The unique properties of nanoparticles and nanoparticle clusters show high potential for nanomaterials to be formulated into numerous products. In this paper, nanosuspensions are formulated by breaking up nanoparticle clusters (called agglomerates) in high-shear flows. A new breakage model is introduced to interpret erosive dispersion of agglomerates, and the population balance modeling is applied to account for effects of breakage on agglomerate size distribution. Effects of suspension structure on its rheology and flow are included in modeling. The population balance equations are solved using the quadrature method of moments (QMOM) that is linked directly to the k−ε model of the computational fluid dynamics (CFD) code FLUENT. In dispersion experiments, the aqueous suspensions of fumed silica particles, Aerosil 200V, are used. The test rig consists of an in-line Silverson rotor−stator mixer and a stirred tank. The head is a two-stage rotor−stator design with the inner stator consisting of round holes and the outer stator consisting of smaller square holes. Experimental results are compared with model predictions.

In-line rotor-stators are used in a wide range of industrial applications-primarily for dispersion processes such as emulsification, deagglomeration. Three rotor-stator heads have been used to investigate their performance in breaking up of nanoparticle clusters within a large project. This article reports the findings of a part of this study aimed at investigating the flow and power characteristics in single phase to highlight the differences of three different mixer heads. Power characteristics are determined using the calorimetry allowing the characteristic power numbers for these devices to be obtained. These are also compared with CFD calculations. Flow characteristics are studied through numerical simulations.

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Many chemical engineering processes involve the suspension of solid particles in a liquid. In dense systems, agitation leads to the formation of a clear liquid layer above a solid cloud. Cloud height, defined as the location of the clear liquid interface, is a critical measure of process performance. In this study, solid-liquid mixing experiments were conducted and cloud height was measured as a function operating conditions and stirred tank configuration. Computational fluid dynamics simulations were then performed using an Eulerian-Granular multiphase model. The effects of hindered and unhindered drag models and turbulent dispersion force on cloud height were investigated. A comparison of the experimental and computational data showed excellent agreement over the full range of conditions tested.

This study was carried out to investigate the break up of nanoparticle clusters in a liquid using an in-line rotor stator. Two types of fumed silica particles were dispersed in distilled water: Aerosil 200 V, which is hydrophilic, has a primary particle size of 12 nm and Aerosil R816 which is based on Aerosil 200 V and surface modified to render it hydrophobic. The article reports on the rheology of the dispersions, particle size analysis, the effect of concentration, and processing conditions such as the rotor speed, that is, the specific power input, and flow rate, that is, the residence time.