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Hu X, Ilgun AD, Passalacqua A, Fox RO, Bertola F, Milosevic M, Visscher F. CFD simulations of stirred-tank reactors for gas-liquid and gas-liquid-solid systems using OpenFOAM®. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2021. [DOI: 10.1515/ijcre-2019-0229] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
An open-source CFD software OpenFOAM® is used to simulate two multiphase stirred-tank reactors relevant to industrial processes such as slurry polymerization and fuel production. Gas-liquid simulations are first performed in a single-impeller stirred-tank reactor, studied experimentally by Ford, J. J., T. J. Heindel, T. C. Jensen, and J. B. Drake. 2008. “X-Ray Computed Tomography of a Gas-Sparged Stirred-Tank Reactor.” Chemical Engineering Science 63: 2075–85. Three impeller rotation speeds (200, 350 and 700 rpm) with three different bubble diameters (0.5, 1.5 and 2.5 mm) are investigated. Flow patterns compared qualitatively to those from experiments. Compared to the experimental data, the simulations are in relatively good agreement for gas holdup in the reactor. The second multiphase system is a multi-impeller stirred-tank reactor, studied experimentally by Shewale, S. D., and A. B. Pandit. 2006. “Studies in Multiple Impeller Agitated Gas-Liquid Contractors.” Chemical Engineering Science 61: 486–504. Gas-liquid simulations are performed at two impeller rotation speeds (3.75 and 5.08 RPS). The simulated flow patterns agree with published pictures from the experiments. Gas-liquid-solid simulations of the multi-impeller stirred-tank reactor are also carried out at impeller rotation speed 5.08 RPS. The addition of solid particles with a volume fraction characteristic of slurry reactors changes the flow pattern significantly. The bottom Rushton turbine becomes flooded, while the upper pitched-blade downflow turbines present a radial-pumping flow pattern instead of down-pumping. Nonetheless, the solid phase has a similar flow pattern to the liquid phase, indicating that the particles modify the effective density of the fluid.
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Affiliation(s)
- Xiaofei Hu
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
| | - Aziz Dogan Ilgun
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
- Department of Chemical and Biological Engineering , Iowa State University , 618 Bissell Rd , Ames , IA 50011-1098 , USA
| | - Alberto Passalacqua
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
| | - Rodney O. Fox
- Department of Chemical and Biological Engineering , Iowa State University , 618 Bissell Rd , Ames , IA 50011-1098 , USA
| | - Francesco Bertola
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
| | - Miran Milosevic
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
| | - Frans Visscher
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
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Bowler AL, Bakalis S, Watson NJ. A review of in-line and on-line measurement techniques to monitor industrial mixing processes. Chem Eng Res Des 2020. [DOI: 10.1016/j.cherd.2019.10.045] [Citation(s) in RCA: 38] [Impact Index Per Article: 9.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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Ye G, Nienow AW, Alberini F. Quantitative Measurements of the Critical Impeller Speed for Solid‐Liquid Suspensions. Chem Eng Technol 2019. [DOI: 10.1002/ceat.201800716] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Guichuan Ye
- University of Birmingham, School of Chemical Engineering Edgbaston Campus B15 2TT Birmingham United Kingdom
- China University of Mining and Technology School of Chemical and Environmental Engineering 11 Xueyuan Road 100083 Beijing China
| | - Alvin W. Nienow
- University of Birmingham, School of Chemical Engineering Edgbaston Campus B15 2TT Birmingham United Kingdom
| | - Federico Alberini
- University of Birmingham, School of Chemical Engineering Edgbaston Campus B15 2TT Birmingham United Kingdom
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Mishra P, Ein-Mozaffari F. Using tomograms to assess the local solid concentrations in a slurry reactor equipped with a Maxblend impeller. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.07.007] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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Lassaigne M, Blais B, Fradette L, Bertrand F. Experimental investigation of the mixing of viscous liquids and non-dilute concentrations of particles in a stirred tank. Chem Eng Res Des 2016. [DOI: 10.1016/j.cherd.2016.01.005] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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Mo J, Gao Z, Bao Y, Huang X. Turbulence Properties of Continuous Phase in Agitated Gas–Liquid–Solid Systems. JOURNAL OF CHEMICAL ENGINEERING OF JAPAN 2015. [DOI: 10.1252/jcej.14we027] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Junyuan Mo
- State Key Laboratory of Chemical Resource Engineering, School of Chemical Engineering, Beijing University of Chemical Technology
| | - Zhengming Gao
- State Key Laboratory of Chemical Resource Engineering, School of Chemical Engineering, Beijing University of Chemical Technology
| | - Yuyun Bao
- State Key Laboratory of Chemical Resource Engineering, School of Chemical Engineering, Beijing University of Chemical Technology
| | - Xiongbin Huang
- State Key Laboratory of Chemical Resource Engineering, School of Chemical Engineering, Beijing University of Chemical Technology
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Influence of drag and turbulence modelling on CFD predictions of solid liquid suspensions in stirred vessels. Chem Eng Res Des 2014. [DOI: 10.1016/j.cherd.2013.10.020] [Citation(s) in RCA: 38] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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Characterization of Minimum Impeller Speed for Suspension of Solids in Liquid at High Solid Concentration, Using Gamma-Ray Densitometry. INTERNATIONAL JOURNAL OF CHEMICAL ENGINEERING 2012. [DOI: 10.1155/2012/945314] [Citation(s) in RCA: 20] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
Abstract
The successful design and operation of Liquid-Solid (LS) and Gas-Liquid-Solid (GLS) stirred tank reactors requires an accurate determination of the level of solid suspension needed for the process at hand. A poor design of the stirred tank to achieve optimum conditions and maintain the system under these conditions during operation may cause significant drawbacks concerning product quality (selectivity and yield) and cost. In this paper, the limitations of applying conventional measurement techniques for the accurate characterization of critical impeller speed for just off-bottom suspension (NJS) at high solid concentrations are described. Subsequently, the Gamma-Ray Densitometry technique for characterizingNJSis introduced, which can overcome the limitations of previous experimental techniques. The theoretical concept of this method is explained, and experimental validation is presented to confirm the accuracy of the Gamma-Ray Densitometry technique. The effects of clearance, scale, and solid loading onNJSfor several impellers are discussed. ExperimentalNJSvalues are compared with correlations proposed in the literatures, and modifications are made to improve the prediction. Finally, by utilizing the similarity to the incipient movement of solid particles in other systems, a theoretical model forNJSprediction is presented.
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Joshi JB, Nere NK, Rane CV, Murthy BN, Mathpati CS, Patwardhan AW, Ranade VV. CFD simulation of stirred tanks: Comparison of turbulence models. Part I: Radial flow impellers. CAN J CHEM ENG 2011. [DOI: 10.1002/cjce.20446] [Citation(s) in RCA: 123] [Impact Index Per Article: 9.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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Kasat GR, Pandit AB. Review on Mixing Characteristics in Solid-Liquid and Solid-Liquid-Gas Reactor Vessels. CAN J CHEM ENG 2008. [DOI: 10.1002/cjce.5450830403] [Citation(s) in RCA: 56] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
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Bao Y, Hao Z, Gao Z, Shi L, Smith JM, Thorpe RB. GAS DISPERSION AND SOLID SUSPENSION IN A THREE-PHASE STIRRED TANK WITH MULTIPLE IMPELLERS. CHEM ENG COMMUN 2006. [DOI: 10.1080/00986440500267261] [Citation(s) in RCA: 16] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Micale G, Grisafi F, Brucato A. Assessment of Particle Suspension Conditions in Stirred Vessels by Means of Pressure Gauge Technique. Chem Eng Res Des 2002. [DOI: 10.1205/026387602321143444] [Citation(s) in RCA: 42] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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