreasing turbulent kinetic energy in the quiescent zone and at the pulp-froth interface.

Numerical and Experimental Investigations of Horizontal Turbulent Particle–Liquid Pipe Flow

A Eulerian–Eulerian computational fluid dynamics approach is used in conjunction with appropriate auxiliary models for turbulence and solid dynamic properties to study the complex turbulent flow of particle–liquid suspensions in a horizontal pipe. Numerical simulations of the detailed flow field are fully and successfully validated using a unique experimental technique of positron emission particle tracking. The study includes nearly neutrally buoyant as well as dense particles, ranging from small to large at low to high concentrations, conveyed by a Newtonian liquid. Results are analyzed in terms of radial particle and liquid velocity profiles as well as particle distribution in the pipe. The approach provides predictions with a high degree of accuracy. Particle behavior can be classified into three categories depending on their size and particle–liquid density ratio. An analysis of the forces governing the two-phase flow is used to interpret the phenomena observed.

Optimization of Reaction Selectivity Using CFD-Based Compartmental Modeling and Surrogate-Based Optimization

Mixing is considered as a critical process parameter (CPP) during process development due to its significant influence on reaction selectivity and process safety. Nevertheless, mixing issues are difficult to identify and solve owing to their complexity and dependence on knowledge of kinetics and hydrodynamics. In this paper, we proposed an optimization methodology using Computational Fluid Dynamics (CFD) based compartmental modelling to improve mixing and reaction selectivity. More importantly, we have demonstrated that through the implementation of surrogate-based optimization, the proposed methodology can be used as a computationally non-intensive way for rapid process development of reaction unit operations. For illustration purpose, reaction selectivity of a process with Bourne competitive reaction network is discussed. Results demonstrate that we can improve reaction selectivity by dynamically controlling rates and locations of feeding in the reactor. The proposed methodology incorporates mechanistic understanding of the reaction kinetics together with an efficient optimization algorithm to determine the optimal process operation and thus can serve as a tool for quality-by-design (QbD) during product development stage.