CFD-PBM coupled modeling of the liquid-liquid dispersion characteristics and structure optimization for Kenics static mixer

Kenics static mixers(KSM)are extensively used in industrial mixing-reaction processes by virtue of high mixing efficiency,low power homogenization and easy continuous production.Resolving liquid droplet size and its distribution and thus revealing the dispersion characteristics are of great significance for structural optimization and process intensification in the KSM.In this work,a computational fluid dynamics-population balance model(CFD-PBM)coupled method is employed to systematically investigate the effects of operating conditions and structural parameters of KSM on droplet size and its distribution,to further reveal the liquid-liquid dispersion characteristics.Results indicate that higher Reynolds numbers or higher dispersed phase volume fractions increase energy dissipation,reducing Sauter mean diameter(SMD)of dispersed phase droplets and with a shift in droplet size distribution(DSD)towards smaller size.Smaller aspect ratios,greater blade twist and assembly angles amplify shear rate,leading to smaller droplet size and a narrower DSD in the smaller range.The degree of impact exerted by the aspect ratio is notably greater.Notably,mixing elements with different spin enhance shear and stretching efficiency.Compared to the same spin,SMD becomes 3.7-5.8 times smaller in the smaller size range with a significantly narrower distribution.Taking into account the pressure drop and efficiency in a comprehensive manner,optimized structural parameters for the mixing element encompass an aspect ratio of 1-1.5,a blade twist angle of 180°,an assembly angle of 90°,and interlaced assembly of adjacent elements with different spin.This work provides vital theoretical underpinning and future reference for enhancing KSM performance.

Comparative analysis of different static mixers performance by CFD technique:An innovative mixer

The flow and mixing behavior of two miscible liquids has been studied in an innovative static mixer by using CFD,with Reynolds numbers ranging from 20 to 160.The performance of the new mixer is compared with those of Kenics,SMX,and Komax static mixers.The pressure drop ratio(Z-factor),coefficient of variation(CoV),and extensional efficiency(α)features have been used to evaluate power consumption,distributive mixing,and dispersive mixing performances,respectively,in all mixers.The model is firstly validated based on experimental data measured for the pressure drop ratio and the coefficient of variation.CFD results are consistent with measured data and those obtained by available correlations in the literature.The new mixer shows a superior mixing performance compared to the other mixers.

The numerical simulation of a new double swirl static mixer for gas reactants mixing

For the nitrogen oxide removal processes,high performance gas mixer is deeply needed for the injection of NH3 or O3.In this study,a new type of double swirl static mixer in gas mixing was investigated using computational fluid dynamics(CFD).The results obtained using Particle Image Velocimetry(PIV)correlated well with the results obtained from simulation.The comparisons in pressure loss between the experimental results and the simulation results showed that the model was suitable and accurate for the simulation of the static mixer.Optimal process conditions and design were investigated.When L/D equaled 4,coefficient of variation(COV)was<5%.The inlet velocity did not affect the distributions of turbulent kinetic energy.In terms of both COV and pressure loss,the inner connector is important in the design of the static mixer.The nozzle length should be set at 4 cm.Taking both COV and pressure loss into consideration,the optimal oblique degree is 450.The averaged kinetic energy changed according to process conditions and design.The new static mixer resulted in improved mixing performance in a more compact design.The new static mixer is more energy efficient compared with other SV static mixers.Therefore,the double swirl static mixer is promising in gas mixing.

Conversion enhancement of tubular fixed-bed reactor for Fischer-Tropsch synthesis using static mixer

Recently, Fischer-Tropsch synthesis （FTS） has become an interesting technology because of its potential role in producing biofuels via Biomass- to-Liquids （BTL） processes. In Fischer-Tropsch （FT） section, biomass-derived syngas, mainly composed of a mixture of carbon monoxide （CO） and hydrogen （H2）, is converted into various forms of hydrocarbon products over a catalyst at specified temperature and pressure. Fixed-bed reactors are typically used for these processes as conventional FT reactors. The fixed-bed or packed-bed type reactor has its drawbacks, which are heat transfer limitation, i.e. a hot spot problem involved highly exothermic characteristics of FT reaction, and mass transfer limitation due to the condensation of liquid hydrocarbon products occurred on catalyst surface. This work is initiated to develop a new chemical reactor design in which a better distribution of gaseous reactants and hydrocarbon products could be achieved, and led to higher throughput and conversion. The main goal of the research is the enhancement of a fixed-bed reactor, focusing on the application of KenicsTM static mixer insertion in the tubular packed-bed reactor. Two FTS experiments were carried out using two reactors i.e., with and without static mixer insertion within catalytic beds. The modeled syngas used was a mixed gas composed of H2/CO in 2 ： 1 molar ratio that was fed at the rate of 30 mL（STP）·min^- 1 （GHSV ≈ 136 mL·gcat^-1 ·h^-1） into the fixed Ru supported aluminum catalyst bed of weight 13.3 g. The reaction was carried out at 180 ℃ and atmospheric pressure continuously for 36 h for both experiments. Both transient and steady-state conversions （in terms of time on stream） were reported. The results revealed that the steady-state CO conversion for the case using the static mixer was approximately 3.5 times higher than that of the case without static mixer. In both cases, the values of chain growth probability of hydrocarbon products （α） for Fischer-Tropsch synthesis were 0.92 and 0.89 for the case with and without static mixer, respectively.

Transfer Characteristics in Mechanically Stirred Airlift Loop Reactors with or without Static Mixers

The mechanically stirred internal loop airlift reactors equipped with or without static mixers are devised for intensification of gas-liquid mass transfer rate. The influences of superficial gas velocity, agitation or static mixers on gas hold-up, mixing time, liquid circulating velocity and volumetric mass transfer coefficient have been investigated with tap water and carboxymethyl cellulose (CMC) aqueous solution. The experimental results indicate that mechanical agitation is more efficacious than static mixer in highly viscous media for improving mass transfer in airlift reactors. The empirical correlation of volumetric mass transfer coefficient with apparent viscosity, and energy consumption for mechanical agitation and aeration is developed.

A Study on a Gas Agitated Extractor with Static Mixer

1 INTRODUCTIONMany chemical engineering operations involve the mass and heat transfer between two liquidphases in reactions.Mechanically agitated liquid-liquid extractor can be one of the examples forsuch operations.It has been well developed and used in the nuclear energy,petrochemical andother chemical industries.However,not much attention has been paid to the gas agitated liquid-

PRESSURE DROP OF PSEUDO-PLASTIC FLUIDS IN STATIC MIXERS

1 INTRODUCTIONUse of static mixers to process non-Newtonian fluids is quite commn.Data on thepressure drop of non-Newtonian fluids in Kenics static mixers are very useful in thedesign and engineering application of such mixers.However,only a few studies con-cerned with the pressure drop of non-Newtonian fluid flow in static ndxers can befound in literature.Wilkinson and Cliff presented pressure drop data for aqueousglycerine solutions(Newtonian fluids)and aqueous 1% polyacrylamide solution showingviscoelastic behavior.They found no difference between the friction factors of

A novel method of utilizing static mixer to obtain mixing homogeneity of multi-species powders in laser metal deposition

Real-time mixing of multi-species powder challenges Laser Metal Deposition(LMD)of Functionally Graded Materials(FGMs).The current work proposes a novel method of using a static mixer to realize rapid,uniform multi-species powder mixing.Firstly,copper powder and 316L stainless steel powder are selected to complete the powder mixing observation experiment with Scanning Electron Microscope(SEM)and Energy Dispersive Spectrometer(EDS).Secondly,computational fluid dynamics and particle mixing simulation models are used to analyze the flow field and particle motion characteristics in the static mixer.Finally,LMD experiment and metallo-graphic observation are carried out with 316L stainless steel powder and WC powder to verify the feasibility of the static mixer.This study provides a theoretical and practical basis for powder mixing in laser processing with a static mixer.The conclusions can also be applied to other processing fields requiring real-time and uniform mixing of multi-species powders.

Solvent extraction of Ce(Ⅲ) and Pr(Ⅲ) with P507 using SiC foam as a static mixer

Extraction reactor is a major research area of interest within the field of rare earths extraction and separation.SiC foam offers excellent material characteristics as well as three-dimensional(3-D) reticulated structure;however,very little research has been carried out on its application in extraction reactor so far.In this work,a static mixer reactor based on SiC foam was designed and demonstrated to extract and separate Ce(Ⅲ) and Pr(Ⅲ) from nitric acid media by using 2-ethylhexyl phosphoric acid mono-2-ethylhexyl ester(P507) as extractant.The structure-performance relationship between SiC foam and extraction performance was studied by experiment combined with computational fluid dynamics(CFD)simulation.The experiment data are in good agreement with the simulation results.Contrast experiment by using a Kenics mixer was carried out,and SiC foam shows better extraction and mass transfer performance.Using the optimal structural SiC foam(pore size D=2.3 mm,open porosity ε=85%,foam length L=80 mm),high extraction efficiency η(Pr(Ⅲ):94.6%,Ce(Ⅲ):88.5%) and separation factor β(2.27) between Ce(Ⅲ) and Pr(Ⅲ) is achieved at a high total throughput of 200 mL/min.Besides,overall volumetric mass transfer coefficient K_(L)a of Pr(Ⅲ) and Ce(Ⅲ) are 0.519 and 0.378 s^(−1) at the residence time τ of 3.6 s,respectively,which reach the high level of microchannel reactors and are better than conventional extractors and other static mixers.SiC foam is found to be applicable as a static mixer for efficient and high-throughput extraction and separation of rare earths.

Optimizing flow field in an SCR system of a 600 MW power plant:effects of static mixer alignment style

The fluid flow in a selective catalytic reduction(SCR)system of a 600 MW power station is optimized using the numerical simulation method in this work.Given that guide plates and straightening gratings are properly installed,the relative standard deviation(C_(v))of velocity related to the inlet of an ammonia injection grid(AIG)and catalysts satisfy the engineering demand of<15%,suggesting that a relatively uniform velocity field is obtained.The in-line arrangement of static mixers strengthens the disturbance of fluid,promoting the mixing of reductant NH_(3)with flue gas.The NH_(3)mole fraction C_(v)value correlated to the inlet of catalysts drops to ca.3.5%,which is lower than that in the cases when the mixers are aligned in a staggered style.These results indicate that a solid foundation is achieved for the effective abatement of NO_(x)in practical applications.

Combined static mixers for high viscous fluids mixing

A new static mixer Cross-over-Disc has been invented to strip off the boundary layer and to make strong radial mixing.The pressure drop of Cross-over-Disc is 12–26 times as large as that of empty pipe with equivalent diameter and length.The mixing performance of Cross-over-Disc with 14 elements has been investigated in the viscosity range of 190–250 Pa·s by decoloration method,and the gray analysis of images shows that mixing inhomogeneity is about 7.5%and 9.4%for the mixing ratio of 5∶1 and 10∶1,respectively.Furthermore,mixing inhomogeneity for a combination of static mixing elements(four from Cross-over-Disc and three pairs from Sulzer-type)can be decreased to 2.1%–3.1%within a reasonable range of pressure drop.

基于CFD-DEM算法的气力输送气固两相流特性分析

超轻粉体颗粒由于质量较小,在运输过程中易受气流扰动而飘散,物料的管道气力输送过程不稳定,易发生堵塞。为了研究超轻粉体颗粒在旋流气力输送中气固两相流流动特性,采用计算流体力学与离散单元法(CFD-DEM),对Komax型静态混合器内气固两相流动特性进行数值模拟研究。研究发现,带有Komax型元件的水平管道可以改变颗粒的流动情况,改善了水平管道内颗粒堆积和分布不均匀的现象;分别从颗粒相和流体相的流动状态分析得到元件长径比Ar=3时为最优几何结构;通过正交实验极差分析得到影响气固两相流动特性的因素顺序:输送气速>颗粒质量流量>颗粒粒径。当元件Ar=3时,颗粒-颗粒和颗粒-管壁的碰撞次数与碰撞强度呈现负相关,结合出口颗粒流分散状态,优选输送气速为3~4m/s;主要考虑输送气速对管内压降的影响,提出了带有Komax型元件的水平管道气力运输过程中压降与输送气速和轴向位置的经验拟合式。

静态混合器结构优化设计与流场特性分析

为油田高能效驱油以提高原油产量,针对SK型和SX型静态混合器混合单元结构,通过创新设计和三维建模开发多重螺旋混合单元静态混合器,基于静态混合原理,利用FLUENT数值模拟软件,采用有限体积法,对所开发混合器内流体的流场进行仿真分析,研究该结构静态混合器的流动特性,结果表明,该种静态混合器使流体产生剪切和正反向涡旋作用,流体被充分扰动,混合均匀,满足油田注聚驱油要求,可为油田开发新型高效静态混合器提供一定技术支持。

穿孔对穿孔型Kenics静态混合器混合性能的影响

为了提升传统Kenics静态混合器的混合效果,在传统螺旋插入带结构中引入穿孔结构,设计出穿孔型Kenics静态混合器。采用浓度变异系数评估穿孔内径(d)、穿孔间距(S)、混合单元长径比(Ar)对穿孔型静态混合器混合性能的影响。模拟结果表明,设置的穿孔结构会显著改变流体的流动状态,在穿孔处区域产生加速流动,进而提升混合器的混合性能;随着d的增加,流体之间的对流和交换作用逐渐增强,混合效果逐渐增强,但随着d的持续增加,导致混合器内部螺旋通道被破坏,混合效果反而减弱;仅改变S对混合效果没有明显影响;对于相同的混合器长度,Ar的减小导致混合元件数量增加,液体之间的扭转、剪切效果增强,混合器混合效果更好。

非牛顿流体在叶片式静态混合器中的传热强化特性

非牛顿流体在化学、食品和材料等领域具有关键作用,但高表观黏度使其通常具有低传热特性。叶片式静态混合器作为一种高效的传热强化设备,在化工过程强化中具有鲜明的技术特色。本文针对非牛顿流体在Kenics静态混合器(KSM)和Lightnin静态混合器(LSM)内的流动和传热特性进行了比较研究。重点分析了体积流量、元件长径比及流体浓度等参数对羧甲基纤维素(CMC)幂律流体的流动及传热影响。结果表明,在相同工况下,随着CMC溶液的体积流量增大,管道内的换热系数和压降均增大。静态混合元件的插入使得换热系数和压降显著提高且Lightnin元件产生的影响更明显。元件长径比和CMC溶液浓度影响流体在管道内的流动和换热。随着长径比的减小,传热性能得到提高,但其增大的阻力系数影响占据主导地位,综合换热性能系数(PEC)降低。溶液浓度的增大使得管道换热能力逐步削弱,并对管道内压降的提升有显著影响,综合换热性能降低。总结得出,在体积流量为4.5×10^(-4)m^(3)/s,质量分数为0.374%、长径比为3.0时,KSM的PEC最大为2.114。

Kenics型静态混合器中幂律流体与颗粒混合过程分析

针对Kenics型静态混合器内固体颗粒在幂律流体中的孤岛现象的产生机理进行研究。运用Fluent数值模拟固相颗粒与CMC水溶液在Kenics静态混合器中的混合过程,并利用浓度变异系数(COV)对颗粒分布特性进行量化分析。研究表明:提高流体表观黏度和流体入口速度,颗粒停留时间缩短,COV值降低,混合效果提高。在第4~8个扭旋叶片中间截面上均形成了两对对称的无粒子孤岛,降低流体表观黏度和提高流体入口速度,孤岛边界更清晰。扭旋叶片诱导的内流涡旋和近壁面涡旋有较高的涡量,涡旋中心局域形成无粒子孤岛,相邻叶片交错区域,随着涡旋耗散孤岛消失。

薄板式静态混合器混合性能数值模拟

薄板式静态混合器内构件简单、通量高、压降低,可以有效降低稀释水掺混能耗。文中以不均匀系数ψ和管路压降Δp作为评价指标,利用CFD(计算流体动力学),对比分析单直管、单顺流羽状管、单逆流羽状管和双顺流羽状管等4种注水方式的混合效果和压降。研究发现,在注水管安装在L/D=5.3处,单管注入时,注水两侧形成的径向二次流强度Se变化缓慢,稳定的涡旋流在混合器内产生混合“死区”,降低了静态混合器的油水混合速度;当ψ降至0.05时,混合距离超过18D。此混合死区解释了单管注入时分散相注入点附近易出现局部高浓度区。双顺流羽状管注入时,对撞水相产生较高径向二次流强度Se,且迅速降低。快速变化的流场显著减少混合距离,与单管注入相比,ψ降至0.05时混合距离减少76.9%,Δp增加1.5%。

天然气管道随动流量掺氢实验及新认识

如何获得高掺混均匀度和精度的掺氢天然气是天然气管道掺氢输送的核心问题之一。虽然目前常采用随动流量掺氢工艺,但国内外尚未见公开报道的实验数据,氢气和天然气的掺混均匀度和掺混精度得不到实验验证,在一定程度上制约了掺氢天然气管道输送技术的进一步发展。为此,研究了天然气管道随动流量掺氢工艺,并基于高效静态混合器、氢组分浓度三维在线检测和双反馈随动流量定比掺氢,搭建了天然气管道随动流量掺氢实验系统,最后开展了掺氢流量100 Nm3/h以内、掺氢比5.0%~20.0%的实验研究。研究结果表明:①设计搭建的随动流量掺氢实验系统的掺混均匀度大于95%,不考虑测量误差影响时掺氢精度绝对值小于等于1.67%,考虑测量误差影响时,当掺氢比大于等于10.0%时掺氢精度绝对值小于等于3.30%,而掺氢比为20.0%时掺氢精度绝对值小于等于1.70%,随动流量掺氢性能优于标准规范技术指标;②相同实验条件下,受氢气分析仪精度等级和量程的影响,掺氢比越小,掺氢精度越低;③为合理表征掺氢精度,在制定相关标准规范时建议根据掺氢比范围分级定义随动流量掺氢精度。结论认为,该成果认识可为掺氢天然气管道输送技术的发展和相关标准规范的制定提供重要理论和技术参考。

Kenics型静态混合器对含水原油均质化效果影响数值模拟

目的针对含水原油在输送过程中水分分布不均匀或大量聚集的现象,将Kenics静态混合器引入到含水原油输送过程中,并对其均质化效果进行分析。方法采用FLUENT软件对管道内流场进行模拟,并用变异系数和液滴平均粒径对均质化效果进行评价,分析了混合单元排列方式、扭角、长径比和数量对均质化效果的影响。结果使用排列方式为异向叉排、扭角为240°、长径比为0.5、数量为10个的Kenics静态混合器不仅能使油水两相分布均匀,还能获得更小的液滴平均粒径,从而实现更好的均质化效果。结论排列方式为异向叉排时均质化效果最好;随着扭角的增大,管线出口的变异系数和液滴平均粒径呈下降趋势;随着长径比的减小和数量的增多,出口的变异系数值趋于相同,但能获得更小的液滴平均粒径。通过均质化处理后,可以使取样样本更加准确地体现储罐原油的含水率,避免造成油品交接纠纷,保证油品外输任务的完成。

基于SMX静态混合器的天然气掺氢流动影响研究

为了获取均匀的天然气掺氢混合气,确保掺氢燃气管道稳定、安全输送,采用数值模拟与试验相结合的方法研究了天然气与氢气在SMX静态混合器中的掺混特性及影响因素,详细分析了掺混单元数量、运行工况和掺氢体积比等因素对掺混性能的影响。研究结果表明,氢气与天然气的混合主要依赖于混合单元不断改变流动状态,实现左旋和右旋相互交替,达到均匀混合。流动损失主要取决于静态混合器内流动速度,综合考虑SMX静态混合器的压力损失和混合均匀度性能指标,采用4个掺混单元、进口气流速度10 m/s是一个优选方案。此外,增大掺氢体积比和加长流经混合器出口下游管道长度均有利于提升氢气和天然气掺混均匀度,要结合燃气管道的具体情况来确定掺氢体积比的合理范围。