A General Review of the Current Development of Mechanically Agitated Vessels
Abstract
:1. Introduction
- -
- to disperse one immiscible liquid into another or to combine miscible liquids; to disperse solid materials in a fluid, often followed by a different process, e.g., chemical reaction, leaching or flotation; to disperse gas into a liquid, usually followed either by a chemical reaction between the liquid and the gaseous species or by absorption; to disperse a solid and gas into a liquid phase to cause reactions.
- -
- -
- the fluid properties (densities, number of phases, a viscosity [7]);
- -
- the location and mode of operation of the impeller (flow-pumping direction, clearance).
2. Mixing
2.1. Fluid Flow
2.2. Gas-Liquid and Gas-Liquid-Liquid System
2.3. Electrical Resistance Tomography (ERT) in Gas—Liquid System
2.4. A Solid-Liquid System in a Mechanically Agitated Vessel
2.5. Solid Suspension
2.6. Solid Particle Distribution—Selected Technique
2.7. Electrical Resistance Tomography (ERT) in the Mixing of Highly Concentrated Slurries
2.8. Particle in Three-Phase Reactors. Drawdown of Floating
Dispersive of the Gas Phase in the Flotation Chamber
- a viscosity effect, due to damping of the turbulence by the solids [72];
2.9. Liquid-Liquid Mixture
2.10. Tomography in Mixing Process
2.11. The Effect of Impellers
3. CFD Simulation of the Mixing Process
3.1. Gas-Liquid Phase in CFD
3.2. Mixing System Optimisation
3.3. Mass Transfer with CFD
3.4. CFD Models any Turbulence in Rotary Mixers
3.5. Impeller Rotation Modelling
4. Conclusions
Author Contributions
Funding
Conflicts of Interest
Nomenclature
a | gas-liquid interfacial area, m2 |
C | impeller off-bottom clearance, m |
D | impeller diameter, m |
dp | particle size or particle diameter, µm |
dS | diameter of the sparger ring, m |
H | liquid height in the vessel, m |
T | tank diameter, m |
V | tank volume, m3 |
h | distance between the agitator and bottom of the vessel, m |
A | height of the agitator blade, m |
B | width of the agitator blade, m |
Bo | Bond number (Bo = D2gΔρ/δ) |
Cb | bed packing coefficient, v/v |
Cv | solids volume concentration, v/v |
(Cv)max | maximum solids concentration, upper limit, v/v |
Cvb | solids packing volume concentration (v/v) |
Fr | Froude number (Fr = DN2ρmΔρg) |
Ga | Galileo number (Ga = D3gρmΔρ/μ2m) |
Ho | dimensionless homogeneity index/degree |
Jg | superficial gas rates, cm/s |
kLa | volumetric mass transfer coefficient at the gas-liquid interface, s–1 |
L | length of the baffle, m |
MS | mass of solids, kg |
MI | mixing index |
N | impeller speed, rps |
Ncdg | minimum impeller speed needed for complete liquid-liquid–gas dispersion |
NH | homogenization speed, rpm |
Njs | minimum impeller speed required for just complete off-bottom suspension of solids under un-gassed conditions, rps |
Njsg | minimum impeller speed required for just complete off-bottom suspension of solids under gassed conditions, rps |
P | power consumption under un-gassed condition, W |
Pjs | agitator power for just-off-bottom solids suspension, W |
ReG | gas Reynolds number |
ReE | Reynolds number of turbulent eddies at Njs |
SB | bubble surface area flux, s–1 |
tH | homogenisation time, s |
tm | mixing time, s |
w | width of the baffle, m |
Δρ | density difference between solid and liquid, kg/m3 |
φ | gas hold-up |
X | Zweitering solids loading, w/w |
Xv | volume solids fractions, dim |
εjs | agitator power per unit solids mass at the just-off-bottom solids suspension condition, W/kg |
µ | viscosity, Pa.s |
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Index | Effect | Impeller Type 1 | Experimental Method | Ref. |
---|---|---|---|---|
D, µ, C, dp | Axial flow impellers are more favourable for solid suspensions Increasing solids loading delays the homogenization in a more pronounced way for axial impellers The cloud height and the particle distribution increase with a larger clearance | PBT, RT, CBT, HE-3, A310, InterMIGs | Gamma-ray densitometry | [36] |
D, C | Njs decreases when D increases (∝D−2) Njs = f(C/T) shows 3 zones for PBT: C/T < 0.1, constant; 0.1 < C/T < 0.35, slight increase; C/T > 0.35, steep increase | PBT | Visual observation | [37] |
D | For D = T/3 impellers, higher efficiency than D = T/2 in turbulent regime For T/3 impeller, higher energy efficiency The power model aptly predicts of Njs for impellers in the full range of C and up to Cv = 27 wt% | A310 | Visual observation, CFD | [38,39] |
D/T = 0.35 is the optimal ratio- D/T = 0.35 is the optimal ratio | PBT, HE-3 | Visual observation CFD | [40] | |
D = T/3 disk turbine shows poor ability to suspend particles in 1 Pa·s fluid | Mixed flow, HE3 InterMIGs | Visual observation | [41,42] | |
µ, C | Flow patterns change due to the dampening of axial circulation (_ up to 1 Pa·s). Njs and the specific energy dissipation rate εjs increase when _ increases For 1 Pa·s fluid, Njs is minimum at C = T/4, as particle accumulation and significant momentum loss are prevented | RT, PBT, HE3, A310, InterMIGs | Visual observation | [43,44] |
dp, µ | The plurality of conclusions reflects the complexity of the effect of dp, The multiplication of particle interactions leads to poorer suspension | LightninA310, PBT, | Visual observation | [45,46] |
dp, µ | Larger dp implies larger settling velocity and higher NH Higher settling times facilitate the homogenization once the particles have been lifted | A100, A200, A310, A320 | Electrical resistance tomography (ERT), CFD | [47,48] |
dp, Cv, µ | Defined mixing index (MI) as a homogeneity measure MI improve with impeller speed increasing, approx. 0.8 Njs for increase particle size For the fine fraction, MI depends on the range 0.5 Njs to 1.4 Njs. | RT | ERT | [49] |
D, dp, µ, C | Smaller particles are easier to suspend in water Njs is independent of dp for unbaffled tanks Njs decreases when _increases for baffled tanks The most efficiency of aerobic bioremediation of soils is to an unbaffled bioslurry reactor stirred by a Rushton turbine with D = T/3 and C = T/3 | RT, A310 | Steady cone radius method, Laser Sheet Image Analysis (LSIA) | [50,51,52,53] |
Axial impellers exhibit a radial profile that leads to a less efficient suspension taking place at the centre | RT, PBT, A320 | Visualization techniques | [54] | |
Due to a decrease of the settling velocity, higher _ results in smaller Njs | A310, PBT, DT | Laser Doppler velocimetry | [55] | |
Mixing times are larger for large solids concentrations (>10 wt%) | PBT, DT, propeller | Decolorization method | [56] | |
Above 10 wt% of solids loading, the blend time increases, and there is a clear layer at the surface | A-310, A-315, InterMIGs | Decolorization method, visual method | [57] | |
C, Cv, D | NJS (expressed as NFr,JS) and (P/m)JS, and one can note that an increase in solid concentration (Cv) has an influence on NJS values NFr,JS ∝ C = 0.13 (visual method) NFr,JS ∝ C = 0.12 (conductivity method) the values of Ntm, and NJS decrease with an increase of impeller diameter Ntm is the lowest for (D/T = 0.45) | PTD-two down-pumping | Joosten visual method, conductivity method | [58] |
D, dp, C, Cv | The use vessel with baffles enhanced the Ho obtained by the Maxblend impeller for optimal rotor speed and fixed particles content (N = 180–600 rpm; dp = 209–752 μm; Cv = 5–30 wt%; C = T/8–T/4 The extent of homogeneity and mixing index in the system increase with the agitation speed The highest Ho for the impeller clearance of C = T/8. | A200, RT, Maxblend | ERT | [59] |
D, dp, C, X | Increasing the particle size resulted in an increase in the just-suspended speed and power number (A310) The extent of homogeneity was enhanced with the decreasing particle size from dp = 5000 to 753 μm The highest homogeneity (Ho) by reducing the solids loading from X = 55.0 wt% to 30 wt%. | PBT, PF3,A310 | ERT, CFD | [60,61] |
µ, D, | The mixing time of coaxial mixer increased when the consistency index and yield stress were raised | DSAC; SSAC, | ERT, CFD, statistic | [62,63] |
µ, D, T | The power consumption and mixing time were determined for used impellers system | DSAC, DPBTAC | [64] | |
µ, D | The mixing of the viscous non-Newtonian fluids The coaxial mixers are more efficient for the mixing of yield-pseudoplastic fluids Multi-impeller mixers are more compact for the larger scale of mixing operations The coaxial mixer system composed of double Scaba impellers and an anchor was the most efficiency | DSAC, Scaba-Rushton-anchor, Scaba- anchor, Scaba-PBT PBT--Scaba | ERT, CFD | [65] |
µ, dp, Cv, db | The air superficial velocity causes the increase gas hold-up to 19% for the column operating with growing solids concentration (5–15%) The gas hold-up decreases with the solids content. | No rotor-air mixing | ERT, pressure transducers (PT) | [66] |
X | The decrease inhomogeneity index for increasing X down to a plateau, and finally a small increase inhomogeneity at large X. | 4PBT | positron emission (PEPT), CFD | [67] |
dp, µ, Xv, D, C | The increase in D leading to a decrease in Njs NH, The homogenization with large impellers is easier Higher clearances is hindered for large particles | two PBT | pressure gauge technique, ERT | [68] |
dp, Cv, T | The increase of Cv significantly increases the mass transfer coefficient due to increase Njs The mass transfer coefficient as a measure of the effectiveness of the suspension | RT | Visual method | [69] |
dp, Cv, X, ρs, ρl, µ, T | ReE and NJS are proportional to (T/D)1.50 and independent of (C/T), | RT | Visual method | [70] |
D, C, X, µ, Cv | The high shear is beneficial with using very high Cv. The larger impellers (up to a max D/T = 0.5) outperformed smaller ones The baffles inhibit the suspension of powder with the Cv increases As the Cv increases, the flow regime changes, from laminar to turbulent | RDT6, UP-PBT4, DP-PBT4, A310 hydrofoil, Torrance sawtooth | Visual method | [71] |
dp, db, µ, Cv | The kLa decrease with a fall in gas hold-up In the salt, solution kLa decreased to 40% for Cv = 0 wt% and around 19% solids by volume of dispersion | 6HBT, 6MFU-45° | Visual method | [72] |
dp, µ, Cv, w | (Cv)max = Cvb = 0:90, with baffles (Cv)max = Cvb = 0:98, without baffles: the average optimum Cv with min. power consumption, is the range 0.25–0.35 v/v the εjs values decrease with an increase the number blades of impellers each impellers type can be a critical particle size | DT6, DT4, DT3, 30PBT6, 20-45PBT4, 30PBT3, A310 | Visual method | [73] |
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Jaszczur, M.; Młynarczykowska, A. A General Review of the Current Development of Mechanically Agitated Vessels. Processes 2020, 8, 982. https://doi.org/10.3390/pr8080982
Jaszczur M, Młynarczykowska A. A General Review of the Current Development of Mechanically Agitated Vessels. Processes. 2020; 8(8):982. https://doi.org/10.3390/pr8080982
Chicago/Turabian StyleJaszczur, Marek, and Anna Młynarczykowska. 2020. "A General Review of the Current Development of Mechanically Agitated Vessels" Processes 8, no. 8: 982. https://doi.org/10.3390/pr8080982
APA StyleJaszczur, M., & Młynarczykowska, A. (2020). A General Review of the Current Development of Mechanically Agitated Vessels. Processes, 8(8), 982. https://doi.org/10.3390/pr8080982