Modelling of solids distribution in stirred tanks: analysis of simulation strategies and comparison with experimental data

The predictive capabilities of CFD techniques as applied to solid–liquid stirred vessels are investigated. The distribution of solid particles was simulated in three baffled stirred tanks agitated with single and multiple impellers. Suspensions of glass beads of different diameters and average concentration up to 6?vol. % in water were studied. The simulations of solid–liquid suspensions in the stirred vessels were performed by using fully predictive approaches. Eulerian multiphase models were adopted for modelling the solid–liquid flow, coupled with three different extensions of the standard k-? model to the case of multiphase flows. The simulated particle axial concentration profiles are compared with experimental data and critically discussed. The most successful simulation strategy and one possible implementation are described.     

Effects of particle size and concentration on bubble coalescence and froth formation in a slurry bubble column

A new approach for simulating the formation of a froth layer in a slurry bubble column is proposed. Froth is considered a separate phase, comprised of a mixture of gas, liquid, and solid. The simulation was carried out using commercial flow simulation software (FIRE v2014) for particle sizes of 60–150 μm at solid concentrations of 0–40 vol%, and superficial gas velocities of 0.02–0.034 m/s in a slurry bubble column with a hydraulic diameter of 0.2 m and height of 1.2 m. Modelling calculations were conducted using a Eulerian–Eulerian multiphase approach with k–ε turbulence. The population balance equations for bubble breakup, bubble coalescence rate, and the interfacial exchange of mass and momentum were included in the computational fluid dynamics code by writing subroutines in Fortran to track the number density of different bubble sizes. Flow structure, radial gas holdup, and Sauter mean bubble diameter distributions at different column heights were predicted in the pulp zone, while froth volume fraction and density were predicted in the froth zone. The model was validated using available experimental data, and the predicted and experimental results showed reasonable agreement. To demonstrate the effect of increasing solid concentration on the coalescence rate, a solid-effect multiplier in the coalescence efficiency equation was used. The solid-effect multiplier decreased with increasing slurry concentration, causing an increase in bubble coalescence efficiency. A slight decrease in the coalescence efficiency was also observed owing to increasing particle size, which led to a decrease in Sauter mean bubble diameter. The froth volume fraction increased with solid concentration. These results provide an improved understanding of the dynamics of slurry bubble reactors in the presence of hydrophilic particles.     

Numerical simulation of counter-current flow field in the downcomer of a liquid–solid circulating fluidized bed

A comprehensive study on the hydrodynamics in the downcomer of a liquid–solid circulating fluidized bed (LSCFB) is crucial in the control and optimization of the extraction process using an ion exchange LSCFB. A computational fluid dynamics model is proposed in this study to simulate the counter-current two-phase flow in the downcomer of the LSCFB. The model is based on the Eulerian–Eulerian approach incorporating the kinetic theory of granular flow. The predicted results agree well with our earlier experimental data. Furthermore, it is shown that the bed expansion of the particles in the downcomer is directly affected by the superficial liquid velocity in downcomer and solids circulation rate. The model also predicts the residence time of solid particles in the downcomer using a pulse technique. It is demonstrated that the increase in the superficial liquid velocity decreases the solids dispersion in the downcomer of the LSCFB.     

Computation of particle dispersion in turbulent liquid flows using an efficient Lagrangian trajectory model

The dispersion of solid particles in a turbulent liquid flow impinging on a centrebody through an axisymmetric sudden expansion was investigated numerically using a Eulerian–Lagrangian model. Detailed experimental measurements at the inlet were used to specify the inlet conditions for two-phase flow computations. The anisotropy of liquid turbulence was accounted for using a second-moment Reynold stress transport model. A recently developed stochastic–probabilistic model was used to enhance the computational efficiency of Lagrangian trajectory computations. Numerical results of the stochastic–probabilistic model using 650 particle trajectories were compared with those of the conventional stochastic discrete-delta-function model using 18 000 particle trajectories. In addition, results of the two models were compared with experimental measurements. © 1998 John Wiley & Sons, Ltd.     

Hydrodynamics and energy consumption studies in a three-phase liquid circulating three-phase fluid bed contactor

The hydrodynamics and energy consumption have been studied in a cold flow, bubbling and turbulent, pressurized gas–liquid–solid three-phase fluidized bed (0.15 m ID × 1 m height) with concurrent gas–liquid up flow is proposed with the intention of increasing the gas hold up. The hydrodynamic behaviour is described and characterised by some specific gas and liquid velocities. Particles are easily fluidized and can be uniformly distributed over the whole height of the column. The effect of parameters like liquid flow rate, gas flow rate, particle loading, particle size, and solid density on gas hold up and effect of gas flow rate, solid density and particle size on solid hold up, energy consumption and minimum fluidization velocity has been studied. At the elevated pressures a superior method for better prediction of minimum fluidization velocity and terminal settling velocities has been adopted. The results have been interpreted with Bernoulli’s theorem and Richardson–Zaki equation. Based on the assumption of the gas and liquid as a pretend fluid, a simplification has been made to predict the particle terminal settling velocities. The Richardson–Zaki parameter n′ was compared with Renzo’s results. A correlation has been proposed with the experimental results for the three-phase fluidization.     

Numerical study of elbow erosion due to sand particles under annular flow considering liquid entrainment

Sand particle erosion is always a challenge in natural gas production. In particular, the erosion in gas–liquid–solid annular flow is more complicated. In this study, a three-phase flow numerical model that couples the volume of fluid multiphase flow model and the discrete phase model was developed for prediction of erosion in annular flow. The ability of the numerical model to simulate the gas–liquid annular flow is validated through comparison with the experimental data. On the basis of the above numerical model, the phase distribution in the pipe was analyzed. The liquid entrainment behavior was reasonably simulated through the numerical model, which guaranteed the accuracy of predicting the particle erosion. Additionally, four erosion prediction models were used for the erosion calculation, among them, the Zhang et al. erosion model predicted the realistic results. Through the analysis of the particle trajectory and the particle impact behavior on the elbow, the cushion effect of the liquid film on the particles and the erosion morphology generation at the elbow were revealed.     

Lagrangian particle dispersion in turbulent flow over a wall mounted obstacle

Large-eddy simulations (LES) of particle-laden turbulent flows are presented in order to investigate the effects of particle response time on the dispersion patterns of a space developing flow with an obstruction, where solid particles are injected inside the wake of an obstacle [Vincont, J.Y., Simoens, S., Ayrault M., Wallace, J.M., 2000. Passive scalar dispersion in a turbulent boundary layer from a line source at the wall and downstream of an obstacle. J. Fluid Mech. 424, 127–167]. The numerical method is based on a fully explicit fractional step approach and finite-differences on Cartesian grids, using the immersed boundary method (IBM) to represent the existence of solid obstacles. Two different turbulence models have been tested, the classical Smagorinsky turbulence model and the filtered structure function model. The dispersed phase was modelled either by an Eulerian approach or a Lagrangian particle tracking scheme of solid particles with Stokes numbers in the range St = 0–25, assuming one-way coupling between the two phases. A very good agreement was observed between the Lagrangian and Eulerian approaches. The effect of particle size was found to significantly differentiate the dispersion pattern for the inhomogeneous flow over the obstacle. Although in homogeneous flows like particle-laden turbulent channels near-wall particle clustering increases monotonically with particle size, for the examined flow over an obstacle, preferential concentration effects were stronger only for an intermediate range of Stokes numbers.     

Dynamic coupling of fluid and structural mechanics for simulating particle motion and interaction in high speed compressible gas particle laden flow

In this work, structural finite element analyses of particles moving and interacting within high speed compressible flow are directly coupled to computational fluid dynamics and heat transfer analyses to provide more detailed and improved simulations of particle laden flow under these operating conditions. For a given solid material model, stresses and displacements throughout the solid body are determined with the particle–particle contact following an element to element local spring force model and local fluid induced forces directly calculated from the finite volume flow solution. Plasticity and particle deformation common in such a flow regime can be incorporated in a more rigorous manner than typical discrete element models where structural conditions are not directly modeled. Using the developed techniques, simulations of normal collisions between two 1 mm radius particles with initial particle velocities of 50–150 m/s are conducted with different levels of pressure driven gas flow moving normal to the initial particle motion for elastic and elastic–plastic with strain hardening based solid material models. In this manner, the relationships between the collision velocity, the material behavior models, and the fluid flow and the particle motion and deformation can be investigated. The elastic–plastic material behavior results in post collision velocities 16–50% of their pre-collision values while the elastic-based particle collisions nearly regained their initial velocity upon rebound. The elastic–plastic material models produce contact forces less than half of those for elastic collisions, longer contact times, and greater particle deformation. Fluid flow forces affect the particle motion even at high collision speeds regardless of the solid material behavior model. With the elastic models, the collision force varied little with the strength of the gas flow driver. For the elastic–plastic models, the larger particle deformation and the resulting increasingly asymmetric loading lead to growing differences in the collision force magnitudes and directions as the gas flow strength increased. The coupled finite volume flow and finite element structural analyses provide a capability to capture the interdependencies between the interaction of the particles, the particle deformation, the fluid flow and the particle motion.     

Numerical simulation of gas–solid flow with two fluid model in a spouted-fluid bed

The flow characteristics in a spouted-fluid bed differ from those in spouted or fluidized beds because of the injection of the spouting gas and the introduction of a fluidizing gas. The flow behavior of gas–solid phases was predicted using the Eulerian–Eulerian two-fluid model (TFM) approach with kinetic theory for granular flow to obtain the flow patterns in spouted-fluid beds. The gas flux and gas incident angle have a significant influence on the porosity and particle concentration in gas–solid spouted-fluid beds. The fluidizing gas flux affects the flow behavior of particles in the fountain. In the spouted-fluid bed, the solids volume fraction is low in the spout and high in the annulus. However, the solids volume fraction is reduced near the wall.     

Two-fluid modeling of Geldart A particles in gas–solid micro-fluidized beds

The fluidization behavior of Geldart A particles in a gas–solid micro-fluidized bed was investigated by Eulerian–Eulerian numerical simulation. The commonly used Gidaspow drag model was tested first. The simulation showed that the predicted minimum bubbling velocities were significantly lower than the experimental data even when an extremely fine grid size (of approximately one particle diameter) was used. The modified Gibilaro drag model was therefore tested next. The predicted minimum bubbling velocity and bed voidage were in reasonable agreement with the experimental data available in literature. The experimentally observed regime transition phenomena from bubbling to slugging were also reproduced successfully in the simulations. Parametric studies indicated that the solid-wall boundary conditions had a significant impact on the predicted gas and solid flow behavior.     

Explosive dispersal of solid particles

Abstract. The rapid dispersal of inert solid particles due to the detonation of a heterogeneous explosive, consisting of a packed bed of steel beads saturated with a liquid explosive, has been investigated experimentally and numerically. Detonation of the spherical charge generates a blast wave followed by a complex supersonic gas-solid flow in which, in some cases, the beads catch up to and penetrate the leading shock front. The interplay between the particle dynamics and the blast wave propagation was investigated experimentally as a function of the particle size (100–925 m) and charge diameter (8.9–21.2 cm) with flash X-ray radiography and blast wave instrumentation. The flow topology during the dispersal process ranges from a dense granular flow to a dilute gas-solid flow. Difficulties in the modeling of the high-speed gas-solid flow are discussed, and a heuristic model for the equation of state for the solid flow is developed. This model is incorporated into the Eulerian two-phase fluid model of Baer and Nunziato (1986) and simulations are carried out. The results of this investigation indicate that the crossing of the particles through the shock front strongly depends on the charge geometry, the charge size and the material density of the particles. Moreover, there exists a particle size limit below which the particles cannot penetrate the shock for the range of charge sizes considered. Above this limit, the distance required for the particles to overtake the shock is not very sensitive to the particle size but remains sensitive to the particle material density. Overall, excellent agreement was observed between the experimental and computational results. Received 16 August 1999 / Accepted 26 June 2000     

Numerical study of concentrated fluid–particle suspension flow in a wavy channel

The particle migration effects and fluid–particle interactions occurring in the flow of highly concentrated fluid–particle suspension in a spatially modulated channel have been investigated numerically using a finite volume method. The mathematical model is based on the momentum and continuity equations for the suspension flow and a constitutive equation accounting for the effects of shear‐induced particle migration in concentrated suspensions. The model couples a Newtonian stress/shear rate relationship with a shear‐induced migration model of the suspended particles in which the local effective viscosity is dependent on the local volume fraction of solids. The numerical procedure employs finite volume method and the formulation is based on diffuse‐flux model. Semi‐implicit method for pressure linked equations has been used to solve the resulting governing equations along with appropriate boundary conditions. The numerical results are validated with the analytical expressions for concentrated suspension flow in a plane channel. The results demonstrate strong particle migration towards the centre of the channel and an increasing blunting of velocity profiles with increase in initial particle concentration. In the case of a stenosed channel, the particle concentration is lowest at the site of maximum constriction, whereas a strong accumulation of particles is observed in the recirculation zone downstream of the stenosis. The numerical procedure applied to investigate the effects of concentrated suspension flow in a wavy passage shows that the solid particles migrate from regions of high shear rate to low shear rate with low velocities and this phenomenon is strongly influenced by Reynolds numbers and initial particle concentration. Copyright © 2008 John Wiley & Sons, Ltd.     

Hydrodynamic and thermal fields analysis in gas-solid two-phase flow

The present work aims to investigate numerically the flowfield and heat transfer process in gas-solid suspension in a vertical pneumatic conveying pipe. The Eulerian-Lagrangian model is used to simulate the flow of the two-phases. The gas phase is simulated based on Reynolds Average Navier-Stokes equations (RANS) with low Reynolds number k-ε model, while particle tracking procedure is used for the solid phase. An anisotropic model is used to calculate the Reynolds stresses and the turbulent Prandtl number is calculated as a function of the turbulent viscosity. The model takes into account the lift and drag forces and the effect of particle rotation as well as the particles dispersion by turbulence effect. The effects of inter-particles collisions and turbulence modulation by the solid particles, i.e. four-way coupling, are also included in the model. Comparisons between different models for turbulence modulation with experimental data are carried out to select the best model. The model is validated against published experimental data for velocities of the two phases, turbulence intensity, solids concentration, pressure drop, heat transfer rates and Nusselt number distribution. The comparisons indicate that the present model is able to predict the complex interaction between the two phases in non-isothermal gas-solid flow in the tested range. The results indicate that the particle-particle collision, turbulence dispersion and lift force play a key role in the concentration distribution. In addition, the heat transfer rate increases as the mass loading ratio increases and Nusselt number increases as the pipe diameter increases.     

Two-phase flow laden with spherical particles in a microcapillary

Solid–liquid two-phase flow in a finite Reynolds number range (2 < Re < 12), transporting neutrally-buoyant microspheres with diameters of 6, 10, and 16 μm through a 260-μm microcapillary, is investigated. A standard microparticle-tracking velocimetry (μ-PTV) that consists of a double-pulsed Nd:YAG laser, an epi-fluorescent microscope, and a cooled-CCD camera is used to examine the flow. The solid particles are visualized in view of their spatial distributions. We observe a strong radial migration of the particles across the flow streamlines at substantially small Re. The degree of particle migration is presented in terms of probability density function. Some applications based on this radial migration phenomena are discussed in conjunction with particle separation/concentration in microfluidic devices, where the spatial distribution of particles is of great importance. In doing so, we propose a particle-trajectory function to empirically construct the spatial distribution of solid particles, which is well correlated with our experimental data. It is believed that this function provides a simple method for estimating the spatial distribution of particles undergoing radial migration in solid–liquid two-phase flows.     

Validation of a numerical model for the simulation of an electrostatic powder coating process

Numerical modeling of a complete powder coating process is carried out to understand the gas-particle two-phase flow field inside a powder coating booth and results of the numerical simulations are compared with experimental data to validate the numerical results. The flow inside the coating booth is modeled as a three-dimensional turbulent continuous gas flow with solid powder particles as a discrete phase. The continuous gas flow is predicted by solving Navier–Stokes equations using a standard k–ε turbulence model with non-equilibrium wall functions. The discrete phase is modeled based on a Lagrangian approach. In the calculation of particle propagation, a particle size distribution obtained through experiments is applied. The electrostatic field, including the effect of space charge due to free ions, is calculated with the use of the user defined scalar transport equations and user defined scalar functions in the software package, FLUENT, for the electrostatic potential and charge density.     

A Lagrangian–Eulerian model of particle dispersion in a turbulent plane mixing layer

A Lagrangian–Eulerian model for the dispersion of solid particles in a two‐dimensional, incompressible, turbulent flow is reported and validated. Prediction of the continuous phase is done by solving an Eulerian model using a control‐volume finite element method (CVFEM). A Lagrangian model is also applied, using a Runge–Kutta method to obtain the particle trajectories. The effect of fluid turbulence upon particle dispersion is taken into consideration through a simple stochastic approach. Validation tests are performed by comparing predictions for both phases in a particle‐laden, plane mixing layer airflow with corresponding measurements formerly reported by other authors. Even though some limitations are detected in the calculation of particle dispersion, on the whole the validation results are rather successful. Copyright © 2002 John Wiley & Sons, Ltd.     

Prediction of aggregation behavior of submicron-sized particles of praseodymium-doped zirconium silicate in aqueous suspension by population balance model

The aggregation behavior of submicron-sized particles of praseodymium-doped zirconium silicate, a ceramic pigment, in aqueous suspension was predicted by a modified population balance model. In the model, the collision frequencies were selected to describe evolution of the particle size distribution of the suspension. The collision efficiency was estimated as a function of interaction potential between particles based on Derjaguin–Landau–Verwey–Overbeek theory. The population balance model was modified to predict the stable state of the aggregation by introducing the volume mean size of aggregate to stability ratio. In addition, aggregation of the particles in aqueous suspension in the presence of sodium dodecyl benzene sulfonate or potassium chloride was experimentally investigated. The predicted data (i.e., the final aggregate size, aggregation rate, and particle size distribution) were similar to the experimental results.     

On the deposition of particles in liquid metals onto vertical ceramic walls

The deposition of non-metallic particles in liquid-metal flows is a serious industrial problem because the build-up of particles on ceramic walls clogs the flow path and interrupts the production, and this leads to large economic losses. This paper is an effort to extend the current state-of-the-art knowledge of particle deposition in air in order to predict particle deposition rates in liquid-metal flows using an improved Eulerian deposition model and considering Brownian and turbulent diffusion, turbophoresis and thermophoresis as transportation mechanisms. The model was used to predict the rate of deposition of particles in an air flow, and the predictions were compared to published measurements to demonstrate its performance. The model was then modified to take into account the differences in properties between air and liquid metals and thereafter applied to liquid-metal flows. Effects on the deposition rate of parameters such as steel flow rate, particle diameter, particle density, wall roughness and temperature gradient near the wall were investigated. It is shown that the steel flow rate has a very important influence on the rate of deposition of large particles, for which turbophoresis is the main deposition mechanism. For small particles, both wall roughness and thermophoresis have a significant influence on the particle deposition rate. Particle deposition rates under various conditions were successfully predicted.     

Modeling of aerated stirred tanks with shear-thinning power law liquids

Detailed simulations of aerated stirred tanks with shear-thinning power law liquids are presented. The lattice-Boltzmann scheme was used to discretize the filtered conservation equations of the liquid phase. The motion of bubbles was tracked based on the Euler–Lagrange approach with a bubble cluster concept. The collision, breakup and coalescence of bubbles were modeled as stochastic events. The predicted flow field of a single-phase stirred tank with shear-thinning power law liquid shows reasonable agreement with experimental data. For aerated systems, qualitatively similar gas holdup distribution was achieved when comparing the predicted result with experiments. Using the proposed modeling approach, it was found that a change in rheology alters the number mean diameter, Sauter diameter and the shape of bubble size distribution.     

An impedance probe for the measurements of liquid hold-up and mixing time in two/three-phase stirred tank reactors

A new probe based on the measurement of the electrical impedance has been developed to measure liquid hold-up in gas/liquid, solid/liquid and gas/solid/liquid stirred tank reactors. It allows measurements of liquid hold-up and mixing time to be made in stirred tanks. The main advantage of the new probe is that it is absolutely non-intrusive, because it uses the shaft and the baffles' support as electrodes, and that it can be used both for laboratory scale reactors as well as for industrial stirred tank reactors. The relation between impedance and liquid hold-up under loading conditions closely follows the predictions made by means of the Bruggeman model. Therefore, the new probe does not need any calibration, in that the liquid hold-up can be theoretically computed by the measurement of impedance. Received: 1 January 2000/Accepted: 8 March 2001