Micromixing performance of the teethed high shear mixer under semi-batch operation

doi:10.1007/s11705-021-2069-3

Front. Chem. Sci. Eng.

2022, Vol. 16

Issue (4) : 546-559 https://doi.org/10.1007/s11705-021-2069-3

RESEARCH ARTICLE

Micromixing performance of the teethed high shear mixer under semi-batch operation

Xiaoning Li¹, Lin Yang¹, Junheng Guo¹, Wei Li¹, Mingliang Zhou²(

), Jinli Zhang^1,³(

)

¹. School of Chemical Engineering and Technology, Tianjin University, Tianjin 300350, China
². Department of Geotechnical Engineering, Tongji University, Shanghai 200092, China
³. School of Chemistry and Chemical Engineering, Shihezi University, Shihezi 832003, China

Download: PDF(2183 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

Semi-batch operated reaction processes are necessary for some competitive reaction systems to achieve a desirable process selectivity and productivity of fine chemical products. Herein the structural and operating parameters of the teethed high shear mixers were adjusted to study the micromixing performance in the semi-batch operated system, using the Villermaux/Dushman reaction system. The results indicate that the rising of the rotor speed and the number of rotor teeth, the decrease of the width of the shear gap and the radial distance between the feed position and the inner wall of stator can enhance the micromixing level and lead to the decrease of the segregation index. Additionally, computational fluid dynamics calculations were carried out to disclose the evolution of the flow pattern and turbulent energy dissipation rate of the semi-batch operated high shear mixer. Furthermore, the correlation was established with a mean relative error of 8.05% and R² of 0.955 to fit the segregation index and the parameters studied in this work, which can provide valuable guidance on the design and optimization of the semi-batch operated high shear mixers in practical applications.

Keywords high shear mixer semi-batch operation micromixing performance Villermaux/Dushman system segregation index

Corresponding Author(s): Mingliang Zhou,Jinli Zhang

Online First Date: 11 August 2021 Issue Date: 21 March 2022

Cite this article:

Xiaoning Li,Lin Yang,Junheng Guo, et al. Micromixing performance of the teethed high shear mixer under semi-batch operation[J]. Front. Chem. Sci. Eng., 2022, 16(4): 546-559.

URL:

https://academic.hep.com.cn/fcse/EN/10.1007/s11705-021-2069-3
https://academic.hep.com.cn/fcse/EN/Y2022/V16/I4/546

Fig.1 Schematic diagram of experimental apparatus and specific structure. (a) Schematic diagram of the experimental apparatus; (b) structure diagram of the shear head; (c) section view of shear head; (d) details of the stator head (D_si = inner diameter of stator, mm; D_so = outer diameter of stator, mm); (e) details of the rotor with 6-teeth (D_ri = inner diameter of rotor, mm; D_ro = outer diameter of rotor, mm); (f) details of the rotor with 3-teeth; (g) details of the rotor with 2-teeth.

Tab.1 Main structural parameters of the teethed HSMs

Tab.2 Compositions of the working fluid

Fig.2 Details of the calculation domain and mesh structure. (a) Fluid calculation domain of HSM-6-0.5-8; (b) the rotating component; (c) half section view of Part A; (d) the mesh structure of the plane at y = 0 m; (e) the mesh structure of the plane at z = 0.01 m; (f) enlarged view of the mesh structure of the shear head in the plane of y = 0 m.

Fig.3 Diagram for mesh independence verification. (a) ε distribution of 12 points evenly distributed on a circle of the shear gap with a radius of 0.00975 m and z = 0.01 m of HSM-6-0.5-8 at N = 6000 r·min^–1; (b) velocity distribution of y = 0.02 m in the z direction of HSM-6-0.5-8 at N = 6000 r·min^–1.

Item	Cells	$ε ¯ Body1$ /(m²·s^–3)	P/W
Mesh (1)	1.51 million	130.99	6.20
Mesh (2)	3.66 million	138.77	6.49
Mesh (3)	5.43 million	144.16	6.88
Mesh (4)	6.51 million	144.41	6.86

Tab.3

ε ¯ Body1

from Eq. (14) and power consumption (P) calculated of HSM-6-0.5-8 by Eq. (15) for different mesh structures when N = 6000 r·min^–1

Fig.4 Effect of injection time of the feed acid on X_s and the flow field. (a) Effect of injection time of the feed acid on X_s; (b1) front view (plane 1) of fluid domain of HSM-6-0.5-8 at the feed position F3; (b2) section view (plane 2) of fluid domain of HSM-6-0.5-8 at the feed position F3; (c) contours of velocity vector at the feed pipe and shear head region of HSM-6-0.5-8 at the feed position F3, under the condition of (c1) when N = 3000 r·min^–1 and Q = 1.5 mL·min^–1; (c2) when N = 12000 r·min^–1 and Q = 1.5 mL·min^–1; (c3) when N = 12000 r·min^–1 and Q = 12 mL·min^–1; (d) Contour of mass fraction distribution of solution A of HSM-6-0.5-8 at feed position F3 when N = 12000 r·min^–1 and Q = 1.5 mL·min^–1 when injection time is 0.035 s.

Tab.4 Q at different N at F3

Fig.5 Effect of acid concentration and N on X_s and ε: (a) Effect of acid concentration and N on X_s; (b) contours of ε of plane 2 of HSM-6-0.5-8 at feed position F3: (b1) N = 3000 r·min^–1; (b2) N = 6000 r·min^–1; (b3) N = 12000 r·min^–1.

Fig.6 Effect of feed position on ε and X_s: (a) time-average contours of ε of HSM-6-0.5-8 at N = 6000 r·min^–1; (b) effect of feed position on X_s.

Fig.7 Effect of n on X_s and ε: (a) effect of n on X_s; (b) contours of ε of plane 2 of HSM-n-0.5-8 at feed position F3 when N = 6000 r·min^–1; (b1) n = 2; (b2) n = 3; (b3) n = 6.

Fig.8 Effect of δ on X_s and ε: (a) effect of δ on X_s; (b) contours of ε of shear head region of plane 2 of HSM-6-δ-8 at feed position F3 N = 6000 r·min^–1; (b1) δ = 1.0 mm; (b2) δ = 0.75 mm; (b3) δ = 0.5 mm.

Fig.9 Effect of h on X_s and ε: (a) effect of h on X_s; (b) contours of the ε of plane 2 of HSM-6-0.5-h when N = 6000 r·min^–1 at feed position F3. (b1) h = 8 mm; (b2) h = 11 mm; (b3) h = 14 mm.

Tab.5 Comparisons of X_s with different mixers

Fig.10 A plot of X_s vs P_v: comparisons of X_s with various semi-batch devices. (a) [H⁺] = 1.0 mol·L^–1; (b) [H⁺] = 2.0 mol·L^–1.

Tab.6 Comparisons of t_m with other HSMs

1	J R Bourne. Mixing and the selectivity of chemical reactions. Organic Process Research & Development, 2003, 7(4): 471–508 https://doi.org/10.1021/op020074q
2	D Wenzel, A Górak. Review and analysis of micromixing in rotating packed beds. Chemical Engineering Journal, 2018, 345: 492–506 https://doi.org/10.1016/j.cej.2018.03.109
3	Y C Yang, Y Xiang, C Pan, H K Zou, G W Chu, M Arowo, J F Chen. Influence of viscosity on micromixing efficiency in a rotating packed bed with premixed liquid distributor. Journal of Chemical Engineering of Japan, 2015, 48(1): 72–79 https://doi.org/10.1252/jcej.14we153
4	A Nie, Z Gao, L Xue, Z Cai, G M Evans, A Eaglesham. Micromixing performance and the modeling of a confined impinging jet reactor/high speed disperser. Chemical Engineering Science, 2018, 184: 14–24 https://doi.org/10.1016/j.ces.2018.03.032
5	J S Zhang, K Wang, Y C Lu, G S Luo. Characterization and modeling of micromixing performance in micropore dispersion reactors. Chemical Engineering and Processing, 2010, 49(7): 740–747 https://doi.org/10.1016/j.cep.2009.10.009
6	J Bałdyga, R Pohorecki. Turbulent micromixing in chemical reactors—a review. Chemical Engineering Journal, 1995, 58(2): 183–195
7	P Guichardon, L Falk. Characterisation of micromixing efficiency by the iodide-iodate reaction system. Part I: experimental procedure. Chemical Engineering Science, 2000, 55(19): 4233–4243 https://doi.org/10.1016/S0009-2509(00)00068-3
8	X Duan, X Feng, C Yang, Z Mao. CFD modeling of turbulent reacting flow in a semi-batch stirred-tank reactor. Chinese Journal of Chemical Engineering, 2018, 26(4): 675–683 https://doi.org/10.1016/j.cjche.2017.05.014
9	M Assirelli, W Bujalski, A Eaglesham, A W Nienow. Study of micromixing in a stirred tank using a rushton turbine. Chemical Engineering Research & Design, 2002, 80(8): 855–863 https://doi.org/10.1205/026387602321143390
10	L Nouri, J Legrand, N Benmalek, F Imerzoukene, A R Yeddou, F Halet. Characterisation and comparison of the micromixing efficiency in torus and batch stirred reactors. Chemical Engineering Journal, 2008, 142(1): 78–86 https://doi.org/10.1016/j.cej.2008.01.030
11	J L Zhang, S Q Xu, W Li. High shear mixers: a review of typical applications and studies on power draw, flow pattern, energy dissipation and transfer properties. Chemical Engineering and Processing, 2012, 57–58: 25–41 https://doi.org/10.1016/j.cep.2012.04.004
12	J Z Fang, D J Lee. Micromixing efficiency in static mixer. Chemical Engineering Science, 2001, 56(12): 3797–3802 https://doi.org/10.1016/S0009-2509(01)00098-7
13	K Yang, G W Chu, L Shao, Y Luo, J F Chen. Micromixing efficiency of rotating packed bed with premixed liquid distributor. Chemical Engineering Journal, 2009, 153(1–3): 222–226 https://doi.org/10.1016/j.cej.2009.06.006
14	W Li, F Xia, H Qin, M Zhang, W Li, J Zhang. Numerical and experimental investigations of micromixing performance and efficiency in a pore-array intensified tube-in-tube microchannel reactor. Chemical Engineering Journal, 2019, 370: 1350–1365 https://doi.org/10.1016/j.cej.2019.03.189
15	Y H Su, G W Chen, Q Yuan. Ideal micromixing performance in packed microchannels. Chemical Engineering Science, 2011, 66(13): 2912–2919 https://doi.org/10.1016/j.ces.2011.03.024
16	L Zha, X Pu, M J Shang, G X Li, W H Xu, Q H Lu, Y H Su. A study on the micromixing performance in microreactors for polymer solutions. AIChE Journal. American Institute of Chemical Engineers, 2018, 64(9): 3479–3490 https://doi.org/10.1002/aic.16188
17	H Hu, Z Chen, Z Jiao. Characterization of micro-mixing in a novel impinging streams reactor. Frontiers of Chemical Engineering in China, 2009, 3(1): 58–64 https://doi.org/10.1007/s11705-009-0106-8
18	H Y Qin, C Zhang, Q Xu, X H Dang, W Li, K L Lei, L T Zhou, J L Zhang. Geometrical improvement of inline high shear mixers to intensify micromixing performance. Chemical Engineering Journal, 2017, 319: 307–320 https://doi.org/10.1016/j.cej.2017.02.150
19	H Qin, Q Xu, W Li, X Dang, Y Han, K Lei, L Zhou, J Zhang. Effect of stator geometry on the emulsification and extraction in the inline single-row blade-screen high shear mixer. Industrial & Engineering Chemistry Research, 2017, 56(33): 9376–9388 https://doi.org/10.1021/acs.iecr.7b01362
20	T P John, J S Panesar, A Kowalski, T L Rodgers, C P Fonte. Linking power and flow in rotor-stator mixers. Chemical Engineering Science, 2019, 207: 504–515 https://doi.org/10.1016/j.ces.2019.06.039
21	J James, M Cooke, A Kowalski, T L Rodgeys. Scale-up of batch rotor-stator mixers. Part 2—mixing and emulsification. Chemical Engineering Research & Design, 2017, 124: 321–329 https://doi.org/10.1016/j.cherd.2017.06.032
22	J James, M Cooke, L Trinh, R Hou, P Martin, A Kowalski, T L Rodgers. Scale-up of batch rotor-stator mixers. Part 1—power constants. Chemical Engineering Research & Design, 2017, 124: 313–320 https://doi.org/10.1016/j.cherd.2017.06.020
23	V Vikash, D Deshawar, V Kumar. Hydrodynamics and mixing characterization in a novel high shear mixer. Chemical Engineering and Processing, 2017, 120: 57–67 https://doi.org/10.1016/j.cep.2017.06.008
24	L Yang, W Li, J Guo, W Li, B Wang, M Zhang, J Zhang. Effects of rotor and stator geometry on dissolution process and power consumption in jet-flow high shear mixers. Frontiers of Chemical Science and Engineering, 2020, 15(2): 384–398 https://doi.org/10.1007/s11705-020-1928-7
25	V Vikash, K D P Nigam, V Kumar. Design and development of high shear mixers: fundamentals, applications and recent progress. Chemical Engineering Science, 2021, 232: 116296 https://doi.org/10.1016/j.ces.2020.116296
26	G W Chu, Y H Song, H J Yang, J M Chen, H Chen, J F Chen. Micromixing efficiency of a novel rotor-stator reactor. Chemical Engineering Journal, 2007, 128(2–3): 191–196 https://doi.org/10.1016/j.cej.2006.10.024
27	W Li, F Xia, S Zhao, J Guo, M Zhang, W Li, J Zhang. Mixing performance of an inline high-shear mixer with a novel pore-array liquid distributor. Industrial & Engineering Chemistry Research, 2019, 58(44): 20213–20225 https://doi.org/10.1021/acs.iecr.9b03728
28	A Hernandez-Guzman, I M Navarro-Gutierrez, P A Melendez-Hernandez, J U Hernandez-Beltran, H Hernandez-Escoto. Enhancement of alkaline-oxidative delignification of wheat straw by semi-batch operation in a stirred tank reactor. Bioresource Technology, 2020, 312: 123589 https://doi.org/10.1016/j.biortech.2020.123589
29	T Zhang, B Nagy, B Szilágyi, J Gong, Z K Nagy. Simulation and experimental investigation of a novel supersaturation feedback control strategy for cooling crystallization in semi-batch implementation. Chemical Engineering Science, 2020, 225: 115807 https://doi.org/10.1016/j.ces.2020.115807
30	B Liu, Y Zheng, B Huang, L Qian, Z Jin. The influence of feeding location on the micromixing performance of novel large-double-blade impeller. Journal of the Taiwan Institute of Chemical Engineers, 2015, 52: 65–71 https://doi.org/10.1016/j.jtice.2015.02.012
31	J Yang, Q Zhang, Z S Mao, C Yang. Enhanced micromixing of non-newtonian fluids by a novel zigzag punched impeller. Industrial & Engineering Chemistry Research, 2019, 58(16): 6822–6829 https://doi.org/10.1021/acs.iecr.9b00465
32	M Yoshida, N Shimada, R Kanno, S Matsuura, Y Otake. Liquid flow and mixing in bottom regions of baffled and unbaffled vessels agitated by turbine-type impeller. International Journal of Chemical Reactor Engineering, 2014, 12(1): 629–638 https://doi.org/10.1515/ijcre-2014-0086
33	B Liu, N Sun, Z Jin, Y Zhang, B Sunden. Numerical investigation and estimating correlation of micromixing performance of coaxial mixers. Industrial & Engineering Chemistry Research, 2019, 58(49): 22376–22388 https://doi.org/10.1021/acs.iecr.9b04406
34	M C Fournier, L Falk, J Villermaux. A new parallel competing reaction system for assessing micromixing efficiency—experimental approach. Chemical Engineering Science, 1996, 51(22): 5053–5064 https://doi.org/10.1016/0009-2509(96)00270-9
35	P Guichardon, L Falk, J Villermaux. Characterisation of micromixing efficiency by the iodide-iodate reaction system. Part II: kinetic study. Chemical Engineering Science, 2000, 55(19): 4245–4253 https://doi.org/10.1016/S0009-2509(00)00069-5
36	A N Manzano Martĺnez, A S Haase, M Assirelli, J van der Schaaf. Alternative kinetic model of the iodide-iodate reaction for its use in micromixing investigations. Industrial & Engineering Chemistry Research, 2020, 59(49): 21359–21370 https://doi.org/10.1021/acs.iecr.0c04901
37	J M Commenge, L Falk. Villermaux-Dushman protocol for experimental characterization of micromixers. Chemical Engineering and Processing, 2011, 50(10): 979–990 https://doi.org/10.1016/j.cep.2011.06.006
38	M Jasinska, J Baldyga, M Cooke, A J Kowalski. Specific features of power characteristics of in-line rotor-stator mixers. Chemical Engineering and Processing, 2015, 91: 43–56 https://doi.org/10.1016/j.cep.2015.03.015
39	T P John, C P Fonte, A Kowalski, T L Rodgers. A comparison of power and flow characteristics between batch and in-line rotor-stator mixers. Chemical Engineering Science, 2019, 202: 481–490 https://doi.org/10.1016/j.ces.2019.03.015
40	G Ozcan-Taskin, D Kubicki, G Padron. Power and flow characteristics of three rotor-stator heads. Canadian Journal of Chemical Engineering, 2011, 89(5): 1005–1017 https://doi.org/10.1002/cjce.20553
41	M Jasinska, J Baldyga, M Cooke, A Kowalski. Application of test reactions to study micromixing in the rotor-stator mixer (test reactions for rotor-stator mixer). Applied Thermal Engineering, 2013, 57(1–2): 172–179 https://doi.org/10.1016/j.applthermaleng.2012.06.036
42	X Duan, X Feng, Z Mao, C Yang. Numerical simulation of reactive mixing process in a stirred reactor with the DQMOM-IEM model. Chemical Engineering Journal, 2019, 360: 1177–1187 https://doi.org/10.1016/j.cej.2018.10.156
43	M Assirelli, S P Lee, A W Nienow. Further studies of micromixing: scale-up, baffling and feed pipe backmixing. Journal of Chemical Engineering of Japan, 2011, 44(11): 901–907 https://doi.org/10.1252/jcej.11we042
44	M Assirelli, W Bujalski, A Eaglesham, A W Nienow. Intensifying micromixing in a semi-batch reactor using a Rushton turbine. Chemical Engineering Science, 2005, 60(8–9): 2333–2339 https://doi.org/10.1016/j.ces.2004.10.041
45	A Utomo, M Baker, A W Pacek. The effect of stator geometry on the flow pattern and energy dissipation rate in a rotor-stator mixer. Chemical Engineering Research & Design, 2009, 87(4A): 533–542 https://doi.org/10.1016/j.cherd.2008.12.011
46	A T Utomo, M Baker, A W Pacek. Flow pattern, periodicity and energy dissipation in a batch rotor-stator mixer. Chemical Engineering Research & Design, 2008, 86(12A): 1397–1409 https://doi.org/10.1016/j.cherd.2008.07.012
47	S Hall, M Cooke, A El-Hamouz, A J Kowalski. Droplet break-up by in-line Silverson rotor-stator mixer. Chemical Engineering Science, 2011, 66(10): 2068–2079 https://doi.org/10.1016/j.ces.2011.01.054
48	J Villermaux, L Falk. A generalized mixing model for initial contacting of reactive fluids. Chemical Engineering Science, 1994, 49(24): 5127–5140 https://doi.org/10.1016/0009-2509(94)00303-3
49	R Lafficher, M Digne, F Salvatori, M Boualleg, D Colson, F Puel. Influence of micromixing time and shear rate in fast contacting mixers on the precipitation of boehmite and NH4-dawsonite. Chemical Engineering Science, 2018, 175: 343–353 https://doi.org/10.1016/j.ces.2017.10.011

[1]	Lin Yang, Wenpeng Li, Junheng Guo, Wei Li, Baoguo Wang, Minqing Zhang, Jinli Zhang. Effects of rotor and stator geometry on dissolution process and power consumption in jet-flow high shear mixers[J]. Front. Chem. Sci. Eng., 2021, 15(2): 384-398.

Viewed

Full text

Abstract

Cited

Shared

Discussed