Using electrical resistance tomography to characterize and optimize the mixing of micron sized polymeric particles in a slurry reactor

A solid-liquid mixing system has a significant role in the suspension polymerization, crystallization, adsorption, and solid-catalyzed reactions. In this study, Electrical Resistance Tomography (ERT) was employed to investigate the effect of the particle size, the design parameters such as impeller type, impeller clearance and impeller diameter as well as operating conditions such as impeller speed, impeller pumping mode, and solids concentration on the mixing of micron sized latex particles in a slurry reactor. The ERT data were used to calculate the concentration profile and the degree of homogeneity in three dimensions, as a function of design parameters and operating within the reactor. In this work, tap water and latex particles (5.2 µm, 8.5 µm, 9.1 µm) were used as liquid and solid phase, respectively. Six axial impellers were utilized (A310, A100, A200, A320, A315, 3AM) with impeller speed (N) varying from 252 rpm to 400 rpm. Impeller diameter to tank diameter ratios (D/T) were in the range of 0.29 to 0.47 while, the impeller clearance (C/T) was changed in the range of T/3.8 to T/2.5. Impeller pumping was tested in both downward and upward directions. The concentration of latex particles was ranged between 15 wt% and 30 wt%. This study shows that the level of homogeneity in a solid-liquid mixing system improved with the increase in impeller speed. However, after achieving the maximum level of homogeneity, any further rise in the impeller speed had a detrimental effect on the level of homogeneity. A310 impeller, wtih D/T ratio of 0.31, demonstrated the highest level of homogeneity while the upward pumping direction was found to be more efficient than the downward one. In addition, a clearance of T/3 proved to create the highest level of homogeneity. Also, the results showed that a rise in the size and concentration of particles decreases the level of homogeneity. Thus, 5.2 µm latex particles with the concentration of 15 wt% demonstrated the highest level of homogeneity. Applying the findings of this study will lead to improved equipment design, chemical cost reduction, increased production rate, improved quality of products, and more efficient use of power in slurry reactors.

Using electrical resistance tomography to characterize and optimize the mixing of micron sized polymeric particles in a slurry reactor

A solid-liquid mixing system has a significant role in the suspension polymerization, crystallization, adsorption, and solid-catalyzed reactions. In this study, Electrical Resistance Tomography (ERT) was employed to investigate the effect of the particle size, the design parameters such as impeller type, impeller clearance and impeller diameter as well as operating conditions such as impeller speed, impeller pumping mode, and solids concentration on the mixing of micron sized latex particles in a slurry reactor. The ERT data were used to calculate the concentration profile and the degree of homogeneity in three dimensions, as a function of design parameters and operating within the reactor. In this work, tap water and latex particles (5.2 µm, 8.5 µm, 9.1 µm) were used as liquid and solid phase, respectively. Six axial impellers were utilized (A310, A100, A200, A320, A315, 3AM) with impeller speed (N) varying from 252 rpm to 400 rpm. Impeller diameter to tank diameter ratios (D/T) were in the range of 0.29 to 0.47 while, the impeller clearance (C/T) was changed in the range of T/3.8 to T/2.5. Impeller pumping was tested in both downward and upward directions. The concentration of latex particles was ranged between 15 wt% and 30 wt%. This study shows that the level of homogeneity in a solid-liquid mixing system improved with the increase in impeller speed. However, after achieving the maximum level of homogeneity, any further rise in the impeller speed had a detrimental effect on the level of homogeneity. A310 impeller, wtih D/T ratio of 0.31, demonstrated the highest level of homogeneity while the upward pumping direction was found to be more efficient than the downward one. In addition, a clearance of T/3 proved to create the highest level of homogeneity. Also, the results showed that a rise in the size and concentration of particles decreases the level of homogeneity. Thus, 5.2 µm latex particles with the concentration of 15 wt% demonstrated the highest level of homogeneity. Applying the findings of this study will lead to improved equipment design, chemical cost reduction, increased production rate, improved quality of products, and more efficient use of power in slurry reactors.

Using tomography and computational fluid dynamics to study the performance of a maxblend impeller for solid-liquid mixing operations

A thorough literature review suggests that no comprehensive research work has been done regarding the characterization of the local solid concentrations in a slurry reactor equipped with a Maxblend impeller. The aim of this research work was to assess the mixing performance of a Maxblend impeller in a slurry reactor through electrical resistance tomography (ERT) and computational fluid dynamics (CFD). The mixing efficiency of the Maxblend impeller for solid-liquid mixing operation was compared to those measured for the A200 (an axial-flow impeller) and the Rushton turbine (a radial-flow impeller). The tomography images were employed to assess the particles distribution inside the slurry reactor. The CFD model was created using the Eulerian and Eulerian (E-E) method, standard k-ε turbulence model, and sliding mesh (SM) technique for simulating the two-phase fluid flow, turbulence effects, and stirrer rotation, respectively. The validated CFD model was utilized to obtain the particle concentration profiles and to determine the local particle distributions attained by the Maxblend impeller. The data were utilized to analyze the impacts of various important parameters such as the agitation speed, particle concentration, particle diameter, specific gravity of the particle, and the use of baffles on the mixing efficiency of the Maxblend impeller in terms of the extent of homogeneity and mixing index. The particle distribution in the slurry reactor furnished with a Maxblend impeller was also assessed through clouding height and just suspended agitation speed approaches in this study. The results from this study showed that the assessment of the optimum impeller speed is extremely important to enhance the local mixing quality in the mixing vessel. Experimental tests demonstrated that maximum homogeneity attained by the Maxblend impeller was higher than those for the A200 and Rushton impellers.

Using tomography and computational fluid dynamics to study the performance of a maxblend impeller for solid-liquid mixing operations

A thorough literature review suggests that no comprehensive research work has been done regarding the characterization of the local solid concentrations in a slurry reactor equipped with a Maxblend impeller. The aim of this research work was to assess the mixing performance of a Maxblend impeller in a slurry reactor through electrical resistance tomography (ERT) and computational fluid dynamics (CFD). The mixing efficiency of the Maxblend impeller for solid-liquid mixing operation was compared to those measured for the A200 (an axial-flow impeller) and the Rushton turbine (a radial-flow impeller). The tomography images were employed to assess the particles distribution inside the slurry reactor. The CFD model was created using the Eulerian and Eulerian (E-E) method, standard k-ε turbulence model, and sliding mesh (SM) technique for simulating the two-phase fluid flow, turbulence effects, and stirrer rotation, respectively. The validated CFD model was utilized to obtain the particle concentration profiles and to determine the local particle distributions attained by the Maxblend impeller. The data were utilized to analyze the impacts of various important parameters such as the agitation speed, particle concentration, particle diameter, specific gravity of the particle, and the use of baffles on the mixing efficiency of the Maxblend impeller in terms of the extent of homogeneity and mixing index. The particle distribution in the slurry reactor furnished with a Maxblend impeller was also assessed through clouding height and just suspended agitation speed approaches in this study. The results from this study showed that the assessment of the optimum impeller speed is extremely important to enhance the local mixing quality in the mixing vessel. Experimental tests demonstrated that maximum homogeneity attained by the Maxblend impeller was higher than those for the A200 and Rushton impellers.

Effects of Sn on the catalytic performance for one step syngas to DME in slurry reactor

Slurry catalysts with a suitable amount of Sn significantly suppress the water gas shift reaction.

Selective synthesis of epichlorohydrin via liquid-phase allyl chloride epoxidation over a modified Ti-MWW zeolite in a continuous slurry bed reactor

The epoxidation of allyl chloride (ALC) to epichlorohydrin (ECH) with H2O2 using a piperidine (PI)-modified Ti-MWW catalyst (Ti-MWW-PI) in a continuous slurry reactor was investigated to develop an efficient reaction system for the corresponding industrial process.