Impellers in stirred vessels are often characterized by dimensionless numbers such as the power and flow numbers. These are often crucial in determining mixing performance. Previous studies for high‐shear mixers have yielded correlations between the power, flow, and mixer geometries, since in these mixers the flow can be independently varied. For stirred vessels, dimensional analysis is typically used to develop such correlations, leading to less accurate predictive models. Here, we combine an analysis based on a balance of angular momentum balance with computational fluid dynamics simulations to comprehensively study the effect of impeller geometry on the relationship between power and flow. The results allow for the prediction of the flow generated by the impeller based on the easily measurable impeller power consumption and the geometrical dimensions of the impeller. The models are accurate over a wide range of geometries. Furthermore, we are able to predict both the primary and total flows.
The relationship between power and flow characteristics of batch rotor-stator mixers has been studied using CFD simulations with experimental power validation. The mixer studied was the Silverson L5M batch mixer with the standard emulsor head. The size of the holes in the screen and the constriction of the base hole were changed in small increments. The MRF technique was used to model rotor rotation. A model is developed in this study which links the power and flow numbers of the mixer. Since power is easy to measure experimentally, one can use this model to predict the flow number by measuring torque. A second model is also developed which allows one to predict the flow number using solely the geometry of the mixing head. This study greatly enhances our understanding of the relationship between power, flow and mixer geometry in rotor-stator mixers.
We present a model for the evolution of concentrations of orientable species undergoing a collisional binary reaction and examine the dependence of the concentration of the reaction product on flow parameters in Poiseuille flow. Interesting patterns of concentration are obtained depending on parameters. We use the model to investigate the reaction in a microfluidic device known as the shear superposition micromixer. Simulation results over a range of Péclet, Damköhler, and rotational Péclet numbers indicate that this micromixer is well suited to enhance the rate of reaction via the mechanism of simultaneous mixing and alignment of the orientable species. Connections to biological systems are discussed.
Rotor-stator mixers are used in many industries to perform emulsification and de-agglomeration processes. Despite previous research, different modes of operation have not been compared in terms of flow and power characteristics. The aim of this study was to use CFD to investigate power and flow characteristics of a Silverson L5M mixer operating in batch and in-line mode.MRF was used along with the standard k − turbulence model for the simulations. Results suggest that batch mixers can be characterised in the same was as in-line mixers, and for a given mixing head design, the characterisation is independent of the mode of operation. A new way of the calculating flow number is proposed, which explains some discrepant results from previous studies. Overall, this work enhances our understanding of rotor-stator mixers and allows for better design choices of mixer.
Process analytical technology (PAT) has developed significantly since its introduction in pharma where many in situ analytical probes and measuring devices are now commercially available, replacing the use of off-line quality control measurements that are typically laborious and time intensive. The use of PAT instrumentation should not interfere with the process itself and subsequently should have no effect on the product whilst measuring representative samples. Implementation of these devices is typically arbitrary using empirical means. Therefore, the objective of this study is to highlight the use of computational fluid dynamics modeling to investigate the effect of interfacing parameters and process parameters of an inline near-infrared (NIR) probe used to determine the viscosity of a non-Newtonian micellar liquid. The parameters investigated for the probe were immersion depth, immersion angle, gap size, and fluid velocity. The results conclude that the immersion angle and depth should both be optimized to prevent stagnant fluid accumulating in the measuring gap ensuring that the NIR measurements are representative of the bulk. The gap size determines the optical pathlength and therefore was also investigated against an existing predictive viscosity model showing no changes in model performance with varying gap size. The use of computational modeling to develop a digital twin prior to PAT implementation at the equipment design stage ensures the technology can perform at its best and will also aid in calibration transfer studies.
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