Liquid flow circulating within an unbaffled vessel agitated with an unsteady forward–reverse rotating impeller

Liquid‐phase mixing is a common operation, often performed in vessels using mechanically rotating impellers. To enhance axial mixing the vessels are generally equipped with baffles; however, in industries where cleaning the vessel interior is a major concern, i.e. food and pharmaceuticals, and crystallization, where baffles can disturb particle growth, unbaffled vessels are preferred. One method of agitation in unbaffled vessels is an impeller that periodically changes either the direction or rate of rotation: so‐called unsteady rotation. For use in an enhanced agitation vessel, an agitation technology using an unsteady forward–reverse rotating impeller in an unbaffled vessel was investigated. Such unsteady agitation is expected to enhance mixing. However, knowledge of the liquid flows in such an apparatus remains elusive. Thus an aim of this work was to characterize the circulation flow in such a system. Circulation by a disk turbine impeller with six flat blades was studied through examination of tracer particle trajectories. Images showing flow patterns with the forward–reverse rotating impeller resembled those obtained with a unidirectionally rotating impeller in a baffled vessel. The pattern was characterized by a circulation loop whose pathway exits from the impeller rotational region and returns to that region past the wall and bottom of the vessel. Time‐series particle tracking velocimetry (PTV) images obtained during one forward–reverse rotation of the impeller showed that the flow near the vessel wall reduced the periodic fluctuation downstream and that a flow that was almost independent of time was induced near the vessel bottom. For the flow from the bottom to the impeller, unsteadiness was provided by proximity to the impeller. Based on the intensity distribution of the unsteady flow produced by this type of forward–reverse rotating impeller within the vessel, the unsteady flow was shown to have the potential to reach the region near the vessel wall. Copyright © 2010 Society of Chemical Industry     

Effect of impeller clearance on liquid flow within an unbaffled vessel agitated with a forward–reverse rotating impeller

For an unbaffled agitated vessel with an unsteadily forward–reverse rotating impeller whose rotation proceeds with repeated acceleration, deceleration, and stop–reverse processes, liquid flow was studied through visualisation and measurement using particle tracking velocimetry (PTV). A disk turbine impeller with six flat blades was used with varied height settings. The impeller clearance and its forward–reverse rotation cycle characterised the impeller region flow: the radially outward flow in the deceleration process for the larger clearance relative to the vessel diameter of 1/3, and the axially downward flow in the acceleration process for the smaller clearance relative to the vessel diameter of 1/8. The flow patterns within the vessel resulting from the impeller's larger and smaller clearances were outlined, respectively, by double loops and a single loop of circulation, resembling the pattern produced by unidirectionally rotating turbine‐type impellers. The discharge flow was revealed to contain a comparable level of periodic circumferential velocity component, irrespective of the impeller clearance.     

Solid–liquid mass transfer characteristics of an unbaffled agitated vessel with an unsteadily forward–reverse rotating impeller

To develop an enhanced form of solid‐liquid apparatus, an unbaffled agitated vessel has been constructed, fitted with an agitation system using an impeller whose rotation alternates unsteadily in direction, i.e. a forward‐reverse rotating impeller. In this vessel, solid‐liquid mass transfer was studied using a disc turbine impeller with six flat blades. The effect of impeller rotation rate as an operating variable on the mass transfer coefficient was evaluated experimentally using various geometrical conditions of the apparatus, such as impeller diameter and height, in relation to the impeller power consumption. Mixing of gas above the free surface into the bulk liquid, i.e. surface aeration, which accompanied the solid‐liquid agitation, was also investigated. Comparison of the mass transfer characteristics between this type of vessel and a baffled vessel with a unidirectional rotating impeller underscored the sufficient solid‐liquid contact for prevention of gas mixing in the forward‐reverse rotation mode of the impeller. Copyright © 2008 Society of Chemical Industry     

Agitation requirements for complete solid suspension in an unbaffled agitated vessel with an unsteadily forward–reverse rotating impeller

Background: To develop a new type of solid–liquid apparatus, we have proposed the application of an agitation system with an impeller whose rotation alternates direction unsteadily, i.e., a forward–reverse rotating impeller. For an unbaffled agitated vessel fitted with this system, the suspension of solid particles in a liquid was studied using a disk turbine impeller with six flat blades. Results: The effects of the solid–liquid conditions and geometrical conditions of the apparatus on the minimum rotation rate and the corresponding impeller power consumption were evaluated experimentally for a completely suspended solid. The power consumption for a just suspended solid with this type of vessel was comparable with that for a baffled vessel with a unidirectionally rotating impeller, taking the liquid flow along the vessel bottom into consideration. Conclusion: Empirical relationships to predict the parameters of agitation requirements were found. A comparative investigation demonstrated the usefulness of the forward–reverse rotation mode of the impeller for off‐bottom suspension of solid particles. Copyright © 2007 Society of Chemical Industry     

Flow and mass transfer in aerated viscous Newtonian liquids in an unbaffled agitated vessel having alternating forward–reverse rotating impellers

Flow and mass transfer characteristics in aerated viscous Newtonian liquids were studied for an unbaffled aerated agitated vessel with alternating rotating impellers (AAVAI), ie with multiple forward–reverse rotating impellers having four delta blades. The effects of operating conditions such as gas sparging rate, agitation rate and the number of impeller stages, and the liquid physical properties (viscosity) on the gas hold‐up, ?_gD, and volumetric oxygen transfer coefficient, k_La_D were evaluated experimentally. The dependences of ?_gD and k_La_D on the specific total power input and superficial gas velocity differed, depending on the ranges of liquid viscosity. Empirical relationships are presented for each viscosity range to predict ?_gD and k_La_D as a function of the specific total power input, superficial gas velocity and viscosity of liquid. Based on a comparative investigation of the volumetric coefficient in terms of the specific total power input between the AAVAI and conventional aerated agitated vessels (CAAVs) having unidirectionally rotating impellers, the usefulness of AAVAI as a gas–liquid agitator treating viscous Newtonian liquids is also discussed. © 2001 Society of Chemical Industry     

Power characteristics of unsteadily forward–reverse rotating impellers in an unbaffled aerated agitated vessel

Power characteristics of an unbaffled aerated agitated vessel with unsteadily forward‐reverse rotating impellers, ie a new type of gas–liquid agitator named ‘AJITER’, treating viscous Newtonian liquids were studied experimentally. Measurements were first made on the agitation torque, ie the torque on the drive shaft on which forward–reverse rotating impellers with four delta‐type blades were attached, and the data obtained were analyzed by fitting them to an equation consisting of two terms with respect to the resistance of the fluid, one due to viscous drag and the other due to added moment of inertia. The effects of operating conditions and physical properties of liquids on the drag and added moment of inertia coefficients were then evaluated, and empirical relationships which estimate values of these coefficients, useful to predict the unsteady behavior and magnitude of agitation torque, were presented. Furthermore, equations were developed for estimating the average and maximum power consumptions as a function of the drag and added moment of inertia coefficients. Prediction of respective power levels in AJITER by these equations was also discussed. © 2001 Society of Chemical Industry     

Unsteady Mixing Characteristics in a Vessel with Forward‐Reverse Rotating Impeller

Usually, mixing is carried out in a vessel with four baffles and a single impeller. In some applications, however, the use of a baffled vessel is not recommended. One of the stirring methods used instead is unsteady agitation with forward‐reverse rotating impellers. The aim of this work was to characterize the agitation characteristics in a baffled and an unbaffled vessel with a turbine impeller. Mixing time and mixing power were evaluated in relation to the presence of baffles and the frequency of forward‐reverse rotation. It was found that the frequency of oscillation does not affect either the mixing time and mixing power values or the drag and added mass coefficients. Power requirements and mixing time were higher compared to the steady mixing conditions in a baffled vessel. The results showed that it is not recommended to use baffles because they have no influence on unsteady mixing.     

Design and operation of unbaffled aerated agitated vessels with unsteadily forward–reverse rotating impellers handling viscous Newtonian liquids

Design and operation of unbaffled aerated agitated vessels with multiple unsteadily forward–reverse rotating impellers (AJITERs) for viscous Newtonian liquids were studied. The effects of operating conditions such as gas sparging rate, agitation rate and the number of impeller stages, geometrical conditions such as the diameters of vessel and impeller, and the physical properties of liquids on the drag and added moment of inertia coefficients, necessary to predict the average and maximum power consumptions of the impellers in AJITERs, were evaluated and the empirical relationships which estimate values of each of these coefficients are presented. The effects of operating conditions, geometrical conditions and liquid physical properties on the gas hold‐up, ?_gD, and volumetric oxygen transfer coefficient, k_La_D, were evaluated in relation to the total power input which is the sum of the average power consumption of impellers, ie average agitation power input, and aeration power input. Empirical relationships, useful for design and operation of AJITERs, were obtained for each viscosity range, where the dependences of ?_gD and k_La_D on the specific total power input and superficial gas velocity differed, to predict ?_gD and k_La_D respectively as a function of the specific total power input, superficial gas velocity and liquid physical properties. © 2003 Society of Chemical Industry     

Turbulent forward–reverse mixing characteristics in vessel with multiple‐turbine impellers

BACKGROUND: Mixing in unbaffled vessel with multiple‐turbine impellers was studied. The mixing time and mixing power were evaluated in relation to the distance between impellers and the number of impellers. RESULTS: It has been confirmed that frequency of oscillation has no influence on the mixing time and mixing power values or on drag and added mass coefficients. The coefficients were greater when distance between impellers was smaller. Moreover added mass coefficient was dependent on Reynolds number (n_i > 2). Compared with unidirectional mixing conditions, for systems with one type of impeller, the power requirement was about 38% higher for forward‐reverse mixing. Despite the fact that the power demand was greater, the mixing time was not shorter, but about 30% higher than unidirectional mixing in a baffled vessel. However, the forward‐reverse mixing mode exhibits a higher level of homogeneity which it achieved faster than unidirectional mixing. CONCLUSION: The power requirements and mixing time for forward‐reverse mixing mode were higher in comparison with unidirectional mixing. Despite this, higher values of homogeneity were achieved faster. Higher levels of shear rate and better homogeneity indicate that forward‐reverse mixing can be beneficial for multi‐phase mixing in vessels with multiple impellers. © 2012 Society of Chemical Industry     

LIQUID FLOW IN IMPELLER REGION OF AN UNBAFFLED AGITATED VESSEL WITH UNSTEADILY FORWARD-REVERSE ROTATING IMPELLER

For an unbaffled agitated vessel with an unsteadily forward-reverse rotating impeller whose rotation proceeds with repeated acceleration, deceleration, and stop-reverse processes, the liquid flow in the impeller region was studied based on photographs showing path lines of tracer particles. An image series taken during one cycle of the forward-reverse rotation was analyzed to characterize the internal stream inside the impeller rotational region and the discharge stream outside its region when a disk turbine impeller with six flat blades was rotated unsteadily. Because of the unsteady flow generated inside the impeller rotational region, the velocity vector of outflow from its region fluctuated periodically with the change of the impeller rotation rate. The circumferential velocity was almost in phase with the impeller rotation rate, oscillating periodically. The radial velocity exhibited larger values in the process for the impeller from decelerating to stopping and reversal. The radial flow, whose velocity decreased downstream outside the impeller rotational region, was clarified to be transformed into upward and downward axial flows that are almost uniform in the circumferential direction throughout the region near the vessel wall.     

LIQUID FLOW IN IMPELLER REGION OF AN UNBAFFLED AGITATED VESSEL WITH UNSTEADILY FORWARD-REVERSE ROTATING IMPELLER

For an unbaffled agitated vessel with an unsteadily forward-reverse rotating impeller whose rotation proceeds with repeated acceleration, deceleration, and stop-reverse processes, the liquid flow in the impeller region was studied based on photographs showing path lines of tracer particles. An image series taken during one cycle of the forward-reverse rotation was analyzed to characterize the internal stream inside the impeller rotational region and the discharge stream outside its region when a disk turbine impeller with six flat blades was rotated unsteadily. Because of the unsteady flow generated inside the impeller rotational region, the velocity vector of outflow from its region fluctuated periodically with the change of the impeller rotation rate. The circumferential velocity was almost in phase with the impeller rotation rate, oscillating periodically. The radial velocity exhibited larger values in the process for the impeller from decelerating to stopping and reversal. The radial flow, whose velocity decreased downstream outside the impeller rotational region, was clarified to be transformed into upward and downward axial flows that are almost uniform in the circumferential direction throughout the region near the vessel wall.     

SOLIDS DISTRIBUTION IN STIRRED SLURRY REACTORS: INFLUENCE OF SOME MIXER CONFIGURATIONS AND LIMITS TO THE APPLICABILITY OF A SIMPLE MODEL FOR PREDICTIONS

The features of solids concentration distribution were investigated in baffled and unbaffled tanks of high aspect ratio, stirred with multiple radial, mixed-flow or axial impellers. In the baffled tanks the average profiles can be predicted with the sedimentation-dispersion model regardless of impeller type - in spite of slight systematic departures from the average trend at the impeller plane and/or midway between the impellers. This is hardly possible for the unbaffled tanks due to lack of physical foundation of this simple model. When the unbaffled tank is stirred with hydrofoil impellers, an inverted profile is even obtained. The mentioned departures and this last anomalous behaviour are qualitatively discussed with reference to particle-turbulence interaction.     

SOLIDS DISTRIBUTION IN STIRRED SLURRY REACTORS: INFLUENCE OF SOME MIXER CONFIGURATIONS AND LIMITS TO THE APPLICABILITY OF A SIMPLE MODEL FOR PREDICTIONS

The features of solids concentration distribution were investigated in baffled and unbaffled tanks of high aspect ratio, stirred with multiple radial, mixed-flow or axial impellers. In the baffled tanks the average profiles can be predicted with the sedimentation-dispersion model regardless of impeller type - in spite of slight systematic departures from the average trend at the impeller plane and/or midway between the impellers. This is hardly possible for the unbaffled tanks due to lack of physical foundation of this simple model. When the unbaffled tank is stirred with hydrofoil impellers, an inverted profile is even obtained. The mentioned departures and this last anomalous behaviour are qualitatively discussed with reference to particle-turbulence interaction.     

Liquid flow in impeller region of an unbaffled agitated vessel with an angularly oscillating impeller

The characteristics of a liquid flow were studied in the impeller region of an unbaffled agitated vessel with an angularly oscillating impeller whose unsteady rotation proceeds while periodically reversing its direction at a set angle. The measurement of the velocity of the liquid flow was performed by particle tracking velocimetry (PTV), abreast of that of the torque of the shaft to which the impeller was attached. When a disk turbine impeller with six flat blades was used with variations in operating conditions, such as the frequency and amplitude of impeller angular oscillation, a series of images obtained during one oscillation cycle were analyzed to characterize the internal and discharge streams inside and outside the impeller rotational region. Energy data were inferred on the basis of the circumferential and radial velocities of an internal flow. Results showed that although the total head provided to the liquid by the impeller blades is almost similar, independent of the amplitude of impeller angular oscillation, namely, the acceleration of its movement, the transformation of energy from the pressure head to the velocity head is more efficient at a larger amplitude. In addition, the discharge flow was characterized in terms of volumetric flow rates calculated from the radial and axial velocities. The operation at a smaller amplitude was shown to transform the flow more successfully from the radial direction to the upward and downward axial directions near the vessel wall.     

CFD simulation of impeller shape effect on quality of mixing in two-phase gas–liquid agitated vessel

Mixing efficiency in two-phase gas–liquid agitated vessel is one of the important challenges in the industrial processes. Computational fluid dynamics technique (CFD) was used to investigate the effect of four different pitched blade impellers, including 15°, 30°, 45° and 60°, on the mixing quality of gas–liquid agitated vessel. The multiphase flow behavior was modeled by Eulerian–Eulerian multiphase approach, and RNG k − ε was used to model the turbulence. The CFD results showed that a strong global vortex plays the main role on the mixing quality of the gas phase in the vessel. Based on the standard deviation criterion, it was observed that the axial distribution of the gas phase in the 30° impeller is about 55% better than the others. In addition, the results showed that the 30° impeller has a uniform radial distribution over the other impellers and the maximum gas phase holdup in the vessel. Investigation of the power consumption of the impellers showed that the 30° impeller has the highest power consumption among the other pitched blade impellers. Also, examine the effect of same power condition for pitched blade impellers showed that the 30° impeller has the best mixing quality in this condition.     

Simulation of flows in stirred vessels agitated by dual rushton impellers using computational snapshot approach

Flow in baffled stirred vessels involves interactions between flow around rotating impeller blades and stationary baffles. When more than one impeller is used (which is quite common in practice), the flow complexity is greatly increased, especially when there is an interaction between two impellers. The extent of interaction depends on relative distances between the two impellers and clearance from the vessel bottom. In this paper we have simulated flow generated by two Rushton (disc) impellers. A computational snapshot approach was used to simulate single-phase flow experiments carried out by Rutherford et al. (1996). The computational model was mapped on the commercial CFD code FLUENT (Fluent Inc., USA). The simulated results were analyzed in detail to understand flow around impellers and interaction between impellers. The model predictions were verified using the data of Rutherford et al. (1996). The results presented in this paper have significant implications for applications of computational fluid mixing tools for designing multiple impeller stirred reactors.     

SIMULATION OF FLOWS IN STIRRED VESSELS AGITATED BY DUAL RUSHTON IMPELLERS USING COMPUTATIONAL SNAPSHOT APPROACH

Flow in baffled stirred vessels involves interactions between flow around rotating impeller blades and stationary baffles. When more than one impeller is used (which is quite common in practice), the flow complexity is greatly increased, especially when there is an interaction between two impellers. The extent of interaction depends on relative distances between the two impellers and clearance from the vessel bottom. In this paper we have simulated flow generated by two Rushton (disc) impellers. A computational snapshot approach was used to simulate single-phase flow experiments carried out by Rutherford et al. (1996). The computational model was mapped on the commercial CFD code FLUENT (Fluent Inc., USA). The simulated results were analyzed in detail to understand flow around impellers and interaction between impellers. The model predictions were verified using the data of Rutherford et al. (1996). The results presented in this paper have significant implications for applications of computational fluid mixing tools for designing multiple impeller stirred reactors.     

Turbulent flow field in a stirred vessel agitated by an Impeller with flexible blades

In order to reveal the effect of the blades normal vibration on flow turbulence in the stirred vessel, we designed three kinds of blades: the flexible, flat‐rigid and curved‐rigid blades. The flow fields produced by the impellers with these three kinds of blades were measured by two‐dimensional particle image velocimetry. The results showed that the calculated turbulent kinetic energy (TKE) based on the pseudo‐isotropic assumption is slightly higher than that by the three fluctuating velocities for the flexible and curved‐rigid impellers, and the difference between above two calculations is smaller for the former impeller. For the flexible blades, the trailing vortices slightly move outwards in radial direction than those for the curved‐rigid blades, enhancing TKE transport from the blade to the bulk region of the vessel. For the flexible impeller, the phase‐averaged TKE differs slightly from that for the flat‐rigid impeller, but is higher than that for the curved‐rigid impeller. © 2018 American Institute of Chemical Engineers AIChE J, 64: 4148–4161, 2018     

Turbulent blend times with off-centre v-mounted agitators

Experimental measurements in a flat-bottom tank with narrow-blade hydrofoil and pitched-blade impellers are used to develop guidelines for off-centre, or eccentric, placement of vertical agitators in unbaffled tanks. The guidelines are based on providing a turbulent blend time that is no more than 20% longer than that of the same impeller operating at the same rotational speed on the centreline of a baffled tank. In addition to investigating the effect of impeller type, impeller diameter and off-bottom clearance are also considered. The results support the commonly noted rule of thumb that as off-centre distance is increased, performance in an unbaffled vessel approaches that in a baffled tank. A notable exception to this axiom occurs when a large impeller is located close to the tank base (specifically, D/T = 0.40, C/T = 0.10, and O/T = 0.25). In this case, a stable impeller tip vortex forms with both impeller types, with slow exchange of material between the vortex and bulk liquid leading to long blend times. Besides blend time decreasing with increasing off-centre distance, the uncertainty or run-to-run variation in blend time also decreases dramatically. In most cases, the pitched-blade turbine requires a smaller off-centre distance than the hydrofoil impeller to approximate the blending performance provided during baffled operation.     

Change in liquid temperature behind the impeller blades with impeller speed in boiling stirred tanks

In our previous study (Fukuda, R., Tokumura, M., Znad, H.T. and Kawase, Y., 2009, Vapour generation from the impellers in boiling stirred tank reactors. Chem Eng Res Des, 87: 452–459), it was found that in boiling stirred tanks with multiple impeller systems vapour was generated from the heater at lower impeller speeds and with an increase in impeller speed most vapour was generated from the top impeller rather than the lower impellers and the heater. The change of nucleation sites with the impeller speed might be controlled by the local liquid temperature. Therefore we measured the liquid temperature behind the impellers blades and found the decrease in liquid temperature with increasing impeller speed. In this paper, a simple model was developed to predict the change in liquid temperature behind the impeller blades in which nucleation takes place. In the proposed model based on the results for pressure distribution on the impeller blade in the literature, the liquid temperature behind the impeller blades is estimated from the measured power consumption. The validation of the proposed model was conducted using the experimental results in our previous study and reasonable agreement was obtained.