Melt-particle mixing in gas-stirred ladles with throughflow

An experimental study is performed on a gas-particle stirred ladle system with throughflow, using a simplified water model. Narrow ladles are used to produce 2-D flows. Flow visualization by the direct photographic method is employed to investigate the effects of ladle geometry, throughflow rate, air flow rate and its injection location on the melt-particle mixing performance. Image processing is applied to aid in determining the mixing performance. It is disclosed that an efficient mixing may be achieved if the gas at a higher flow rate is injected with particles through a nozzle near the bottom corner of the ladle wall on the melt inlet side. The mixing performance is better in a rectangular ladle (aspect ratio of 2) than in a square ladle (aspect ratio of unity). The effect of throughflow rate on mixing is minor. The study has an important application in manufacturing processes, such as continuous casting process, and materials processing.List of symbols AR aspect ratio - B width of water vessel, m - Bn Nozzle location on bottom surface of water vessel, m - H height of water vessel or height between bottom surface and free surface of water vessel, m - Hn Nozzle location on vertical (inlet side) surface of water vessel, m - Q _g volumetric rate of gas, m³/s - Q _l volumetric rate of water, m³/s - Q _s volumetric rate of particle, m³/s - x transverse coordinate, m - y longitudinal coordinate, m Visiting scholar on leave from the Mechanical Engineering Department, Kagoshima University, Japan     

Effects of hydrophilic particles on bubbly flow in slurry bubble column

To investigate the effects of hydrophilic particles on slurry bubble flows in a bubble column, distributions of the local gas holdup and the bubble frequency are measured using an electric conductivity probe. Particles are made of silica and their diameter is 100 μm. The particle volumetric concentration C_S is varied from 0 to 0.40. The measured data imply that the presence of particles promotes bubble coalescence. The film drainage time for two coalescing bubbles in a quasi two-dimensional bubble flow in a small vessel is also measured to quantitatively evaluate the particle effect on coalescence. A particle-effect multiplier is introduced into a coalescence efficiency model by taking into account the data of film drainage time and is implemented into a multi-fluid model. The main conclusions obtained are as follows: (1) the local gas holdup and bubble frequency in slurry bubble flows decrease with increasing the particle concentration, (2) the hydrophilic particles enhance bubble coalescence and the enhancement saturates at C_S ≃ 0.45, (3) the particle effect on coalescence is well accounted for by introducing the particle-effect multiplier to the film drainage time, and (4) the multi-fluid model can give good predictions for the distribution of the local gas holdup in the slurry bubble column.     

Bubbly jets in stagnant water

Air–water bubbly jets are studied experimentally in a relatively large water tank with a gas volume fraction, C_o, of up to 80% and nozzle Reynolds number, Re, ranging from 3500 to 17,700. Measurements of bubble properties and mean axial water velocity are obtained and two groups of experiments are identified, one with relatively uniform bubble sizes and another with large and irregular bubbles. For the first group, dimensionless relationships are obtained to describe bubble properties and mean liquid flow structure as functions of C_o and Re. Measurements of bubble slip velocity and estimates of the drag coefficient are also provided and compared to those for isolated bubbles from the literature. The study confirms the importance of bubble interactions to the dynamics of bubbly flows. Bubble breakup processes are also investigated for bubbly jets. It was found that a nozzle Reynolds number larger than 8000 is needed to cause breakup of larger bubbles into smaller bubbles and to produce a more uniform bubble size distribution. Moreover, the Weber number based on the mean water velocity appears to be a better criteria than the Weber number based on the bubble slip velocity to describe the onset of bubble breakup away from the nozzle, which occurs at a Weber number larger than 25.     

Horizontal bubble flow

An experimental investigation of cocurrent bubble flow in 0.0254 m and 0.0508 m diameter horizontal pipelines has been performed. Gas and liquid mass velocities ranged from 0.00955 to 0.675 and 2720 to 6040 kg/m² sec, respectively, and gas-phase holdups or void fractions ranged from 0.13 to 7.59%.High speed motion pictures revealed that the gas, introduced into the liquid with a concentric nozzle, emerged in the form of a rough jet which was ultimately sheared into 1 times; 10^minus;3 to 3 times; 10^minus;3m diameter bubbles. Approximately 4 meters downstream from the nozzle, a well developed bubble flow was observed where bubble number density and axial velocity were constant with respect to axial position in the pipeline. Bubble velocities ranged from 0.001 to 0.57 m/sec greater than the average liquid velocities. Bubble radial and circumferential spatial distributions were found to be a strong function of the degree of turbulence in the liquid phase. Because of these turbulent flow conditions, bubble shapes were much different than those of equivalent diameter bubbles rising in stagnant liquids. A sphere-ellipsoid of revolution model was developed for characterization of bubble shape and computation of gas-liquid interfacial area and two-phase pressure drop.     

Local gas and liquid phase velocity measurement in a miniature stirred vessel using PIV combined with a new image processing algorithm

A method which combines standard two-dimensional particle image velocimetry (PIV) with a new image processing algorithm has been developed to measure the average local gas bubble velocities, as well as the local velocities of the liquid phase, within small stirred vessel reactors. The technique was applied to measurements in a gas–liquid high throughput experimentation (HTE) vessel of 45 mm diameter, but it is equally suited to measurements in larger scale reactors. For the measurement of liquid velocities, 3 μm latex seeding particles were used. For gas velocity measurements, a separate experiment was conducted which involved doping the liquid phase with fluorescent Rhodamine dye to allow the gas–liquid interfaces to be identified. The analysis of raw PIV images enabled the detection of bubbles within the laser plane, their differentiation from obscuring bubbles in front of the laser plane, and their use in lieu of tracer particles for gas velocity analysis using cross-correlation methods. The accuracy of the technique was verified by measuring the velocity of a bubble rising in a vertical glass column. The new method enabled detailed velocity fields of both phases to be obtained in an air–water system. The overall flow patterns obtained showed a good qualitative agreement with previous work in large scale vessels. The downward liquid velocities above the impeller were greatly reduced by the addition of the gas, and significant differences between the flow patterns of the two-phases were observed.     

Experimental study on turbulent natural convection heat transfer in water with sub-millimeter-bubble injection

Using thermocouples and a particle tracking velocimetry technique, temperature and velocity measurements are conducted to investigate flow and heat transfer characteristics of turbulent natural convection from a vertical heated plate in water with sub-millimeter-bubble injection. Hydrogen-bubbles generated by the electrolysis of water are used as the sub-millimeter-bubbles. In the turbulent region, the heat transfer deterioration occurs for a bubble flow rate Q = 33 mm³/s, while the heat transfer enhancement occurs for Q = 56 mm³/s. Temperature and velocity measurements suggest that the former is caused by a delay of the transition due to the bubble-induced upward flow. On the other hand, the latter is mainly due to two factors: one is the enhancement of the rotation of eddies in the outer layer, and the other is the increase in the gradient of the streamwise liquid velocity at the heated wall. These are caused by bubbles, which are located in the inner layer, rising at high speed.     

Simultaneous PIV and pulsed shadow technique in slug flow: a solution for optical problems

A recent technique of simultaneous particle image velocimetry (PIV) and pulsed shadow technique (PST) measurements, using only one black and white CCD camera, is successfully applied to the study of slug flow. The experimental facility and the operating principle are described. The technique is applied to study the liquid flow pattern around individual Taylor bubbles rising in an aqueous solution of glycerol with a dynamic viscosity of 113×10^–3 Pa s. With this technique the optical perturbations found in PIV measurements at the bubble interface are completely solved in the nose and in annular liquid film regions as well as in the rear of the bubble for cases in which the bottom is flat. However, for Taylor bubbles with concave oblate bottoms, some optical distortions appear and are discussed. The measurements achieved a spatial resolution of 0.0022 tube diameters. The results reported show high precision and are in agreement with theoretical and experimental published data.Symbols D internal column diameter (m) - g acceleration due to gravity (m s^–2) - l _w wake length (m) - Q _v liquid volumetric flow rate (m³ s^–1) - r radial position (m) - r * radial position of the wake boundary (m) - R internal column radius (m) - U _s Taylor bubble velocity (m s^–1) - u _z axial component of the velocity (m s^–1) - u _r radial component of the velocity (m s^–1) - z distance from the Taylor bubble nose (m) - Z * distance from the Taylor bubble nose for which the annular liquid film stabilizes (m) Dimensionless groups Re Reynolds number ( ) - N _f inverse viscosity number ( ) Greek letters liquid film thickness (m) - liquid kinematic viscosity (m² s^–1) - liquid dynamic viscosity (Pa s) - liquid density (kg m^–3)     

Magnetic resonance imaging of velocity fields, the void fraction and gas dynamics in a cavitating liquid

In acoustic cavitation, the relationship between the bubble dynamics on the microscale and the flow properties on the macroscale is critical in determining sonochemical reaction kinetics. A new technique was developed to measure the void fraction and estimate water mobility in the vicinity of cavitating bubbles using phase-encoded magnetic resonance imaging with short characteristic measurement timescales (0.1–1 ms). The exponential behavior of the NMR signal decay indicated the fast diffusion regime, with the relationship between local mechanical dispersion D _mix and the average bubble radius R, D_mix >> \frac2R²10^-4s, D_{\rm mix}\gg \frac{2R^2}{10^{-4}\hbox{s}}, resulting in dispersion of orders of magnitude greater than diffusion in quiescent water. For two different samples (water and a surfactant solution), the independent measurements of three-dimensional void fraction and velocity fields permitted the calculation of compressibility, divergence and vorticity of the cavitating medium. The measured dynamics of the dissolved gas, compared with that of the surrounding liquid, reflected the difference in the bubble coalescence and lifetimes and correlated with the macroscopic flow parameters.     

Bubble formation in co-fed gas–liquid flows in a rotor-stator spinning disc reactor

The gas–liquid flow in a rotor-stator spinning disc reactor, with co-feeding of gas and liquid, is studied for high gas volumetric throughflow rates and high gas/liquid volumetric flow ratios. High speed imaging and spectral analysis of pressure drop signals are employed to analyse the flow. Two mechanisms of bubble formation are observed, one due to gas overpressure leading to large irregular bubbles, and one due to liquid turbulent vortices leading to small, well-defined bubbles. The two mechanisms lead to three distinct gas dispersion regimes, distinguished by their characteristic oscillations in pressure drop. At low rotational Reynolds numbers (Re_ω < 0.4 · 10⁶), in the gas spillover regime, the gas is dispersed as large bubbles only. Above this critical Re_ω, small bubbles are sheared off as well, thus forming a heterogeneous dispersion. At sufficiently high Re_ω, depending on the gas flow rate, the gas is homogeneously dispersed as small bubbles. The maximum gas flow that can be dispersed as small bubbles is linearly proportional to the local energy dissipation rate. The understanding of the bubble formation mechanisms and pressure signature allows prediction and detection of the prevailing hydrodynamic regime in scaled up spinning disc reactors and for different reaction fluids.     

Heat transfer and hydrodynamic studies on two- and three-phase fluidized beds of floating bubble breakers

Heat transfer characteristics in three-phase fluidized beds of floating bubble breakers have been studied in a 0.142 m I.D. x 2.0 m high Plexiglas column fitted with an axially mounted cylindrical heater.Effects of the liquid and gas velocities, the particle size, the volume ratio of floating bubble breaker to particles on phase holdup, the vertical bubble length, and the heat transfer coefficient have been determined.In the bubble-coalescing regime, the heat transfer coefficient in three-phase fluidized beds having the volume ratio V_f/V_s of 10–15% produced a maximum increase in heat transfer coefficient of about 20% in comparison to that in the bed without floating bubble breakers. Also, bubble length and gas-phase holdups exhibited their maximum and minimum values at a volume ratio of 10–15%. The heat transfer coefficient in three-phase fluidized beds of floating bubble breakers can be estimated from the surface renewal model with isotropic turbulence theory.Heat transfer coefficients expressed in terms of the Nusselt number have been correlated with the particle Reynolds number and the volume ratio of floating bubble breakers to particles.     

环形喷管喷口气泡演化的实验研究

水下气泡的发展演化及气泡动力学行为是气液两相动力学的基础理论与水下射流应用的重要基础. 环形喷管/喷口形成的气泡及气体射流具有其不同于圆孔实心射流的特殊表现与规律机制,随着同心筒破水发射等特殊应用的出现,环形喷口气体射流/泡流的基础现象观测和机制分析成为迫切的需求. 基于环形喷管的设计和水下射流条件的分析,设计建立了一套环形喷管水箱实验系统,对水下环形喷管喷口气泡发展演化过程进行了初步的实验研究. 为观测研究气体通过环形喷管气泡生长发展过程,在较低压力、较低流速下,采用高速摄影仪记录气泡生长及发展演化过程. 结合对气泡发展演化过程的图像处理与分析,研究分析了环形喷口气泡形成区制、气泡生长过程形态发展特点、以及气泡形成时间及气泡体积变化特点. 研究表明:在本实验气体流量范围内(50.8~237.3 dm3/min),环形喷口气泡发展演化过程呈现较为明显的三周期区制,前泡尾流影响是环形气泡呈三周期区制的主要原因;不同周期内的气泡形成时间具有较稳定规律,并受到流量影响;气泡生长过程中有较为明显的下沉、回升特征;气泡表面张力、液体惯性与流动的共同作用,造成了典型的气泡顶部坍塌现象.      

The minimum in-line coalescence height of bubbles in non-Newtonian fluid

The minimum in-line coalescence height of bubbles generated from a submerged nozzle was investigated experimentally in shear thinning non-Newtonian fluid at lower Reynolds number (2∼60). Carboxymethyl cellulose sodium (CMC) aqueous solution and carbon dioxide were used as the liquid phase and the gas phase, respectively. The process of the formation, movement and in-line coalescence of bubbles was visualized and recorded by a high-speed digital camera. The influences of bubble size, bubble generation frequency and liquid property on the minimum in-line coalescence height of bubbles were investigated by changing nozzle diameter, gas flow rate and the mass concentration of CMC aqueous solutions. For a given liquid, the generating frequency and size of bubbles increased but the minimum coalescence height of in-line bubbles decreased when the nozzle diameter and gas flow rate were increased. When the nozzle diameter and gas flow rate were fixed, the shear-thinning effect of CMC aqueous solution became stronger with increasing CMC mass concentration, which led to the increase in both the terminal rise velocity and average acceleration of the trailing bubble, consequently, the minimum in-line coalescence height of bubbles decreased. An empirical correlation for estimating the minimum in-line bubble coalescence height was proposed, the calculating values accords well with experimental data with a mean relative deviation only 7.6%.     

On two-phase flow patterns and transition criteria in aqueous methanol and CO2 mixtures in adiabatic,rectangular microchannels

This paper presents flow map investigations of adiabatic two-phase flow in square cross-sectioned, 200 μm deep microchannels fabricated in silicon, employing laser induced fluorescence microscopy. The influence of surface tension and nozzle geometry on the flow pattern transition was investigated using two nozzle widths (orifices of 30 μm and 50 μm, respectively) and methanol–water solutions with CO₂ as the gas phase. It was found and quantified that smaller nozzle geometries and smaller liquid surface tension promote the propagation of capillary gas bubbles at lower superficial gas and liquid velocities. Within the measurement domain of superficial gas (0.01–0.625 m/s) and liquid (0.0005–0.5000 m/s) velocities, we observed dispersed bubbly, regularly ordered bubbly, wedging, slug and annular flows, thus extending the experimental knowledge base to smaller superficial liquid velocities by almost two orders of magnitude. With the help of the flow maps presented herein, we were able to characterize the observed regularly ordered bubbly flow as the transition regime between dispersed bubbly and wedging flow. The results of the present investigation are of direct relevance to the operation of small-scale direct methanol fuel cells.     

A simplified model of bubble-driven flow in an axisymmetric container

A simplified mathematical model simulating a gas bubble agitation system is here examined for the case when the orifice is located at the centre of the base of a cylindrical vessel. The two phase flow which is confined to a cone region is approximated by the drift flux model. The governing equations for the recirculating liquid flow are quai-linearized and the flow domain is transformed by a simple transformation into a cylindrical region. Using standard finite difference techniques numerical solutions are obtained for Reynolds numbers in the range 0–10⁴; Re=U ₀ R ₀/ _eff, where R ₀ is the radius of the vessel, U ₀ the velocity of injection of the gas, the density of the liquid phase & _eff the constant effective turbulent viscosity. For large Re it is shown that the primary recirculating flow is confined to a narrow region adjacent to the two phase/liquid interface.     

Dual characters of interaction between particles and fluid

The unique characteristics of gas-solids two-phase flow and fluidization in terms of the flow structures and the apparent behavior of particles and fluid-particle interactions are closely linked to physical properties of the particles, operating conditions and bed configurations. Fluidized beds behave quite differently when solid properties, gas velocities or vessel geometries are varied. An understanding of hydrodynamic changes and how they, in turn, influence the transfer and reaction characteristics of chemical and thermal operations by variations in gas-solid contact, residence time, solid circulation and mixing and gas distribution is very important for the proper design and scale-up of fluidized bed reactors. In this paper, rather than attempting a comprehensive survey, we concentrate on examining some important positive and negative impacts of particle sizes, bubbles, clusters and column walls on the physical and chemical aspects of chemical reactor performance from the engineering application point of view with the aim of forming an adequate concept for guiding the design of multiphase fluidized bed chemical reactors.One unique phenomenon associated with particle size is that fluidized bed behavior does not always vary monotonically with changing the average particle size. Different behaviors of particles with difference sizes can be well understood by analyzing the relationship between particle size and various forces. For both fine and coarse particles, too narrow a distribution is generally not favorable for smooth fluidization. A too wide size distribution, on the other hand, may lead to particle segregation and high particle elutriation. Good fluidization performance can be established with a proper size distribution in which inter-particle cohesive forces are reduced by the lubricating effect of fine particles on coarse particles for Type A, B and D particles or by the spacing effect of coarse particles or aggregates for Type C powders.Much emphasis has been paid to the negative impacts of bubbles, such as gas bypassing through bubbles, poor bubble-to-dense phase heat & mass transfer, bubble-induced large pressure fluctuations, process instabilities, catalyst attrition and equipment erosion, and high entrainment of particles induced by erupting bubbles at the bed surface. However, it should be noted that bubble motion and gas circulation through bubbles, together with the motion of particles in bubble wakes and clouds, contribute to good gas and solids mixing. The formation of clusters can be attributed to the movement of trailing particles into the low-pressure wake region of leading particles or clusters. On one hand, the existence of down-flowing clusters induces strong solid back-mixing and non-uniform radial distributions of particle velocities and holdups, which is undesirable for chemical reactions. On the other hand, the formation of clusters creates high solids holdups in the riser by inducing internal solids circulations, which are usually beneficial for increasing concentrations of solid catalysts or solid reactants.Wall effects have widely been blamed for complicating the scale-up and design of fluidized-bed reactors. The decrease in wall friction with increasing the column diameter can significantly change the flow patterns and other important characteristics even under identical operating conditions with the same gas and particles. However, internals, which can be considered as a special wall, have been used to improve the fluidized bed reactor performance.Generally, desirable and undesirable dual characteristics of interaction between particles and fluid are one of the important natures of multiphase flow. It is shown that there exists a critical balance between those positive and negative impacts. Good fluidization quality can always be achieved with a proper choice of right combinations of particle size and size distribution, bubble size and wall design to alleviate the negative impacts.     

Direct Observation of Trapped Gas Bubbles by Capillarity in Sandy Porous Media

We investigated the mechanism of residual gas trapping at a microscopic level. We imaged trapped air bubbles in a Berea sandstone chip after spontaneous imbibition at atmospheric pressure. The pore structure and trapped bubbles were observed by microfocused X-ray computed tomography. Distributions of trapped bubbles in Berea and Tako sandstone were imaged in coreflooding at a capillary number of 1.0 × 10⁻⁶. Trapped bubbles are of two types, those occupying the center of the pore with a pore-scale size and others having a pore-network scale size. In low-porosity media such as sandstone, connected bubbles contribute greatly to trapped gas saturation. Effects of capillary number and injected water volume were investigated using a packed bed of glass beads 600μm in diameter, which had high porosity (38%). The trapped N₂ bubbles are stable against the water flow rate corresponding to a capillary number of 1.0 × 10⁻⁴.     

Optimization of a pyrotechnic igniter with the release of reactive particles

This paper deals with the effects of reactive particles on the performance of a pyrotechnic igniter. These particles are placed on the inner surface of a flash tube, released into the main flow of the gas and ignited by the passage of one of the two discontinuities (the shock wave or the contact surface). Two particle sizes have been studied (3m and 10m). It is shown that the best performance is achieved with small particles released into the flow by the shock wave. Another focal point of this study is the combining of two fundamentally different methods to calculate the two phase flow.Nomenclature a₀ sound speed in region 0 - a₂ sound speed in region 2 - C _D drag coefficient - d average particle diameter - d rate change of the particle diameter - e _g total internal energy of the gas - e _s particle internal energy=C ₃ T _s - F drag force - rn mass flow rate - Mo _c shock wave Mach number - N particle number desity - N _u Nusselt number - P pressure - P ₀ pressure in region 0 - P ₂ pressure in region 2 - P _r Prandtl number - Q heat convection - R _e Reynolds number - T _g gas temperature - T _s particle temperature - u ₂ velocity in region 2 - u _g gas velocity - u _s barycentric velocity of the particles - ratio of specific heats - _g thermal conductivity of the gas - _g gas dynamic viscosity - _g gas density - _s apparent density of the particles - _s true density of the particles - defined by (8) This article was processed using Springer-Verlag T_EX Shock Waves macro package 1990.     

Modeling of bubble detachment in reduced gravity under the influence of electric fields and experimental verification

A simple model for predicting bubble volume and shape at detachment in reduced gravity under the influence of electric fields is described in the paper. The model is based on relatively simple thermodynamic arguments and relies on and combines several models described in the literature. It accounts for the level of gravity and the magnitude of the electric field. For certain conditions of bubble development the properties of the bubble source are also considered. Computations were carried out for a uniform unperturbed electric field for a range of model parameters, and the significance of model assumptions and simplifications is discussed for the particular method of bubble formation. Experiments were conducted in terrestrial conditions and reduced gravity (during parabolic flights in NASAs KC-135 aircraft) by injecting air bubbles through an orifice into the electrically insulating working fluid, PF5052. Bubble shapes visualized experimentally were compared with model predictions. Measured data and model predictions show good agreement. The results suggest that the model can provide quick engineering estimates concerning bubble formation for a range of conditions (both for formation at an orifice and boiling) and such a model reduces the need for complex and expensive numerical simulations for certain applications. a Major axis of spheroid (m) - a _m Measured bubble height (m) - b Minor axis of spheroid (m) - b _m Measured bubble width (m) - A, B, C, F Parameters of the Kumar-Kuloor model - a/b Computed aspect ratio - a _m /b _m Measured aspect ratio - D Orifice diameter (m) - E Magnitude of the electric field (V/m) - g Gravitational acceleration (m/s²) - g _t Terrestrial gravity (g _t = 9.81 m/s²) - N _w Electrical Weber number - p Pressure (Pa) - Q Volume flow rate (m³/s) - r Radius of the spherical bubble (m) - R Radius of curvature at the tip of the bubble (m) - t Time (s) - t Time interval (s) - T Temperature (°C) - U Electrical potential (V) - u Velocity (m/s) - V Volume (m³) - x, y Dimensionless coordinates of the Cartesian coordinate system - x, y Scaled coordinates, Cheng-Chaddock model - X, Y Dimensional coordinates of the Cartesian coordinate system - Characteristic wave number (m^–1) - Eötvös number - Absolute dielectric permittivity (F/m) - Contact angle (deg.) - Gibbs free energy (J) - Surface tension (N/m) - Dynamic viscosity (Pa s) - Density (kg/m³) - cr Critical value - d Detachment - eq Equilibrium - g Gas - K Refers to the Kumar-Kuloor model - l Liquid - m Measured value - t Terrestrial