偏心搅拌槽内宏观不稳定性的分离涡模拟及实验研究
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摘要
搅拌是过程工业中常见的单元操作之一,在化工、食品、生物、制药等行业中的应用非常广泛。搅拌涉及到物料的混合、传热、传质、化学反应等操作,对槽内流场的研究是分析这些过程的基础。搅拌槽内流体的流动是一个高度复杂的、非稳态的过程,存在一种大尺度、低频率的流型变化现象,即宏观不稳定性,该现象对搅拌槽内的混合、传热、传质等过程有重要的影响,引起人们的高度重视。本文采用数值模拟和实验测试相结合的方法对偏心搅拌槽内的宏观不稳定性频率进行了研究,分析了宏观不稳定性对偏心搅拌槽内混合过程的影响。
基于分离涡模型建立了搅拌数值模拟方法,对搅拌槽内的三维流场和混合过程进行了数值研究。分析了搅拌槽内流体的速度和湍动能分布以及功率消耗情况,并将分离涡模拟结果与LDV实验结果、大涡模拟结果和雷诺应力模拟结果进行了对比。结果证明分离涡模拟与实验结果吻合较好,能准确捕捉搅拌槽内流体的时均特征和非稳态流动特征,对湍动能及功率消耗的模拟结果也很好,具有和大涡模型相近的模拟精度,且计算量小,约为大涡模型计算量的80%。混合过程的模拟结果表明,分离涡模型对混合时间模拟精度远高于雷诺时均法,与实验值吻合较好,说明该模型也适用于搅拌槽内混合过程的模拟。
利用基于分离涡模型的搅拌数值模拟方法对中心搅拌槽内的宏观不稳定性进行了研究,分析了层流、过渡流和湍流三种不同流动状态下的宏观不稳定性频率,并与大涡模拟及LDV实验结果进行了对比,结果吻合较好。研究发现,不同流动状态下的宏观不稳定性频率不一样,层流和湍流状态下各存在一个单一频率值,而过渡流时存在两个频率值,分别与层流和湍流时的宏观不稳定性频率值相接近。相比之下,层流状态下的宏观不稳定性频率比湍流状态时大,表明层流状态下中心搅拌槽内的宏观不稳定现象比湍流状态时明显。分离涡模拟结果与文献结果吻合较好,说明可以采用分离涡模型研究搅拌槽内的宏观不稳定性。
建立了偏心搅拌的分离涡数值模拟方法,对偏心搅拌槽内的宏观不稳定性进行了数值模拟和PIV实验测量,对不同工况时的宏观不稳定性进行了可视化实验和频谱分析。结果发现,PIV实验结果与分离涡模拟结果吻合较好,都表明偏心搅拌时的宏观不稳定性频率主要在0.1～0.2 Hz范围内,约比中心搅拌时的宏观不稳定性频率高一个数量级,说明偏心搅拌时的宏观不稳定现象比中心搅拌时明显。对不同偏心率、雷诺数和桨径比时偏心搅拌槽内宏观不稳定性频率的研究发现,偏心搅拌时的宏观不稳定性频率随偏心率的增大而减小,高转速时偏心搅拌槽内的宏观不稳定性频率大,此外,桨径比对偏心搅拌槽内的宏观不稳定频率也有很大的影响,频率值随桨径比的增大而增大。
采用雷诺时均法和基于分离涡模型建立的偏心搅拌数值模拟方法研究了偏心搅拌槽内的混合过程,对涡内和涡外两种加料位置时的混合时间做了对比,并与实验结果进行了比较。研究表明,分离涡模拟结果与实验结果吻合较好,与大涡模拟的精度相当,而雷诺时均结果与实验结果之间的偏差则高达60%。对涡内和涡外两种加料位置时混合时间的对比表明,宏观不稳定性对偏心搅拌槽内的混合过程有很大的影响,涡内加料时能缩短混合时间约12%～16%,这说明充分利用宏观不稳定性可以加快搅拌槽内的混合过程,提高混合效率。
Stirring has been recognized as a common unit operation in process industry and has numerous applications in chemical engineering, food processes, biological fermentations, pharmaceutical engineering, etc. Stirring involved in the mixing, heat and mass transfer, chemical reactions and other processes. Investigation on the internal flow field of the stirred tank is of great importance to study these processes. The fluid flow in stirred tank is highly complicated and transient. Besides, there is macroinstability (MI), which is essentially a kind of large-scale, low-frequency (large-scale is referred to the replacements of flow pattern and low-frequency means the period of each flow pattern is longer than the time of one rotation of impeller) temporal mean flow variation phenomenon. MI significantly affects the mixing performance of stirred tanks and accordingly has attracted more and more attention. In this paper, the MI in the eccentrically stirred tank was studied by the combination of the computational fluid dynamics (CFD) and experimental methods. The influence of MI on the mixing process in the eccentrically stirred tank was also investigated.
The numerical simulation method of the stirred tank was firstly established based on the detached eddy simulation (DES) model and the three-dimensional flow fields as well as the mixing processes in stirred tanks were numerically investigated. The velocity and turbulent kinetic energy distributions as well as the power consumption of the stirred tank were mainly investigated and the numerical results were compared with the laser doppler velocimetry (LDV), large eddy simulation (LES) and Reynolds stress model (RSM) results. It was found that there were good agreements between the DES and LDV results, indicating that the DES model can capture the mean and instantaneous flow characteristics in the stirred tank accurately. The simulation results of the turbulent kinetic energy and turbulent kinetic energy dissipation were also satisfactory. The comparisons with the LES model showed that DES model can simulate the flow at less computational cost (about 80% of the LES model) as well as with nearly the same accuracy. Besides, numerical results of the mixing time obtained by the DES model were in good agreements with the experimental data, while the results from the Reynolds-averaged Navier-Stokes (RANS) method were not so good. The results showed that the DES model has higher accuracy than the RANS model, and can be used to simulate the mixing process in stirred tanks.
The MI in the centrically stirred tank was numerically studied by the numerical simulation method established based on the DES model. The MI frequencies in the laminar, transitional and turbulent regimes were studied. The results were compared with the LES and LDV results and good agreements were observed. It was found that the MI frequencies in the centrically stirred tank under different flow regimes are not the same. There is a single MI frequency under the laminar and turbulent flow regimes, respectively. However, there are two MI frequencies under the transitional flow regime, which are nearly the same as the values observed under the laminar and turbulent flow regimes. By comparison, the value under the laminar flow regime is larger than that under the turbulent flow regime, which shows that the MI phenomenon under laminar flow regime is more obvious. The good agreements between the DES and literature results show that the macroinstability in stirred tanks can be investigated by the DES model accurately.
The numerical simulation method of the eccentric stirred tank was then established based on the DES model. The macroinstability in the eccentrically stirred tank was studied by the numerical and PIV experimental method. The visualization analyses of the MI vortex under different operation conditions were presented and the frequency analyses were applied to the velocity recordings obtained by PIV measurements. The PIV experimental results were compared with the DES results and good agreements were observed. The MI frequency in eccentrically stirred tank was found in the range of 0.1～0.2 Hz, which is about 10 times larger than that of the centrically stirred tank. Accordingly, it can be concluded that the MI phenomenon in eccentrically stirred tank is more obvious. The influence of eccentricity, Reynolds number and impeller-tank diameter ratio were mainly discussed. It was found that the MI frequency increases with reducing the eccentricity or increasing the impeller rotational speed. Besides, there was great influence of the impeller-tank diameter ratio on the MI frequency. A positive linear correlation can be observed, which means higher ratio corresponding to a higher MI frequency.
The influence of MI on the mixing process in eccentrically stirred tanks was also investigated by the RANS and DES model. The differences between the mixing times obtained when the tracer was added either inside or outside the processing MI vortex were studied. The DES results were compared with the experimental data and good agreements were observed. The accuracy of DES model is nearly the same with that of the LES model, while the discrepancy between the RANS and experimental results is as high as 60%. The comparison between the mixing times obtained inside and outside the MI vortex indicates that, in the cases studied in this paper, the in-vortex insertion can result in a mixing time reduction of 12%～16%. Results show that the presence of MI in the stirred tank has beneficial implications for mixing operations. The MI phenomenon should be made full use to speed up the mixing process and accordingly improve the mixing efficiency.
基于分离涡模型建立了搅拌数值模拟方法,对搅拌槽内的三维流场和混合过程进行了数值研究。分析了搅拌槽内流体的速度和湍动能分布以及功率消耗情况,并将分离涡模拟结果与LDV实验结果、大涡模拟结果和雷诺应力模拟结果进行了对比。结果证明分离涡模拟与实验结果吻合较好,能准确捕捉搅拌槽内流体的时均特征和非稳态流动特征,对湍动能及功率消耗的模拟结果也很好,具有和大涡模型相近的模拟精度,且计算量小,约为大涡模型计算量的80%。混合过程的模拟结果表明,分离涡模型对混合时间模拟精度远高于雷诺时均法,与实验值吻合较好,说明该模型也适用于搅拌槽内混合过程的模拟。
利用基于分离涡模型的搅拌数值模拟方法对中心搅拌槽内的宏观不稳定性进行了研究,分析了层流、过渡流和湍流三种不同流动状态下的宏观不稳定性频率,并与大涡模拟及LDV实验结果进行了对比,结果吻合较好。研究发现,不同流动状态下的宏观不稳定性频率不一样,层流和湍流状态下各存在一个单一频率值,而过渡流时存在两个频率值,分别与层流和湍流时的宏观不稳定性频率值相接近。相比之下,层流状态下的宏观不稳定性频率比湍流状态时大,表明层流状态下中心搅拌槽内的宏观不稳定现象比湍流状态时明显。分离涡模拟结果与文献结果吻合较好,说明可以采用分离涡模型研究搅拌槽内的宏观不稳定性。
建立了偏心搅拌的分离涡数值模拟方法,对偏心搅拌槽内的宏观不稳定性进行了数值模拟和PIV实验测量,对不同工况时的宏观不稳定性进行了可视化实验和频谱分析。结果发现,PIV实验结果与分离涡模拟结果吻合较好,都表明偏心搅拌时的宏观不稳定性频率主要在0.1～0.2 Hz范围内,约比中心搅拌时的宏观不稳定性频率高一个数量级,说明偏心搅拌时的宏观不稳定现象比中心搅拌时明显。对不同偏心率、雷诺数和桨径比时偏心搅拌槽内宏观不稳定性频率的研究发现,偏心搅拌时的宏观不稳定性频率随偏心率的增大而减小,高转速时偏心搅拌槽内的宏观不稳定性频率大,此外,桨径比对偏心搅拌槽内的宏观不稳定频率也有很大的影响,频率值随桨径比的增大而增大。
采用雷诺时均法和基于分离涡模型建立的偏心搅拌数值模拟方法研究了偏心搅拌槽内的混合过程,对涡内和涡外两种加料位置时的混合时间做了对比,并与实验结果进行了比较。研究表明,分离涡模拟结果与实验结果吻合较好,与大涡模拟的精度相当,而雷诺时均结果与实验结果之间的偏差则高达60%。对涡内和涡外两种加料位置时混合时间的对比表明,宏观不稳定性对偏心搅拌槽内的混合过程有很大的影响,涡内加料时能缩短混合时间约12%～16%,这说明充分利用宏观不稳定性可以加快搅拌槽内的混合过程,提高混合效率。
Stirring has been recognized as a common unit operation in process industry and has numerous applications in chemical engineering, food processes, biological fermentations, pharmaceutical engineering, etc. Stirring involved in the mixing, heat and mass transfer, chemical reactions and other processes. Investigation on the internal flow field of the stirred tank is of great importance to study these processes. The fluid flow in stirred tank is highly complicated and transient. Besides, there is macroinstability (MI), which is essentially a kind of large-scale, low-frequency (large-scale is referred to the replacements of flow pattern and low-frequency means the period of each flow pattern is longer than the time of one rotation of impeller) temporal mean flow variation phenomenon. MI significantly affects the mixing performance of stirred tanks and accordingly has attracted more and more attention. In this paper, the MI in the eccentrically stirred tank was studied by the combination of the computational fluid dynamics (CFD) and experimental methods. The influence of MI on the mixing process in the eccentrically stirred tank was also investigated.
The numerical simulation method of the stirred tank was firstly established based on the detached eddy simulation (DES) model and the three-dimensional flow fields as well as the mixing processes in stirred tanks were numerically investigated. The velocity and turbulent kinetic energy distributions as well as the power consumption of the stirred tank were mainly investigated and the numerical results were compared with the laser doppler velocimetry (LDV), large eddy simulation (LES) and Reynolds stress model (RSM) results. It was found that there were good agreements between the DES and LDV results, indicating that the DES model can capture the mean and instantaneous flow characteristics in the stirred tank accurately. The simulation results of the turbulent kinetic energy and turbulent kinetic energy dissipation were also satisfactory. The comparisons with the LES model showed that DES model can simulate the flow at less computational cost (about 80% of the LES model) as well as with nearly the same accuracy. Besides, numerical results of the mixing time obtained by the DES model were in good agreements with the experimental data, while the results from the Reynolds-averaged Navier-Stokes (RANS) method were not so good. The results showed that the DES model has higher accuracy than the RANS model, and can be used to simulate the mixing process in stirred tanks.
The MI in the centrically stirred tank was numerically studied by the numerical simulation method established based on the DES model. The MI frequencies in the laminar, transitional and turbulent regimes were studied. The results were compared with the LES and LDV results and good agreements were observed. It was found that the MI frequencies in the centrically stirred tank under different flow regimes are not the same. There is a single MI frequency under the laminar and turbulent flow regimes, respectively. However, there are two MI frequencies under the transitional flow regime, which are nearly the same as the values observed under the laminar and turbulent flow regimes. By comparison, the value under the laminar flow regime is larger than that under the turbulent flow regime, which shows that the MI phenomenon under laminar flow regime is more obvious. The good agreements between the DES and literature results show that the macroinstability in stirred tanks can be investigated by the DES model accurately.
The numerical simulation method of the eccentric stirred tank was then established based on the DES model. The macroinstability in the eccentrically stirred tank was studied by the numerical and PIV experimental method. The visualization analyses of the MI vortex under different operation conditions were presented and the frequency analyses were applied to the velocity recordings obtained by PIV measurements. The PIV experimental results were compared with the DES results and good agreements were observed. The MI frequency in eccentrically stirred tank was found in the range of 0.1～0.2 Hz, which is about 10 times larger than that of the centrically stirred tank. Accordingly, it can be concluded that the MI phenomenon in eccentrically stirred tank is more obvious. The influence of eccentricity, Reynolds number and impeller-tank diameter ratio were mainly discussed. It was found that the MI frequency increases with reducing the eccentricity or increasing the impeller rotational speed. Besides, there was great influence of the impeller-tank diameter ratio on the MI frequency. A positive linear correlation can be observed, which means higher ratio corresponding to a higher MI frequency.
The influence of MI on the mixing process in eccentrically stirred tanks was also investigated by the RANS and DES model. The differences between the mixing times obtained when the tracer was added either inside or outside the processing MI vortex were studied. The DES results were compared with the experimental data and good agreements were observed. The accuracy of DES model is nearly the same with that of the LES model, while the discrepancy between the RANS and experimental results is as high as 60%. The comparison between the mixing times obtained inside and outside the MI vortex indicates that, in the cases studied in this paper, the in-vortex insertion can result in a mixing time reduction of 12%～16%. Results show that the presence of MI in the stirred tank has beneficial implications for mixing operations. The MI phenomenon should be made full use to speed up the mixing process and accordingly improve the mixing efficiency.
引文
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