Power consumption and flow field characteristics of a coaxial mixer with a double inner impeller

A coaxial mixer meeting the actual demand of a system with high and variable viscosity is investigated. It has an outer wall-scraping frame and a double inner impeller consisting of a four-pitched-blade turbine and Rushton turbine. The power consumption and flow field characteristics of the coaxial mixer in laminar and transitional flow are simulated numerically, and then the distribution of velocity field, shear rate and mass flow rate are analyzed. The simulation results indicate that the outer frame has little effect on the power consumption of the double inner impeller whether in laminar or transitional flow, whereas the inner combined impeller has a great effect on the power consumption of the outer frame. Compared with the single rotation mode, the power consumption of the outer frame will decrease in co-rotation mode and increase in counter-rotation mode. The velocity, shear rate and mass flow rate are relatively high near the inner impeller in all operating modes, and only under double-shaft agitation will the mixing performance near the free surface be improved.In addition, these distributions in the co-rotation and counter-rotation modes show little difference, but the co-rotation mode is recommended for the advantage of low power consumption.

Experimental study on gas–liquid dispersion and mass transfer in shear-thinning system with coaxial mixer

The effects of impeller type, stirring power, gas flow rate, and liquid concentration on the gas–liquid mixing in a shear-thinning system with a coaxial mixer were investigated by experiment, and the overall gas holdup, relative power demand, and volumetric mass transfer coefficient under different conditions were compared. The results show that, the increasing stirring power or gas flow rate is beneficial in promoting the overall gas holdup and volumetric mass transfer coefficient, while the increasing system viscosity weakens the mass transfer in a shearing–thinning system. Among the three turbines, the six curved-blade disc turbine(BDT-6) exhibits the best gas pumping capacity; the six 45° pitched-blade disc turbine(PBDT-6) has the highest volumetric mass transfer coefficient at the same unit volume power.

Synergistic and interference effects in coaxial mixers: Numerical analysis of the power consumption

This paper is concerned with the design and application of coaxial mixers with the aid of analysis of interaction between each individual impeller. Two types of coaxial mixers pitched blade turbine(PBT)-helical ribbon(HR)and inner-outer HR operated in laminar regime were studied experimentally and numerically. The interaction implies synergistic and interference effects, which was revealed through the investigation of axial circulation rate, energy dissipation rate and power consumption. The influence factors including rotational speed ratio,rotating mode and impeller configuration were explored systematically. Quantitative analysis of power consumption involves three parameters: rate of variation in power consumption, interactive mode and ratio of power consumption. Analysis indicated that some important properties were embodied in the power curve.These properties are one-way and two-way interactions, critical speed ratio and dominant impeller. Finally, a new suggestion for power estimation was given.

Numerical study on solid suspension characteristics of a coaxial mixer in viscous systems

A coaxial mixer consisting of an anchor and a Rushton turbine was selected as the research object,whose solid suspension characteristics were studied with the help of Computational Fluid Dynamics(CFD)method.Based on the Eulerian–Eulerian method and modified Brucato drag model,the just-suspension speed of impeller was predicted,and the simulation results were in good agreement with the experimental data.The quality of solid suspension under different rotation modes was also compared,and the results showed the coaxial mixer operating under co-rotation mode could get the best performance,and a larger anchor speed was beneficial to solid suspension by enhancing the turbulent intensity at the bottom.Compared with the anchor,the inner Rushton turbine played a dominant role in solid suspension due to its high rotational speed,whereas an extremely high inner impeller speed would make the uniformity of solid distributions become worse.Additionally,the effects of solid phase properties were also investigated,the results revealed that the higher the overall solid volume fraction and the smaller the Shields number,the worse the performance of solid suspension,meanwhile the solid suspension was more susceptible to solid density compared with particle diameter within the same Shields number gradient.

Investigation of dense slurry suspensions with coaxial mixers:Influences of design variables through tomography and mathematical modelling

The coaxial mixers enhance the suspension of concentrated slurries in an agitated reactor.In this research work,the complex slurry suspension and dissemination behavior in a coaxial slurry mixing system(comprised of a close clearance anchor rotating with a low speed and an inner axial impeller rotating with a high speed)was analyzed employing ERT(electrical resistance tomography,a non-intrusive flow visualization technique),and computational fluid dynamics(CFD).The numerical models were validated by comparing the axial solid concentration profiles generated using the ERT data and the CFD simulation results.The influences of various important parameters such as the diameter of the inner axial impeller,the inner impeller type,and the inner impeller spacing on the hydrodynamic characteristics of the slurry suspensions in a coaxial mixing vessel were thoroughly analyzed.The radial and axial velocity profiles of solid particles were generated using the validated mathematical models.The assessment of energy loss due to the solid-solid collisions,the particle-fluid frictions,and the particle-vessel wall collisions was conducted.The evaluation of optimum inner impeller clearance and inner impeller diameter is essential to attain a high degree of solids suspension and dissemination in a coaxial slurry mixing system.

双轴搅拌对晶粒降温结晶的影响

工业结晶过程中,一般希望结晶产物具有均匀的粒度和规则的晶形。考虑到带有外桨的双轴搅拌器能有效促进结晶过程的传质与传热,因此课题组以双轴搅拌器作为研究对象,通过实验考察了转速、桨型以及内外桨搅拌模式等参数对结晶产物粒度分布及晶型晶貌的影响;根据不同转速下测得的晶体成核生长动力学参数,建立氯化钾结晶成核速率与生长速率的预测公式。结果表明:双轴搅拌得到的晶体中值粒径明显高于单轴搅拌,但由于外桨的存在,使得粒度分布离散度变大;存在一个最佳转速使晶体中值粒径达到最大且粒度分布较为集中;内外桨同转、桨叶选用轴流桨或混流桨时更适用于结晶操作。氯化钾结晶成核速率与生长速率的预测公式为工业结晶提供一定的理论参考。

新型同心双轴搅拌器功率与混合特性的数值模拟

基于同心双轴搅拌器的结构与运行特点,建立了兼顾其流动、混合过程的三维数学模型,并以过程工业应用较多的两种不同尺寸双层组合桨作为内桨、框式桨作为外桨构成的同心双轴搅拌器为研究对象,数值模拟了其在中高黏牛顿流体中同向及反向转动模式的功率特性、流场特性及混合特性。模拟结果表明,同向转动模式下,整个系统的搅拌功耗更小、混合效率更高;外桨功耗受内桨影响较大,一般随内桨转速的增大,恒速外桨的功耗同向转动时会减小、反向转动时会增大;对由桨式搅拌器构成的组合式内桨而言,当内桨直径与釜体直径之比为0.35左右时,相同Reynolds数下的单位体积混合能更小;中高黏牛顿流体中,同心双轴搅拌器的内桨采用上层六斜叶桨+下层六直叶桨的组合形式时更高效节能,仅在体系Reynolds数小于36时,上层二斜叶桨+下层二直叶桨的内桨组合形式才具有相对优势。

同轴搅拌混合器性能的数值模拟

介绍了由锚式桨和涡轮桨组成的同轴搅拌器,并利用计算流体动力学软件对其进行了数值模拟,工作介质为牛顿流体和非牛顿流体,考虑了3种不同的工作模式:涡轮桨单独旋转、内外桨同向旋转和内外桨反向旋转。通过分析搅拌器内的功率消耗、速度分布、压力分布和剪切速率分布,得出内外桨同向旋转为该同轴搅拌器的最佳操作模式。

剪切变稀体系同心双轴搅拌釜内的气液分散模拟

气液搅拌设备因其良好的适用性被广泛应用于过程工业中。为更好地比较不同工况下剪切变稀体系中的气液分散情况,通过实验研究整体气含率和相对功耗确定适宜的转动模式,进而模拟研究表观气速、体系黏度、搅拌转速对气含率和气泡尺寸的影响。结果表明,相同功率下内外双桨反向旋转模式在理想气液分散条件下,相较于单轴内桨和内外双桨同向旋转模式具有更高的气含率和更好的气体泵送能力;表观气速的增加有利于气泡的均匀分散,但气泡尺寸也会随之增大;有效黏度的增加使得搅拌桨的影响区域变小,不利于气泡的均匀分散,气泡尺寸也随之增大;搅拌转速的增加使得循环涡流的影响区域变大,高气含率区不断扩大。

电磁波相位传感器弹状流混合介电常数分析

根据电磁波传播理论,设计了测量截面含气率的相位传感器。通过在传感器前端加装混相器,使之转化为均相流动,实现弹状流截面含气率的测量,并对不同流动条件下混合介电常数进行了分析。对对数、雷列伊、串并联、H-B和Bruggenman混合介电常数预测模型进行对比评价,平均绝对百分比误差分别为41.51%、6.07%、80.45%、62.51%和56.7%。针对弹状流,提出一种新的加权混合介电常数预测模型,平均绝对百分比误差为4.37%,71.43%的数据在5%的平均相对误差范围内。根据同一流动条件下基于均相流的截面含气率实验模型作为弹状流模型实验中的参比真值,对提出的混合介电常数预测模型求解的截面含气率的结果进行验证及评价,结果表明,截面含气率预测模型的平均绝对百分比误差为0.34%。

同心双轴复合式搅拌釜用于牛顿流体时的功耗及混合特性

在直径0.48m的椭圆底搅拌槽内,液位与槽径比（H/T）为0.6,采用不同粘度的牛顿流体糖浆溶液,研究了分别以CBY,45o四斜叶桨及Rushton涡轮桨作为快速分散桨、锚式桨作为慢速桨构成的同心双轴搅拌系统,在快、慢速轴同向和异向2种旋转方式操作时的功率特性和混合性能.结果表明,分散桨对锚式桨的功率消耗影响较大.两轴同向旋转时,分散桨会使锚式桨的功耗降低,转速比RN增加,降低幅度也增大,RN=14时,锚式桨功率可降至单独旋转时的约10%;异向旋转时锚式桨的功率随RN增加而增加,RN=14时,锚式桨功率可增至单独旋转时的2倍左右.但锚式桨对分散桨的功率消耗影响很小,在±5%以内.计算同心双轴复合搅拌系统的复合功率准数和复合雷诺数关系时考虑了RN的影响,使在实验条件下不同转向及RN的功率曲线较好吻合.混合效果同向旋转优于异向旋转,在牛顿流体中,达到相同混合效果时,CBY桨的能量消耗仅为其他2个分散桨的20%~30%.

同轴相位法找水仪混频器的耐温电路设计研究

井下环境复杂多变,高温高压环境对于各种仪器的性能指标有着非常重要的影响。同轴相位法找水仪高温电路的研究对于提高仪器耐温性能指标的有着十分重要的意义,根据同轴相位法找水仪的测量原理和井下环境的温度要求和测量电路的总体方案,分析了该仪器的混频器电路,设计并优化了适合同轴相位法找水仪的混频器电路,并且通过温度实验,得到了测量数据,达到了140℃的耐温条件,降低了功耗,消除了温度变化对混频器测量相位产生的影响。

同心双轴搅拌器气液分散性能的实验研究

针对气液搅拌操作形式单一的现状,将框式桨和Rushton桨组成的同心双轴搅拌器与黏稠体系中的气液分散操作相结合,实验考察了转动模式、内桨转速、通气量和体系黏度等因素对其气液分散性能的影响。结果表明,与单相黏稠体系中同向旋转模式下的功率与混合性能均占优不同,同心双轴搅拌器在反向旋转模式下的气液分散性能相对更好;外桨转速不变时,内桨转速从100增加到300 r·min^-1,整体气含率提高94.3%,局部气含率也均有增大;通气量从0.4提高到1.2 m^3·h^-1,整体气含率提高了72.5%,但局部气含率和气泡尺寸的增大不显著;体系黏度增加,气泡在釜内的停留时间加长,整体气含率单调增加。作为影响搅拌釜气液分散性能的重要参数,转动模式、内桨转速和通气量的确定还必须兼顾系统的功耗与混合效率,并避免发生气泛。

同轴异速桨在丙烯淤浆反应釜中的流场研究

针对丙烯聚合反应过程,设计了一种同轴异速桨,基于CFD对反应过程进行了数值模拟。建立12 m^3反应釜模型,采用多重参考系方法MRF、Mixture多相流模型、标准k-ε湍流模型模拟搅拌过程,获得了反应3个阶段釜内流体的速度场及浓度场。结果表明:同轴异速桨可以使釜内流体轴向和径向都有着很好的交换;其在反应的各个阶段都能使流体得到很好的混合;桨的转速对混合效果有着较大的影响,随着反应的进行,应逐渐增加折叶桨转速。