Lect1 Blend

ENGG 199 Reacting Flows
Spring 2006
Lecture 1
Process Response
Blending and Motion
Mix Time
Power Calculations
Copyright © 2000, A.W. Etchells, R.K.Grenville & R.D. LaRoche

All rights reserved.
Handbook of
Industrial Mixing
ENGG 199 Lecture 1 Slide 2

Copyright © 2000, A.W. Etchells, R.K.Grenville & R.D. LaRoche. All rights reserved.
Handbook of Industrial Mixing
Table of Contents and Authors
Introduction Edward L. Paul, Victor Atiemo-Obeng, Suzanne M. Kresta
Chapter 1: Residence Time Distributons E. Bruce Nauman
Chapter 2: Turbulence in Mixing Applications Suzanne M. Kresta and Robert S. Brodkey
Chapter 3: Laminar Mixing: A Dynamical Systems Approach Edit S. Szalai, Mario M. Alvarez, Fernando J. Muzzio
Chapter 4: Experimental Methods Part A: Measuring Tools and Techniques for Mixing and Flow Visualization Studies
David A.R. Brown, Pip N. Jones, John C. Middleton Part B: Fundamental Flow Measurement George Papadopoulos and
Engin B. Arik
Chapter 5: Computational Fluid Mixing Elizabeth Marden Marshall and André Bakker
Chapter 6: Mechanically Stirred Vessels Ramesh R. Hemrajani and Gary B. Tatterson
Chapter 7: Mixing in Pipelines Arthur W. Etchells III and Chris F. Meyer
Chapter 8: Rotor-Stator Mixing Devices Victor A. Atiemo-Obeng and Richard V. Calabrese
Chapter 9: Blending of Miscible Liquids Richard K. Grenville and Alvin W. Nienow
Chapter 10: Solid-Liquid Mixing Victor A. Atiemo-Obeng, W. Roy Penney, Piero Armenante
Chapter 11: Gas-Liquid Mixing in Turbulent Systems John C. Middleton and John M. Smith
Chapter 12: Immiscible Liquid-Liquid Systems Douglas E. Leng and Richard V. Calabrese
Chapter 13: Mixing and Chemical Reactions Gary K. Patterson, Edward L. Paul, Suzanne M. Kresta, Arthur W. Etchells III
Chapter 14: Heat Transfer W. Roy Penney and Victor A. Atiemo-Obeng
Chapter 15: Solids Mixing Part A: Fundamentals of Solids Mixing Fernando J. Muzzio, Albert Alexander, Chris
Goodridge, Elizabeth Shen, Troy Shinbrot Part B: Mixing of Particulate Solids in the Process Industries Konanur
Manjunath, Shrikant Dhodapkar Karl Jacob
Chapter 16: Mixing of Highly Viscous Fluids, Polymers, and Pastes David B. Todd
Chapter 17: Mixing in the Fine Chemicals and Pharmaceutical Industries Edward L. Paul, Michael Midler, Yongkui Sun
Chapter 18: Mixing in the Fermentation and Cell Culture Industries Ashraf Amanullah, Barry C. Buckland, Alvin W.
Nienow
Chapter 19: Fluid Mixing Technology in the Petroleum Industry Ramesh R. Hemrajani
Chapter 20: Mixing in the Pulp and Paper Industry Chad P.J. Bennington
Chapter 21: Mechanical Design of Mixing Equipment David S. Dickey and Julian B. Fasano
Chapter 22: Role of the Mixing Equipment Supplier Ronald J. Weetman
CD-ROM: Visual Mixing Suzanne M. Kresta and Keith Boyle

Why is Scale-Up/Scale-Down of Stirred Tank Reactors So Difficult?
Different Design Criteria at Different Scales
Blendtime
Solids Suspension
Gas-Liquid Mass Transfer
Maximum Turbulent Energy Dissipation
Maximum Shear
Liquid-Liquid Mass Transfer
Feed Addition Micromixing/Mesomixing with Competitive
Reactions
Solid-Liquid Mass Transfer

Laminar and Turbulent Flow
All fluid motions seem to consist of two zones
Laminar - linear zone
proportional to viscosity
Complex turbulent zone
not much affected by viscosity

Dimensional Analysis - Pipe Flow
Variables
velocity, V
pipe diameter, D
pipe length, L
fluid density,
fluid viscosity,
Output (Quality)
volumetric flow rate, Q
pressure drop, p
Dimensionless Groups
Reynolds Number VD
Re
Fanning Friction Factor
D p 2 gc
f
4 L V2

Log f vs. Log Re for Pipe Flow

Dimensional Analysis - Rotational Mixer Flow
Variables
rotational speed, N impeller clearance from bottom, C
impeller diameter, D impeller blade width, Dw
tank diameter, T liquid height, Z
fluid density, fluid viscosity,
Output (Quality)
power, mix time, heat & mass transfer coefficients
Dimensionless Groups
Reynolds Number ND 2
Re
Froude Number N 2D
Fr
g
Power Number P
or Newton Number (Ne)
Po
N 3 D5
Geometric Ratios Z T C Dw
, , ,
D D D D
Log Po vs. Log Re for Standard Flat Paddles

Usefulness of the Power Number
Estimate power imparted to the fluid by the impellers
Many engineers may use Power per Tank Volume as a scale-up

criterion
Better Approach: - local power/mass (not average)

In stirred tanks, use power per impeller swept volume for ballpark estimate
P Po N 3 D 5 Po N 3 D 5 Po
Assume N 3D 2 N 3D 2
V imp D2 D2
Dw D
4 4 4
Can be calculated directly from CFD
Local is an important parameter in solids breakup, gas bubble

breakup, mass transfer, cell damage?
Mixing Tank Equipment
Tanks/Vessels
Right Cylinder most common
height-to-diameter ratio - 0.8 to 1.5
dish bottom and flat bottom
Top Entering Shafts
rotational, vertical
Excellent source of impeller data
http://www.postmixing.com/mixing%20forum/impellers/impellers.htm

Turbine Impellers
radial flow patterns
flat 90° blades
4-12 blades (4 most common)
discharge through cylindrical
height
draw suction flow from top and
bottom
sets up jet with velocity decay
away from turbine

Axial Flow Impellers
Axial (Pitched Blade) Turbine
4 to 6 blades angled at 45° (some at 30°)
cheaper to make than marine impeller
on large scale because of weight
pushes liquid off at an angle - axial and
horizontal (radial) components
Hydrofoil (Airfoil) Impellers Marine Propeller

turbines with twisted blades like
airplane propellers
variable pitch

Mixing Tank Baffles
Mixing Tank without baffles
predominantly rotational flow (solid-body rotation)
no interchange between top and bottom
Vertical Baffles
turn rotational component into vertical component
increase top to bottom flow
always specify baffles for turbulent flow
Alternatives to Baffles (for small vessels)
angle mount shaft
off-center vertical mount shaft
side-entering shaft

Standard Baffle Configuration
Full Baffling
4 Vertical Baffles at full length of straight side of tank
Baffle Width, Bw = T/12
Offset from Wall = T/72 (or Bw/6)
Partial Baffling Alternatives
1/2 Height, 1/2 Width, 2 Baffles
Results in some surface vortex
Po (Baffled) is greater than Po (Unbaffled) by 20-50%

Unbaffled Tank Flow Patterns
Surface Vortex
Occasionally need to know vortex depth
draw down of light material
Balance of forces
Kinetic Energy V2 ND ) 2
Potential Energy gX
X = liquid height above quiet liquid level
Suggests Fr for correlations rather than Re

N 2D2
Fr
Xg

Turbine Impellers as Pumps
Flow Devices
Tip Speed = ND
2-6 m/s
Defines maximum velocity
How Much Flow? - Need Measurements
Pitot tubes, Laser Doppler Velocimetry
Integrate Velocity Field over Impeller Outflow Area (Faces)
Pumping Number
Q
Re > 104, NQ constant NQ
ND 3
NQ weak function of D/T
Flow from Impeller Entrains More Flow than Impeller Pumps

How Reliable is CFD as a Process Engineering Tool?
Validation Efforts in the mid-to-late 90 s

45° PBT
Tank Diameter, T = 14.5 cm
Liquid Height, Z = T
Off-bottom Clearance, C = 0.5T
Impeller Diameter, D = 0.35T
Laminar Re = 20.4
Turbulent Re = 21505
Courtesy Dow Chemical and Cray Research

Laminar Flow in a Stirred Tank
Velocity Field Comparison for Re = 20.4
R. D. LaRoche & D. Choudhury

MIXING XV - Banff, Alberta, Canada, June 18-25, 1995

Turbulent Flow Validation

Pumping Numbers
Impeller Type Pumping Number, NQ
Radial (4 blades) 0.6
Radial (6 blades) 0.7 0.85
Axial (4 blades) 0.8
Axial (6 blades) 0.9
Propeller 0.5
A310 Hydrofoil 0.56

Pumping & Head Generation
Axial Flow Impeller - High Capacity/Low Head Pump
Q N Q ND 3 P Po N 3 D 5
P Po N 3 D 5 Po 2
Head H ND
gQ gNQ ND 3 gN Q
Head is proportional to the square of the tip speed
Pumping Capacity Example - How much head is generated?

10000 gallon tank filled with water using Radial-4 impeller
T=4m, H=4m, N=30rpm=0.5sec-1, D=2m, P=7.5HP=5593watts
P 5593 kg m 2 s 3
Head 3
0.24 m
gN Q ND 3 1000 kg m3 9.81m s 2 0.6 0.5 s 1
2m
Typical centrifugal pump generates 30m head

Some Characteristic Velocities
Tip Speed = ND Q
NQ
ND 3
Thrust Velocity - Flow/Area
Axial Impeller Q 4
N Q ND
D2
4
Radial Impeller
Q N Q ND Dw
DDw D
Bulk Velocity - Chemineer Concept

2
Q 4 D
N Q ND
T

Chemineer Blend Scale Method
Need Way to Rate Motion in Tanks
Use Bulk Velocity as Criteria for Describing Motion
Combines Tank Size and Impeller Effect
Little Turbulence is Required with Homogeneous Liquids
Bulk Flow or Pumping is preferred
Standardize
45° Axial-4 Impeller (45° Pitched Blade Turbine)
Off-bottom Clearance, C
2
Rate Bulk Velocity on 1-10 Scale Q 4
N Q ND
D
Low: 1 = 6 ft/min, 5 = 30 ft/min T
High: 10 = 60 ft/min
Correct for Re effect
Crude method but often good enough

Mixing Time
How fast to get to
Homogeneity?
Measurements - Batch
Stirred Tank
Color Change - somewhat
arbitrary
Conductivity or pH - approach to
steady state
Acid/Base Indicator Reactions
Approach to Average
Uniformity
95% approach (or 5% of steady
state)
Extrapolation along exponential
decay curve

Blend Time Techniques
Transport of a tracer
Small amount of liquid tracer added near liquid surface
Concentration of tracer monitored as a function of time
Similar to experimental techniques
Particle trajectories
Release large number of Lagrangian particles
Monitor particle concentration at specified location
Use Particle Tracking

Influence of Measurement Location
U t99= 20s
2.00
Point 1
Point 2
Point 3
Point 4
t99= 21.4s
1.00
t99= 27.4s
t99= 55.8s
0.00
0 10 20 30 40 50
Time, s

Mixing Time Correlations
k
c e
95% Mixing Time when c=0.05
k ln( c) k ln(0.05) 3k
Turbulent Mixing Correlation (Ruzkowski & Grenville)

Based on a wide range of impeller types and tank sizes
2
5.4 T
N for Po1 3 Re 6404
Po1 3 D
Height effect
12
H H
for 1.0
T T

Mixing Time Correlations (cont.)
Laminar Mixing Correlation
T 3 2H 1 2
34600 2 3 2 4 for Po1 3 Re 6404
Po N D
Defining a Fourier Number, Fo
Fo
T 3 2H 1 2
And rearranging to give
186 1
Po1 3 Re for 1186
Fo Fo
Can also be rearranged in this form
1
N
Re
Note that Mix Time goes laminar before Po is in laminar
region

Power Correlations
Experience suggests
fixing geometry (C, Z,
Bw, Dw, pitch) as a
function of D or T
Experimentally measure
effects of L/D, T/D, Z/D
and Fr with baffles - not
significant
Measure Effects of Re,
pitch/D, Dw/D, C/D to get
Po vs. Re plots

Power Correlations (cont.)
Laminar Region
1 P
Po P N 2 D3
Re N 3 D5 ND 2
Power proportional to viscosity

Power independent of density
N up 10% => P up 21%
D up 10% => P up 33%
Turbulent Region
P
Po const const P N 3 D5
N 3 D5
Power independent of viscosity
Power proportional to density
N up 10% => P up 33%
D up 10% => P up 61%

Power (P), Speed (N) and Impeller Diameter (D)
Power, P, quantified by motor sizes
3, 5, 7.5, 10, 20, 30, 50, 75, 100 HP
Speed, N, quantified by American Gear Manufacturers
Assoc.
25, 30, 45, 56, 68, 84, 100, 125 min-1 (rpm) based on 1750 rpm output motor
speed
alternative motor speeds: 1150, 1750, 3500 rpm (60 Hz in U.S.)
Process responds to fluid velocity generated by impeller
specifying two variables sets the third
given P and N, know D
given N and D, know P
Power Units
1 HP = 550 ft-lbf/sec = 745.7 watts Po N 3 D5 lbm ft
P gc 32.17
1 watt = 1 joule/sec = 1 kg-m2/s3 gc lb f sec 2
Need gc with English units

Power and Flow
P Po N 3 D 5 and Q N Q ND 3
Combine to get
13 13 35 35
P NQ P P NQ P
Q NQ D3 D 4 3 or Q NQ N N4 5
Po D 5 Po1 3 Po N 3 Po3 5
In Turbulent Region, NQ and Po are constant for a given impeller type,

therefore:
13 35
P P
Q D 4 3 or Q N4 5
For a given Q, a larger D results in P decreasing

For a given Q, a smaller N results in P decreasing

Mixer Design
Should be designed to run at low speeds
Hence gear boxes save energy by allowing the system to run at lower speeds
than the electric motor
Gear boxes are clockwork mechanisms that take motor speed and reduce it
to operating speed without a change in power transmitted
P Po N 3 D 5 and Q N Q ND 3
To Increase Flowrate (Q) at constant impeller diameter (D)

P N 3 and Q N P Q3
To Increase Flowrate (Q) at constant impeller speed (N)

P D 5 and Q D3 P Q5 3

Power Numbers under Turbulent Conditions
Shuie & Wong, Can. J. Chem. Engg., 62 (1984)
Impeller Blade Number Dw/D Po

Type Angle of Blades
FBT 90 6 0.2 5.0
CBT 90 6 0.269 4.0
CBT 90 4 0.154 4.6
PBT 45 4 0.231 1.74
PBT 45 2 0.231 1.2
Propeller -- 3 -- 0.67
FBT 90 4 0.20 3.0
PBT 45 4 0.20 1.0
FBT-Flat Blade Turbine, CBT-Curved Blade Turbine, PBT-Pitched Blade Turbine

Power Numbers under Laminar & Turbulent Conditions
Prof. J.M. Smith, Univ. Surrey
A C
Po B
Re 1000 Re
A=Kp or NeRe (Laminar Power Number)
B~Po (Turbulent Power Number)
Impeller Blade Number A B C

Type Angle of Blades
FBT 90 6 67 3.2 1.8
CBT 90 6 67 2.6 2.2
PBT 45 4 49 1.5 0.3
PBT 60 4 50 4.0 1.0
Propeller -- 3 47 0.9 0.3
FBT 90 4 50 4.0 1.0

FBT-Flat Blade Turbine, CBT-Curved Blade Turbine, PBT-Pitched Blade Turbine
Pumping Efficiency
NQ/Po
Propeller - 0.5/0.67 = 0.75
Axial - 0.8/1.74 = 0.46
Radial - 0.6/3.0 = 0.20
Where does the extra Power go? Turbulence
High (Pumping) Efficiency Impellers use Low Power
Lightnin A310
Prochem
Ekato
Can get High Efficiency at Constant NQ and Po by
increasing Impeller Diameter, D

Power Number and Drag Coefficient
Drag Coefficient, CD
2
V2 ND
Fdrag CD A CD DDw
2 2
Torque Fdrag lblade

3 Dw
P Torque 2 N CD N 3 D5
D
Po contains Dw/D effect, therefore:
P Po N 3 D 5 Po CD
Po is proportional to CD


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ENGG 199 Reacting Flows

Copyright © 2000, A.W. Etchells, R.K.Grenville & R.D. LaRoche

ENGG 199 Lecture 1 Slide 2

ENGG 199 Lecture 1 Slide 3

ENGG 199 Lecture 1 Slide 4

ENGG 199 Lecture 1 Slide 5

ENGG 199 Lecture 1 Slide 6

ENGG 199 Lecture 1 Slide 7

ENGG 199 Lecture 1 Slide 9

Many engineers may use Power per Tank Volume as a scale-up

Better Approach: - local power/mass (not average)

Can be calculated directly from CFD

Local is an important parameter in solids breakup, gas bubble

ENGG 199 Lecture 1 Slide 11

ENGG 199 Lecture 1 Slide 12

Hydrofoil (Airfoil) Impellers Marine Propeller

ENGG 199 Lecture 1 Slide 13

ENGG 199 Lecture 1 Slide 14

ENGG 199 Lecture 1 Slide 15

Suggests Fr for correlations rather than Re

ENGG 199 Lecture 1 Slide 16

ENGG 199 Lecture 1 Slide 17

Validation Efforts in the mid-to-late 90 s

Courtesy Dow Chemical and Cray Research

ENGG 199 Lecture 1 Slide 18

Velocity Field Comparison for Re = 20.4

R. D. LaRoche & D. Choudhury

ENGG 199 Lecture 1 Slide 19

ENGG 199 Lecture 1 Slide 20

Impeller Type Pumping Number, NQ

Radial (4 blades) 0.6

Radial (6 blades) 0.7 0.85

Axial (4 blades) 0.8

Axial (6 blades) 0.9

A310 Hydrofoil 0.56

ENGG 199 Lecture 1 Slide 21

Pumping Capacity Example - How much head is generated?

Typical centrifugal pump generates 30m head

ENGG 199 Lecture 1 Slide 22

Bulk Velocity - Chemineer Concept

ENGG 199 Lecture 1 Slide 23

ENGG 199 Lecture 1 Slide 24

ENGG 199 Lecture 1 Slide 25

ENGG 199 Lecture 1 Slide 26

ENGG 199 Lecture 1 Slide 27

Turbulent Mixing Correlation (Ruzkowski & Grenville)

ENGG 199 Lecture 1 Slide 28

ENGG 199 Lecture 1 Slide 29

ENGG 199 Lecture 1 Slide 30

Power proportional to viscosity

ENGG 199 Lecture 1 Slide 31

ENGG 199 Lecture 1 Slide 32

In Turbulent Region, NQ and Po are constant for a given impeller type,

For a given Q, a larger D results in P decreasing

ENGG 199 Lecture 1 Slide 33

To Increase Flowrate (Q) at constant impeller diameter (D)

To Increase Flowrate (Q) at constant impeller speed (N)

ENGG 199 Lecture 1 Slide 34

Impeller Blade Number Dw/D Po

FBT-Flat Blade Turbine, CBT-Curved Blade Turbine, PBT-Pitched Blade Turbine

Impeller Blade Number A B C

CBT 90 6 67 2.6 2.2

PBT 45 4 49 1.5 0.3

PBT 60 4 50 4.0 1.0