Dynamic generation of aqueous foams and fiber foams in a mixing tank

Mixing tanks are employed in paper and pulp industries to generate aqueous foams and fiber foams. The aim of the present study was to investigate the effect of impeller geometry on dynamic foam generation in a 60 L mixing tank. Three impeller geometries including two radial—Rushton turbine (RT), Bakker turbine (BT6), one axial high solidity pitched blade turbine (HSPBT), and four dual impeller combinations were investigated. Compressed air, water and sodium dodecyl sulphate were used as gas phase, liquid phase and surfactant, respectively, to generate aqueous foam. 1% mass consistency softwood fiber was used to generate fiber foam. The change in aqueous foam density for any given impeller was limited to ± 40 kg/m3 indicating foam density was dictated by impeller type rather than power input. Single impellers generated bubbly liquids whereas dual impellers generated low-density aqueous foams. Besides, stable foam was produced even at low power input compared to single impellers due to increase in impeller swept volume and blade contact area. Addition of fibers increased the foam density by ~ 100–150 kg/m3 and reduced the half-life time by almost threefold for all impellers due to lower air content and higher bubble size. Placement of high shear impeller (BT6) at bottom and down-pumping axial impeller (HSPBT) on top generated fine bubbles.

Predicting the Diameters of Droplets Produced in Turbulent Liquid-Liquid Dispersion

The droplet size distribution in liquid-liquid dispersions is a complex convolution of impeller speed, impeller type, fluid properties, and flow conditions. In this work, we present three a priori modeling approaches for predicting the droplet diameter distributions as a function of system operating conditions. In the first approach, called the two-fluid approach, we use high-resolution solutions to the Navier-Stokes equations to directly model the flow of each phase and the corresponding droplet breakup/coalescence events. In the second approach, based on an Eulerian-Lagrangian model, we describe the dispersed fluid as individual spheres undergoing ongoing breakup and coalescence events per user-defined interaction kernels. In the third approach, called the Eulerian-Parcel model, we model a sub-set of the droplets in the Eulerian-Lagrangian model to estimate the overall behavior of the entire droplet population. We discuss output from each model within the context of predictions from first principles turbulence theory and measured data.

Mixing time in yield stress fluids

Yield stress fluids are commonly encountered in the pharmaceutical, wastewater and bioprocess industries. On agitation of these fluids with an impeller, a zone of significant motion (cavern) is formed surrounded by stagnant regions. These inhomogeneous conditions are undesirable from a product quality standpoint. Therefore, to evolve a mixing system design that would eliminate these problems, experimental measurements of mixing time were obtained and combined with power consumption to provide a measure of mixing system efficiency. The effect of different parameters such as fluid rheology, impeller rotational speed, impeller type and impeller clearance on the mixing times was also investigated. In addition, using CFD, numerical mixing times were calculated and a comparison of the numerical and experimental mixing times were conducted to investigate the capability of the CFD tool to correctly predict the homogenization process in mixing tanks. In general, it was observed that the power characteristics of the different agitators were well reproduced by the computational package. In addition, CFD was able to correctly predict the effect of impeller rotational speed and fluid yield stress on the mixing times. However, the effect of impeller clearance on the mixing time was not correctly predicted by the CFD package when compared with experimental results obtained in this work as well as those obtained by other researchers. A comparison of the impellers used in this study (Pitched Blade Turbine (PBT), marine propeller and Lightnin A320) using the mixing time correlations available in the literature to fit the experimental data revealed that the PBT was superior to the other impellers in mixing yield stress fluids. In addition, the validated CFD model was used to measure the dimensions of the cavern formed around the impeller and it showed good agreement with the Elson's cavern model.

Mixing time in yield stress fluids

Yield stress fluids are commonly encountered in the pharmaceutical, wastewater and bioprocess industries. On agitation of these fluids with an impeller, a zone of significant motion (cavern) is formed surrounded by stagnant regions. These inhomogeneous conditions are undesirable from a product quality standpoint. Therefore, to evolve a mixing system design that would eliminate these problems, experimental measurements of mixing time were obtained and combined with power consumption to provide a measure of mixing system efficiency. The effect of different parameters such as fluid rheology, impeller rotational speed, impeller type and impeller clearance on the mixing times was also investigated. In addition, using CFD, numerical mixing times were calculated and a comparison of the numerical and experimental mixing times were conducted to investigate the capability of the CFD tool to correctly predict the homogenization process in mixing tanks. In general, it was observed that the power characteristics of the different agitators were well reproduced by the computational package. In addition, CFD was able to correctly predict the effect of impeller rotational speed and fluid yield stress on the mixing times. However, the effect of impeller clearance on the mixing time was not correctly predicted by the CFD package when compared with experimental results obtained in this work as well as those obtained by other researchers. A comparison of the impellers used in this study (Pitched Blade Turbine (PBT), marine propeller and Lightnin A320) using the mixing time correlations available in the literature to fit the experimental data revealed that the PBT was superior to the other impellers in mixing yield stress fluids. In addition, the validated CFD model was used to measure the dimensions of the cavern formed around the impeller and it showed good agreement with the Elson's cavern model.

Mixing time study in agitated multiple-lamp UV photoreactor using electrical resistance tomography

The present study is devoted to the mixing time investigation in a single stirrer UV photoreactor aiming at the drinking water disinfection process. Electrical resistance tomography (ERT) was employed to measure the mixing quality due to the significant advantages. The reactor was a flat-bottomed cylindrical tank with a diameter of 38.1 cm and a height of 60.1 cm fitted with four symmetrically located vertical baffles. The performaces of a 6-blade Rushton turbine and a 4-blade 45° pitched-blade turbine were explored in this study. In the absence of the UV light, four PVC rods were used to replace four UV lamps and evaluate the impact of the locations of the UV tubes on the mixing time. The experimental results demonstrated the feasibility of the ERT system to monitor the mixing process in the UV photoreactor. The ERT results also indicated that the locations of the UV tubes had a signigicant impact on the mixing performance in such a batch stirred tank reactor. Other parameters encompassing the impeller rotational speed the impeller type, and off-bottom clearance were presented with respect to the extensive effects on the mixing time and power consumption.

Mixing time study in agitated multiple-lamp UV photoreactor using electrical resistance tomography

The present study is devoted to the mixing time investigation in a single stirrer UV photoreactor aiming at the drinking water disinfection process. Electrical resistance tomography (ERT) was employed to measure the mixing quality due to the significant advantages. The reactor was a flat-bottomed cylindrical tank with a diameter of 38.1 cm and a height of 60.1 cm fitted with four symmetrically located vertical baffles. The performaces of a 6-blade Rushton turbine and a 4-blade 45° pitched-blade turbine were explored in this study. In the absence of the UV light, four PVC rods were used to replace four UV lamps and evaluate the impact of the locations of the UV tubes on the mixing time. The experimental results demonstrated the feasibility of the ERT system to monitor the mixing process in the UV photoreactor. The ERT results also indicated that the locations of the UV tubes had a signigicant impact on the mixing performance in such a batch stirred tank reactor. Other parameters encompassing the impeller rotational speed the impeller type, and off-bottom clearance were presented with respect to the extensive effects on the mixing time and power consumption.

Using electrical resistance tomography to measure the yield stress of pretreated wheat straw and wheat straw slurries

Wheat straw is a low-cost feedstock for production of biofuels as a viable alternative to fossil -based fuels. Pretreatment process is an important stage in producing biofuels. Pretreated wheat straw slurries (PWS) are non-Newtonian fluids with yield stress. In mixing operations, the presence of yield stress creates a region of active motion (cavern) around the impeller and stagnant zones elsewhere which causes difficulties in the production of biofuels. In this study, for the first time electrical resistance tomography (ERT) was utilized to measure the cavern dimensions as a function of the impeller type (A200, A100, and A315), impeller speed (20 to 110 rpm), fiber size (≤ 2 and ≤ 6 mm), and PWS concentration (6, 8, and 10 wt%). The cavern sizes were used to measure the yield stress of PWS slurries as a function of fiber size and fiber concentration. The average yield stresses of 6, 8, and 10 wt% PWS slurries with the fiber sizes of ≤ 2 mm were 2.00, 5.43, and 8.51 Pa, respectively, and 4.26, 9.30, and 13.84 Pa for the fiber sizes of ≤ 6 mm.

Using electrical resistance tomography to measure the yield stress of pretreated wheat straw and wheat straw slurries

Wheat straw is a low-cost feedstock for production of biofuels as a viable alternative to fossil -based fuels. Pretreatment process is an important stage in producing biofuels. Pretreated wheat straw slurries (PWS) are non-Newtonian fluids with yield stress. In mixing operations, the presence of yield stress creates a region of active motion (cavern) around the impeller and stagnant zones elsewhere which causes difficulties in the production of biofuels. In this study, for the first time electrical resistance tomography (ERT) was utilized to measure the cavern dimensions as a function of the impeller type (A200, A100, and A315), impeller speed (20 to 110 rpm), fiber size (≤ 2 and ≤ 6 mm), and PWS concentration (6, 8, and 10 wt%). The cavern sizes were used to measure the yield stress of PWS slurries as a function of fiber size and fiber concentration. The average yield stresses of 6, 8, and 10 wt% PWS slurries with the fiber sizes of ≤ 2 mm were 2.00, 5.43, and 8.51 Pa, respectively, and 4.26, 9.30, and 13.84 Pa for the fiber sizes of ≤ 6 mm.