Study of Hydrodynamics and Upscaling of Immiscible Fluid Stirred Tank using Computational Fluid Dynamics Simulation
DOI:
https://doi.org/10.37934/cfdl.14.6.115133Keywords:
Immiscible liquid-liquid stirred tank, Computational fluid dynamics, Scale up, Hydrodynamic, Mixing timeAbstract
Stirred tanks are prevalent in various industries, including chemical, biochemical, and pharmaceutical industries. These reactors are suitable for ensuring efficient mass and heat transfer because adequate mixing can be achieved. Numerous studies have been conducted on small-scale stirred-tank reactors. However, upscaling such reactors is challenging because of the complex flow behavior inside the system, especially for the mixing of immiscible liquid–liquid systems. Thus, the objectives of this study were to examine the flow behavior and upscale an immiscible liquid–liquid stirred tank using CFD simulation by investigating a flat-bottomed stirred tank reactor, equipped with a six-blade Rushton turbine. The simulated results were in good agreement with those obtained experimentally. The scale of the reactor significantly affects the hydrodynamic behavior, and the uniformity of the radial distribution of the velocity decreases with increasing Reynolds number. Furthermore, the upscaling criteria were evaluated for geometric similarity and equal mixing times. The proposed scaling law reliably scaled up the immiscible liquid–liquid mixing in a stirred tank with a difference in the range of ±10%.
Downloads
References
Tadros, Tharwat F. "Emulsion formation, stability, and rheology." Emulsion formation and stability 1 (2013): 1-75. https://doi.org/10.1002/9783527647941.ch1
Leng, Douglas E., and Richard V. Calabrese. "Immiscible liquid–liquid systems." Handbook of Industrial Mixing: Science and Practice 3952, no. 2006 (2004): 639-753. https://doi.org/10.1002/0471451452.ch12
Fabio Laurenzi, Mirella Coroneo, Giuseppina Montante, Alessandro Paglianti, and Franco Magelli. "Experimental and computational analysis of immiscible liquid–liquid dispersions in stirred vessels." Chemical Engineering Research and Design 87, no. 4 (2009): 507-514. https://doi.org/10.1016/j.cherd.2008.12.007
Mohd Izzudin Izzat Zainal Abidin, Abdul Aziz Abdul Raman, and Mohamad Iskandr Mohamad Nor. "Experimental Investigations in Liquid–Liquid Dispersion System: Effects of Dispersed Phase Viscosity and Impeller Speed." Industrial & Engineering Chemistry Research 53, no. 15 (2014): 6554-6561. https://doi.org/10.1021/ie5002845
Piero M. Armenante, Changgen Luo, Chun-Chiao Chou, Ivan Fort, and Jaroslav Medek. "Velocity profiles in a closed, unbaffled vessel: comparison between experimental LDV data and numerical CFD predictions." Chemical Engineering Science 52, no. 20 (1997): 3483-3492. https://doi.org/10.1016/S0009-2509(97)00150-4
Dang Cheng, Jingcai Cheng, Yumei Yong, Chao Yang, and Zaisha Mao. "CFD Prediction of the Critical Agitation Speed for Complete Dispersion in Liquid-Liquid Stirred Reactors." Chemical Engineering & Technology 34, no. 12 (2011): 2005-2015. https://doi.org/10.1002/ceat.201100220
Adnan Ghulam Mustafa, Mohd Fadhil Majnis, and Nor Azyati Abdul Muttalib. "CFD Study on Impeller Effect on Mixing in Miniature Stirred Tank Reactor." CFD Letters 12, no. 10 (2020): 15-26. https://doi.org/10.37934/cfdl.12.10.1526
Suzanne M. Kresta, Deming Mao, and Vesselina Roussinova. "Batch blend time in square stirred tanks." Chemical Engineering Science 61, no. 9 (2006): 2823-2825. https://doi.org/10.1016/j.ces.2005.10.069
Suci Madhania, Tantular Nurtono, Anugrah Budi Cahyani, Yuswan Muharam, Sugeng Winardi, and Widodo Wahyu Purwanto. "Mixing behaviour of miscible liquid-liquid multiphase flow in stirred tank with different marine propeller installment by computational fluid dynamics method." Chemical Engineering Transactions 56 (2017): 1057-1062.
Ian TorotwaChangying Ji. "A Study of the Mixing Performance of Different Impeller Designs in Stirred Vessels Using Computational Fluid Dynamics." Designs 2, no. 1 (2018): 10. https://doi.org/10.3390/designs2010010
Francesco Maluta, Giuseppina Montante, and Alessandro Paglianti. "Analysis of immiscible liquid-liquid mixing in stirred tanks by Electrical Resistance Tomography." Chemical Engineering Science 227 (2020): 115898. https://doi.org/10.1016/j.ces.2020.115898
Nurul Farhana Mohd Yusof, Edmund Ung Eng Soon, Iman Fitri Ismail, and Akmal Nizam Mohammed. "Mixing Performance of Anchor and Helical Stirrer Blades for Viscous Fluid Applications." CFD Letters 13, no. 1 (2021): 58-71. https://doi.org/10.37934/cfdl.13.1.5871
A. Giapos, Chrysostomos Pachatouridis, and Michael Stamatoudis. "Effect of the Number of Impeller Blades on the Drop Sizes in Agitated Dispersions." Chemical Engineering Research & Design 83 (2005): 1425-1430. https://doi.org/10.1205/cherd.04167
Francis X. McConvilleStephen B. Kessler, Scale-Up of Mixing Processes: A Primer, in Chemical Engineering in the Pharmaceutical Industry, D.J. am-Ende, Editor. 2010. p. 249-267. https://doi.org/10.1002/9780470882221.ch14
Hugo A. Jakobsen, Agitation and Fluid Mixing Technology, in Chemical Reactor Modeling: Multiphase Reactive Flows. 2014, Springer International Publishing: Cham. p. 809-881. https://doi.org/10.1007/978-3-319-05092-8_7
Jan-Erik SvenssonAnders Rasmuson. "LDA‐Measurements in a Stirred Tank With a Liquid‐Liquid System at High Volume Percentage Dispersed Phase." Chemical Engineering & Technology 27 (2004): 335-339. https://doi.org/10.1002/ceat.200401981
Nelvin Kaw Chee Qing, Nor Afzanizam Samiran, and Razlin Abd Rashid. "CFD Simulation analysis of Sub-Component in Municipal Solid Waste Gasification using Plasma Downdraft Technique." Journal of Advanced Research in Numerical Heat Transfer 8, no. 1 (2022): 36-43.
Nor Azwadi Che Sidik, Solihin Musa, Siti Nurul Akmal Yusof, and Erdiwansyah Erdiwansyah. "Analysis of Internal Flow in Bag Filter by Different Inlet Angle." Journal of Advanced Research in Numerical Heat Transfer 3, no. 1 (2020): 12-24.
Samsudin Anis, Shilly Muttashillatul Urfi, Adhi Kusumastuti, and Wim Widyo Baskoro. "Analysis of Inlet Temperature and Airflow Rate on Drying Process in a Spray Dryer Using Computational Fluid Dynamics Method." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 94, no. 1 (2022): 163-171. https://doi.org/10.37934/arfmts.94.1.163171
Arina Mohd Noh, Sohif Mat, and Mohd Hafidz Ruslan. "CFD Simulation of Temperature and Air Flow Distribution inside Industrial Scale Solar Dryer." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 45, no. 1 (2018): 156-164.
Thineshwaran SubramaniamMohammad Rasidi Rasani. "Pulsatile CFD Numerical Simulation to investigate the effect of various degree and position of stenosis on carotid artery hemodynamics." Journal of Advanced Research in Applied Sciences and Engineering Technology 26, no. 2 (2022): 29-40. https://doi.org/10.37934/araset.26.2.2940
Parinya Khongprom, Supawadee Ratchasombat, Waritnan Wanchan, Panut Bumphenkiattikul, and Sunun Limtrakul. "Scaling of a catalytic cracking fluidized bed downer reactor based on computational fluid dynamics simulations." RSC Advances 10, no. 5 (2020): 2897-2914. https://doi.org/10.1039/C9RA10080F
Vivek V. Ranade, 10 Stirred Reactors, in Process Systems Engineering, V.V. Ranade, Editor. 2002, Academic Press. p. 285-325. https://doi.org/10.1016/S1874-5970(02)80011-X
Feng WangZai-Sha Mao. "Numerical and Experimental Investigation of Liquid−Liquid Two-Phase Flow in Stirred Tanks." Industrial & Engineering Chemistry Research 44, no. 15 (2005): 5776-5787. https://doi.org/10.1021/ie049001g
Gopal R. Kasat, Avinash R. Khopkar, Vivek Ranade, and Aniruddha Bhalchandra Pandit. "CFD simulation of liquid-phase mixing in solid–liquid stirred reactor." Chemical Engineering Science 63, no. 15 (2008): 3877-3885. https://doi.org/10.1016/j.ces.2008.04.018
Milan Jahoda, L. Tomášková, and Michal Moštěk. "CFD Prediction of Liquid Homogenisation in a Gas–Liquid Stirred Tank." Chemical Engineering Research & Design 87 (2009): 460-467. https://doi.org/10.1016/j.cherd.2008.12.006
Gaurav MittalRafael Issao Kikugawa. "Computational fluid dynamics simulation of a stirred tank reactor." International Conference on Technological Advancements in Materials Science and Manufacturing 46 (2021): 11015-11019. https://doi.org/10.1016/j.matpr.2021.02.102
Widiawaty Candra Damis, Siswantara Ahmad Indra, R. Gunadi Gun Gun, Andira Mohamad Arif, Budiarso, Budiyanto Muhammad Arif, M. Hilman Gumelar Syafei, and Adanta Dendy. "Optimization of inverse-Prandtl of Dissipation in standard k-ε Turbulence Model for Predicting Flow Field of Crossflow Turbine." CFD Letters 14, no. 1 (2022): 112-127. https://doi.org/10.37934/cfdl.14.1.112127
L. Dong, Stein Tore Johansen, and Thorvald Abel Engh. "Flow induced by an impeller in an unbaffled tank—I. Experimental." Chemical Engineering Science 49, no. 4 (1994): 549-560. https://doi.org/10.1016/0009-2509(94)80055-3
L. Dong, Stein Tore Johansen, and Thorvald Abel Engh. "Flow induced by an impeller in an unbaffled tank—II. Numerical modelling." Chemical Engineering Science 49, no. 20 (1994): 3511-3518. https://doi.org/10.1016/0009-2509(94)00150-2
Mohammad Hassan VakiliMohsen Nasr Esfahany. "CFD analysis of turbulence in a baffled stirred tank, a three-compartment model." Chemical Engineering Science 64, no. 2 (2009): 351-362. https://doi.org/10.1016/j.ces.2008.10.037
Zhaoyou Zhu, Bin Qin, Shuhua Li, Yigang Liu, Xin Li, Peizhe Cui, Yinglong Wang, and Jun Gao. "Multi-dimensional analysis of turbulence models for immiscible liquid-liquid mixing in stirred tank based on numerical simulation." Separation Science and Technology 56, no. 2 (2021): 411-424. https://doi.org/10.1080/01496395.2020.1715436
Aoyi OchiengMaurice Onyango. "CFD simulation of the hydrodynamics and mixing time in a stirred tank." Chemical Industry and Chemical Engineering Quarterly 16, no. 4 (2010): 379-386. https://doi.org/10.2298/CICEQ100211040O
Dang Cheng, Xin Feng, Jingcai Cheng, and Chao Yang. "Numerical simulation of macro-mixing in liquid–liquid stirred tanks." Chemical Engineering Science 101 (2013): 272-282. https://doi.org/10.1016/j.ces.2013.06.026
Giuseppina Montante, Michal Moštěk, Milan Jahoda, and Franco Magelli. "CFD simulations and experimental validation of homogenisation curves and mixing time in stirred Newtonian and pseudoplastic liquids." Chemical Engineering Science 60, no. 8-9 (2005): 2427-2437. https://doi.org/10.1016/j.ces.2004.11.020
Nandkishor K. Nere, Ashwin W. Patwardhan, and Jyeshtharaj B. Joshi. "Liquid-Phase Mixing in Stirred Vessels: Turbulent Flow Regime." Industrial & Engineering Chemistry Research 42, no. 12 (2003): 2661-2698. https://doi.org/10.1021/ie0206397
Fah Al-QaessiLaila Abu-Farah. "Prediction of Mixing Time for Miscible Liquids by CFD Simulation in Semi-Batch and Batch Reactors." Engineering Applications of Computational Fluid Mechanics 3, no. 1 (2009): 135-146. https://doi.org/10.1080/19942060.2009.11015260
Zied Driss, Ahmed Kaffel, Bilel Ben Amira, Ghazi Bouzgarrou, and Mohamed Salah Abid. "PIV Measurements to Study the Effect of the Reynolds Number on the Hydrodynamic Structure in a Baffled Vessel Stirred by a Rushton Turbine." American Journal of Energy Research 2, no. 3 (2014): 67-73. https://doi.org/10.12691/ajer-2-3-4
K. W. NorwoodArthur B. Metzner. "Flow patterns and mixing rates in agitated vessels." Aiche Journal 6 (1960): 432-437. https://doi.org/10.1002/aic.690060317
