Mixing of viscoelastic fluids with helical-ribbon agitators. I — Mixing time and flow patterns

Batch mixing of viscous fluids with helical-ribbon agitators in 2.4 liter and 13 liter vessels has been studied for agitator speeds up to 200 RPM. Seven different agitators of different dimensions were employed in this work. Mixing times were measured using a decoloration technique and circulation times were determined by the tracer bead method. In addition, velocity profiles were obtained from streak photographs using selective illumination of the vessel and PVC powder as tracer particles. It was found that the mixing times of Newtonian fluids, which agreed with previously published data, were considerably (3 to 7 times) shorter than those of the viscoelastic fluids. The mixing time was strongly affected by the fluids' elasticity; increasing as the fluid elasticity increased. The velocity profiles were qualitatively similar for all the fluids but showed decreased axial circulation and increased circumferential flow as fluid elasticity increased. However, mixing is not only a function of the axial circulation (impeller pumping rate) but also is a function of the perturbations superimposed on the main flow. A simple, first approximation model based on the impeller geometry and flow patterns is proposed to correlate the circulation capacity and mixing time data for the various geometries studied.     

Modeling of the 3D hydrodynamics of 2-blade impellers in stirred tanks filled with a highly viscous fluid

This paper deals with mixing in stirred tank reactors by paddle agitators and two-blade impellers with different blade widths. Computational Fluid Dynamics (CFD) is used to solve the 3D hydrodynamics and to obtain at every point the flow patterns, the stress components and the viscous dissipation function. From the latter information, the power consumption is calculated. These results are compared with available experimental data: good agreement is observed. For example, for a paddle agitator, the flow is essentially plane far away from the horizontal walls. That means that, in order to create an axial circulation in the volume of the tank, the impeller height has to be decreased. This work documents the ability of CFD to model changes in flow patterns for three dimensional flows in stirred tanks.     

组合桨聚合釜内非牛顿流体的混合特性

在φ476mm的椭圆底有机玻璃聚合釜中,以羧甲基纤维素-甘油水溶液(前者质量分数为1.3％)为实验物系。利用酸碱中和法测定了9种不同的搅拌桨直径与聚合釜直径比接近于1的组合搅拌桨沿聚合釜轴向及径向的混合特性。结果表明：内外螺带-锚式组合桨的轴向混合最强,但径向混合较差。框板式搅拌桨的轴向混合较内外螺带-锚式组合桨弱,但比改进偏框式桨强,其径向混合较后者弱。改进偏框桨的7种不同组合方式沿径向的混合良好,多数组合桨沿轴向的混合较前2种组合桨弱,更接近于平推流。     

Influence of agitator design on powder flow

Design influences the flow within a powder mixer but quantitative guidance is lacking. Here the performance of mixers of different geometry was compared using positron emission particle tracking. One mixer had six long flat blades; the other carried short paddles. With the former, blade angle and number of axial compartments had little effect on agitation in the transaxial plan but axial dispersion was enhanced by longer axial compartments. A loop of circulation was found below the shaft. For the short paddle device, the transaxial agitation was more uniform, with a lower mean angular velocity and narrower ranges of velocities. The mixing elements inhibited the formation of the loop of circulation. In both cases, the axial flow had a cellular structure created by the radial supports for the blades but the short paddles mixer showed more chaotic behaviour, the axial dispersion coefficient being typically five times higher and increasing with fill rather than decreasing as seen with the six-blade device. A rationale for the design of powder mixers is thus emerging.     

多叶片组合式搅拌桨釜内流动特性和混合性能研究

开发可适用于较宽黏度范围的搅拌桨，强化釜内的流体流动和混合过程对于搅拌釜的节能增效具有重要的意义。实验与数值模拟相结合，在大涡模拟层面研究了多叶片组合式搅拌桨（MBC桨）从层流到湍流状态下，釜内的功率特性、流场分布、湍流特性和混合性能。结果表明：预测的功率曲线与实验结果一致；层流状态下釜内以切向流动为主，随着Reynolds数（Re）的增大，釜内轴向和径向流动逐渐增强，当Re达到486时，速度场分布与湍流状态下基本一致；在相同的能耗水平下，MBC桨对高黏度流体的混合性能优于商业Maxblend桨。桨叶的分散组合布置，强化了釜内的轴向和径向流动，使得MBC搅拌桨在从过渡流到湍流状态下均可实现较大的轴径向流动，湍动能分布较为均匀，混合过程显著加快。     

新型搪玻璃搅拌桨搅拌特性数值模拟及实验研究

采用CFD方法模拟了具有相同桨径、不同桨叶折角和叶宽结构的6种新型搪玻璃搅拌桨的搅拌特性。考察了挡板、桨叶离底高度对釜内流场的影响,基于此分析了桨叶折角、叶宽对速度分布的影响。对模拟得到的搅拌功率和混合时间进行了实验验证,并与传统搪玻璃桨式搅拌器进行比较。结果表明：①新型桨叶在加挡板且桨叶离底高度为450 mm时,搅拌效果最佳;②随桨叶折角、叶宽的增大,桨叶区轴向、径向和切向速度均呈增大趋势,当桨叶折角为45°、叶宽为95 mm时,釜内混合效果最好;③随转速增大,搅拌功率呈增大趋势,混合时间呈减小趋势,新型桨明显比传统桨混合性能好,桨叶折角为30°、叶宽95 mm时功率消耗最低,桨叶折角为35°、叶宽95 mm时混合时间最短。     

Study on the flow characteristics and mixing performance of multi-blade combined agitator

Developing an agitator suitable for wide viscosity range is of great significance to the energy saving and efficiency improvement by the intensification of fluid flow and mixing process. The power characteristics, flow field distribution, turbulence characteristics and mixing performance of multi-blade combined (MBC) agitator under laminar to turbulent flow state were studied experimentally and numerically at the level of large eddy simulation. The predicted power curve is consistent with the experimental results. Tangential flow is the main flow in laminar flow. With the increase of Reynolds number (Re), axial and radial flows in the vessel gradually increase. When Re reaches 486, the velocity field distribution is basically the same as that in the turbulent flow. At the same energy consumption level, MBC agitator is superior to the commercial Maxblend agitator in mixing high viscosity fluid. The intensification of axial and radial flows is due to the dispersed arrangement of the blades, enabling the MBC agitator to achieve larger axial and radial flows from the transitional flow to the turbulence state. Moreover, the turbulent kinetic energy is evenly distributed and the mixing process is significantly accelerated.     

酯化反应器内搅拌器的优化设计

搅拌功率和循环流量是考察搅拌桨性能和搅拌槽内混合效果的两个重要参数。作者在直径为5 0 0 m m和 80 0 mm的带导流筒的搅拌槽内 ,试验测试了现工业生产中酯化反应器内的搅拌桨的循环流量准数和功率准数 ,并根据工艺要求优选出以 CBY螺旋浆与直叶透平桨组成的双层浆式搅拌器 ,该搅拌桨比现工业用桨在消耗相同功率的条件下能产生更大的循环流量     

带有新型内外组合桨的搅拌设备内流场的数值研究

以滑移网格法的基本思想为出发点提出了滑移周期的概念.利用滑移网格法计算了以一定转速比反向旋转的新型内外组合桨搅拌的流场.通过对双层斜叶平桨、标准锚式桨和新型内外组合桨产生的流场进行对比,研究了搅拌设备内的宏观流动场、时均速度、速度变化率、剪切速率和轴向循环能力.结果表明：滑移周期概念的提出在一定程度上解决了滑移网格法计算周期长、计算成本高的问题.采用新型内外组合桨,加强了径向流动和轴向流动,改善了搅拌设备近壁区的流动状况,且对假塑性流体流动状况的改善优于牛顿流体.新型内外组合桨的剪切水平和轴向循环能力均优于双层斜叶平桨.     

Mixing in the transition flow regime with helical ribbon agitators

The effects of the non-Newtonian properties on the effective deformation rate, mixing and circulation times and flow behaviour have been investigated in the transition flow regime of mixing systems. Based on the equivalent Couette flow, three models are proposed and are shown to predict similar and drastic increases of the effective deformation rate with the impeller rotational speed in the transition regime. The predictions are shown to fit very well data obtained for various non-Newtonian fluids mixed with helical ribbon agitators, and with literature data for anchor, blade turbine and flat disc agitators. The elasticity along with shear-thinning properties appear to have slight effects on the dimensionless mixing and circulation times in the transition regime, whereas their effects in the laminar regime are quite drastic, as reported by others.     

聚合物溶解槽内双搅拌器流场特性的数值模拟

搅拌设备是目前海上油田实施聚合物驱油的配注系统的关键设备之一。利用计算流体力学方法对聚合物溶解过程采用翼型上推式搅拌器KCXU和锚式搅拌器MS的内外3种组合槽内流场进行了数值模拟,获得了搅拌器槽内的流场特性、循环流量及搅拌器的功率消耗。结果表明:在第1种混合状态时,KCXU搅拌器与转动的MS搅拌器组合时的流场变得更为复杂、无序。在第2,3种混合状态时,KCXU搅拌器与正转的MS搅拌器的组合形成的流场速度较大,加强了KCXU搅拌器的流动范围,并,且形成了最大的循环流量,其功率居中。     

Experimental Study of Influence of the Impeller Spacing on Flow Behaviour of Double‐Impeller Stirred Tank

The flow fields in the stirred tank with three different kinds of combined double‐impeller agitators: disc turbine + disc turbine (DT‐DT, radial impeller), pitched blade turbine + pitched blade turbine (PTD‐PTD, axial impeller) and pitched blade turbine + disc turbine (PTD‐DT), were investigated in detail by using laser Doppler anemometry. The two‐dimensional mean velocity field and the distribution of turbulence intensity were obtained for different impeller spacings. The experimental results show that the impeller spacing has a significant influence on the flow field. To improve flow homogeneity and agitator efficiency, the appropriate impeller spacing should be in the range of 1/2 to 2/3 of the tank diameter.     

橡胶沥青搅拌罐内混合过程的数值模拟

针对橡胶粉与基质沥青混合过程中出现的漂浮、沉底、粘壁及挂料现象,建立了橡胶沥青搅拌罐的几何模型,基于计算流体力学软件对罐内混合过程进行非定常固液两相流数值模拟,分析了影响混合均匀性的因素,如桨叶直径、桨叶位置、挡板及搅拌速度等. 结果表明,尺寸适宜的桨叶直径与合适的桨叶位置有利于形成循环的轴向流,并减少定常流现象,安装挡板有效减少了切向流,搅拌器转速不影响内部流场的基本形态,但适宜的搅拌转速提高了混合均匀性. 混合均匀度与模拟结果印证,且当搅拌器直径800 mm、桨叶距离罐底680 mm、桨叶宽100 mm、搅拌速度280 r/min时,优化后橡胶粉的分布较均匀,混合均匀度为0.24,处于完全离底悬浮状态,模拟结果与实验结果较吻合.     

筒式搅拌器及其开发

介绍了实用新型专利——筒式搅拌器的结构和设计原理。筒式搅拌器主要有筒体和内弯叶片组成,搅拌时能同时产生强大的径向流和轴向流,具有较大的排液量和循环流量,混合效果极强。筒式搅拌叶轮的各尺寸设计取决于液体性质、混合要求、容器直径和转速等因素。     

带有内外组合桨的搅拌设备内流场的数值研究

利用滑移网格法计算了以一定转速比反向旋转的内外组合桨搅拌的搅拌设备内的流场,工作介质分别选取98％甘油和1．5％(wt)CMC水溶液。通过对单桨与内外组合桨产生的流场进行对比,研究了搅拌设备内不同高度处速度、速度变化率、表观粘度及剪切速率的分布特点。结果表明：采用内外组合桨,介质为中粘牛顿流体时,在罐内主体区远离罐壁区域径向速度受到一定削弱,但在某些局部区域被增强,而对于假塑性流体径向速度总体上得到增强。采用内外组合桨可以加强轴向循环,改善搅拌设备近壁区的流动状况,且对假塑性流体流动状况的改善要优于中粘牛顿流体,另外还可以显著地提高搅拌设备内的剪切速率,同时使剪切速率的分布比较均匀。     

制备苯甲醛的液-液非均相反应过程

以天然肉桂醛为原料 ,于w(Na2 CO3 ) =10 %水溶液中进行反醇醛缩合反应实验 ,得到食用苯甲醛。在肉桂醛和碳酸钠水溶液的液 -液非均相反应过程中 ,对涡轮式、桨叶式、锚式、框式、三角式 5种不同搅拌形式的反应器进行考察比较。结果表明 ,既能使流体回转运动又能产生轴向运动的三角式搅拌器最佳。三角式搅拌器不但把油相的肉桂醛分散在碳酸钠水溶液中 ,而且把水相的碳酸钠溶液分散在肉桂醛中 ,使两相良好混合 ,反应过程接近于均相状态。苯甲醛总得率可达 6 0 % ,精馏后的成品w(苯甲醛 ) >99 5 %。     

侧进式搅拌反应器内流场的数值模拟

采用计算流体力学(CFD)技术对某钢铁厂烟气脱硫吸收塔底部浆液池的侧进式搅拌流场进行了数值模拟,研究了搅拌转速和搅拌桨安装角度等因素对3维流场的影响规律.结果表明,在5股流体的相互作用下,反应器内存在一个顺时针的整体大循环流动,相邻搅拌桨之间存在两个小漩涡.随着搅拌转速的增大,中心线上底部的速率迅速增加,当转速大于等于...     

翼形轴流桨用于液液分散的冷模研究

翼形桨是新一代高效轴向流叶轮。本文将这类叶轮用于液液分散的冷模试验，测定了基本流型及其造成的液滴大小分布，研究了分散特性与搅拌功率的关系，并与传统叶轮比较了搅拌混合的综合性能。     

圆盘涡轮式搅拌器的搅拌性能比较分析

在椭圆封头搅拌槽中根据行业标准建立了4种圆盘涡轮式搅拌器的几何模型,利用标准k-ε湍流模型和多参考系(MRF)方法,研究了叶片形状、搅拌速度、旋转方向和流型转变对搅拌功率、排出流量、泵出效率和剪切速率的影响。结果表明：叶片形状对功率、排出流量、泵出效率和流型转变的临界安装高度均有影响;径向流条件下,泵出效率排序为圆弧叶(反)>弯叶(正)>箭叶(反)>圆弧叶(正)>平直叶>箭叶(正)>弯叶(反);流型由径向流转变为轴向流后,搅拌功率及径向排出流量均下降。对标准搅拌器的性能评估为工业搅拌设备的选型和设计提供了参考依据。     

合成橡胶聚合釜的技术进展

从聚合反应工程的角度对合成橡胶聚合釜的技术进行了评述,介绍了国外合成橡胶聚合釜搅拌技术的进展概况,并指出我国目前的开发重点为:a.刮壁式搅拌浆的工业化开发,特别是在顺丁橡胶聚合釜中的应用;b.同轴线双轴异浆异速组合式浆,特别是外层带刮板的组合粟的开发;c.适用于特高粘度体系,如本体聚合,聚合物的脱挥发分过程等的卧式单轴或双轴自清洁式搅拌装置的开发;d.沸腾换热技术和搅拌浆叶内通冷却介质技术在聚合釜领域的推广应用。