Using Computational Fluid Dynamics To Study the Dynamic Behavior of the Continuous Mixing of Herschel−Bulkley Fluids

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.

A Comparative Study of Biogas Reactor Fluid Rheology—Implications for Mixing Profile and Power Demand

Anaerobic digestion (AD) is an established process for integrating waste management with renewable energy and nutrient recovery. Much of the research in this field focuses on the utilisation of new substrates, yet their effects on operational aspects such as fluid behaviour and power requirement for mixing are commonly overlooked, despite their importance for process optimisation. This study analysed rheological characteristics of samples from 21 laboratory-scale continuous stirred-tank biogas reactors (CSTBRs) digesting a range of substrates, in order to evaluate substrate effect on mixing efficiency and power demand through computational fluid dynamics (CFD). The results show that substrate and process parameters, such as solids content and organic loading, all have a significant effect on CSTBR fluid rheology. The correlation levels between rheological and process parameters were different across substrates, while no specific fluid behaviour patterns could be associated with substrate choice. Substrate should thus be considered an equally important rheology effector as process parameters. Additional substrate-related parameters should be identified to explain the differences in correlations between rheological and process parameters across substrate groups. The CFD modelling revealed that the rheology differences among the AD processes have significant implications for mixing efficiency and power demand of the CSTBRs, highlighting the importance of considering the substrate-induced effects on CSTBR rheology before including a new substrate.

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%).

Identifying and overcoming the effect of mass transfer limitation on decreased yield in enzymatic hydrolysis of lignocellulose at high solid concentrations

Cellulose conversion decreases significantly with increasing solid concentrations during enzymatic hydrolysis of insoluble lignocellulosic materials. Here, mass transfer limitation was identified as a significant determining factor of this decrease by studying the hydrolysis of delignified corncob residue in shake flask, the most used reaction vessel in bench scale. Two mass transfer efficiency-related factors, mixing speed and flask filling, were shown to correlate closely with cellulose conversion at solid loadings higher than 15% DM. The role of substrate characteristics in mass transfer performance was also significant, which was revealed by the saccharification of two corn stover substrates with different pretreatment methods at the same solid loading. Several approaches including premix, fed-batch operation, and particularly the use of horizontal rotating reactor were shown to be valid in facilitating cellulose conversion via improving mass transfer efficiency at solid concentrations higher than 15% DM.

The effect of mixing on the liquefaction and saccharification of cellulosic fibers

The enzymatic hydrolysis of cellulosic material is a key step in the biochemical routes for production of renewable fuels and chemicals. This must be performed at high solids to be economically viable. High solids operations creates numerous processing challenges, most importantly the limitations due to mass transfer and poor mixing of enzymes in the cellulose suspensions. We use magnetic resonance imaging (MRI), a cylindrical penetrometer, and HPLC to demonstrate the importance of spatial homogeneity in the distribution of enzyme on the rates of liquefaction of the substrate and in the suspension mechanical strength. Our results show that the largest mechanical strength changes occur in a narrow interval of time during the initial stages of conversion. Differences in enzyme concentration distribution occurring at the centimeter-scale produced order of magnitude differences in liquefaction and saccharification rates, supporting the hypothesis that mixing quality has a major influence in both liquefaction and saccharification rates.