Experimental characterization of mixing and flow field in the liquid plugs of gas–liquid flow in a helically coiled reactor

Flow mixing of two miscible liquids with the addition of gas bubbles is a process often found in industrial chemical apparatus for the production of primary matter. The ongoing optimization of such processes also involves the transformation of batch to continuous mode operation. In that case, the use of helically coiled tubes is an interesting alternative, since those reactors have narrow residence time distributions, very good radial mixing properties and excellent mass transfer can be realized between gases and liquids. For these reasons, in this study the mixing of two miscible liquids with addition of air bubbles in gas–liquid flows has been characterized in a horizontal helically coiled reactor in the laminar flow regime at $${\text{Re}}_{{{\text{total}}}} = 300 \ldots 1088$$ Re total = 300 … 1088 . Eight different superficial liquid velocities and five superficial gas velocities were investigated. In order to characterize mixing in the liquid plugs between two bubbles, laser-induced fluorescence of resorufin was used and particle image velocimetry has been employed to characterize the flow field. Pseudo-3D-visualizations of the resorufin concentration and the Q-criterion, representing the mixing efficiency and vorticity, respectively, were established for individual liquid plugs from the time-resolved measurement results. A time-resolved mixing coefficient, as well as a mean mixing coefficient obtained from multiple liquid plugs, is calculated from the fluorescence images for all examined flow conditions. The experimental results clearly show an increase in the mixing coefficient compared to single-phase conditions, caused by the bubbles. However, distinct mixing pattern, depending on the flow structure, can be recognized on different locations inside the liquid plug. Compared to a stationary case without air bubbles, mixing is worse behind the bubbles and increases inside the plug, reaching a maximum mixing coefficient in front of the next bubble. Overall the mixing coefficient is always increased by the presence of the bubbles. Pseudo-3D-visualizations of the Q-criterion and the vorticity show the presence of secondary vortices right in front of the bubbles, shifted to the outer tube walls, and in addition to the steady Dean vortices. In small plugs, these secondary vortices appear in the whole plug and increase the mixing coefficient drastically. Graphical Abstract

CFD Simulations of Multiphase Flows: Interaction of Miscible Liquids with Different Temperatures

The incorporation of new equations to extend the applicability of open-source computational fluid dynamics (CFD) software according to the user’s needs must be complemented with code verification and validation with a representative case. This paper presents the development and validation of an OpenFOAM®-based solver suitable for simulating multiphase fluid flow considering three fluid phases with different densities and temperatures, i.e., two miscible liquids and air. A benchmark “dam-break” experiment was performed to validate the solver. Ten thermistors measured temperature variations in different locations of the experimental model and the temperature time series were compared against those of numerical probes in analogous locations. The accuracy of the temperature field assessment considered three different turbulence models: (a) zero-equation, (b) k-omega (Reynolds averaged simulation; RAS), and (c) large eddy simulation (LES). The simulations exhibit a maximum time-average relative and absolute errors of 9.3% and 3.1 K, respectively; thus, the validation tests proved to achieve an adequate performance of the numerical model. The solver developed can be applied in the modeling of thermal discharges into water bodies.

Mixing characterization in different helically coiled configurations by laser-induced fluorescence

Flow Mixing of two miscible liquids has been characterized experimentally in three different helically coiled reactor configurations of two different lengths in the laminar flow regime at Re = 50…1000. A straight helical coil, a coiled flow inverter, and a new coiled flow reverser have been built, each in a 3-turn and a 6-turn configuration. Laser-induced fluorescence of resorufin has been used to visualize and quantify mixing in cross-sections throughout the reactors. A mixing coefficient is derived from the fluorescence images to allow for a quantitative measure and comparison of the six configurations. It becomes obvious from these experimental results, that an early flow redirection in the helical configuration is beneficial to mixing. The 3-turn reactors achieve nearly the same mixing coefficients as the 6-turn reactors with the double length. This can be explained by the stabilizing effect of the Dean vortices in the helix, which develop during the first two turns. After that, the liquid is trapped inside the vortices and further mixing is inhibited. Accordingly, the coiled flow inverter and coiled flow reverser configurations lead to much higher mixing coefficients than the straight helical coil. The results of these measurements are now used for validation of numerical simulations, which reproduce the geometrical and flow conditions of the experiments. Some exemplary results of these calculations are also shown in this article. Graphic abstract Mass fractions of tracer fluid at Re = 500 in the six examined helix configurations.

A 3D Printed Jet Mixer for Centrifugal Microfluidic Platforms

Homogeneous mixing of microscopic volume fluids at low Reynolds number is of great significance for a wide range of chemical, biological, and medical applications. An efficient jet mixer with arrays of micronozzles was designed and fabricated using additive manufacturing (three-dimensional (3D) printing) technology for applications in centrifugal microfluidic platforms. The contact surface of miscible liquids was enhanced significantly by impinging plumes from two opposite arrays of micronozzles to improve mixing performance. The mixing efficiency was evaluated and compared with the commonly used Y-shaped micromixer. Effective mixing in the jet mixer was achieved within a very short timescale (3s). This 3D printed jet mixer has great potential to be implemented in applications by being incorporated into multifarious 3D printing devices in microfluidic platforms.

On the mechanism of instability in a two-layer system with limited solubility of components

A two-layer system of miscible liquids is a common model system in studies of both fundamental and applied problems in hydrodynamics that associated with stratified media. Rayleigh-Taylor instabilities or double diffusive one can lead to a disturbance in mechanical equilibrium if both or at least one of the components dissolved in each of the layers are initially unstable stratified. The situation when both components have a stable initial density distribution is believed that absolutely stable and, usually, is not considered by researchers. This paper experimentally demonstrates the possibility of developing instability in such systems and proposes a physical mechanism based on the dependence of the solubility of one of the components on the concentration of the second component. It is shown that the evolution of the density profile, the possibility of the development of instability, and the properties of the arising convective motion are determined by the initial position of the system on the parameters plane of the solubility diagram.