Turbulent emulsification is an important unit operation in chemical engineering. Due to its high energy cost, there is substantial interest in increasing the fundamental understanding of drop breakup in these devices, e.g., for optimization. In this study, numerical breakup experiments are used to study turbulent fragmentation of viscous drops, under conditions similar to emulsification devices such as high-pressure homogenizers and rotor-stator mixers. The drop diameter was kept larger than the Kolmogorov length scale (i.e., turbulent inertial breakup). When varying the Weber number (We) and the disperse-to-continuous phase viscosity ratio in a range applicable to emulsification, three distinct breakup morphologies are identified: sheet breakup (large We and/or low viscosity ratio), thread breakup (intermediary We and viscosity ratio >5), and bulb breakup (low We). The number and size of resulting fragments differ between these three morphologies. Moreover, results also confirm previous findings showing drops with different We differing in how they attenuate the surrounding turbulent flow. This can create ‘exclaves’ in the phase space, i.e., narrow We-intervals, where drops with lower We break and drops with higher We do not (due to the latter attenuating the surrounding turbulence stresses more).
More detailed investigation of the flow inside emulsification devices, e.g. High-pressure homogenizers (HPHs) helps the industry to broaden the fundamental understanding of the working principle of these machines which in turn will pave the road to increase the breakup efficiency of emulsification processes. Direct Numerical Simulation (DNS) is not deemed as a practical method in industry due to the high computational cost and time. This study is the first DNS carried out on a model of an emulsification device model. The goal of this study is to set a benchmark for future CFD investigations using industrially favorable tools (RANS, LES, etc.). A scale-up model HPH is designed and the results show a successful modeling of the flow field mimicking the flow behavior inside a typical HPH.
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