Mixing dynamics in uncovered unbaffled stirred tanks

Abstract The present work is aimed at providing experimental information on mixing rates in an unbaffled vessel under free surface vortexing conditions. The planar laser induced fluorescence (PLIF) technique was used for measuring the dispersion dynamics of a passive tracer over a vertical section of the vessel. In agreement with the quite scant literature information available for these systems, results confirm the existence of two well defined, partially segregated, zones that give rise to a double mixing dynamics behavior. A suitable mixing time definition is proposed and applied to a number of experimental runs with different stirrer geometries and agitation speeds. Results confirm that…

A NOVEL TECHNIQUE FOR MEASURING LOCAL BUBBLE SIZE DISTRIBUTION

A novel experimental technique for measuring the local gas hold-up and the statistical distribution of local bubble size, is proposed. The technique is based on laser sheet illumination of the gas-liquid dispersion and synchronized camera, i.e. on equipment typically available in PIV set-ups. The liquid phase is made fluorescent by a suitable dye, and a band-pass optical filter is placed in front of the camera optics, in order to allow only fluoresced light to reach the camera CCD. In this way bubbles intercepted by the laser sheet are clearly identified thanks to the neat shade resulting in the images. This allows excluding from subsequent analysis all bubbles visible in the images but not…

Mass transfer and hydrodynamic characteristics of unbaffled stirred bio-reactors: Influence of impeller design

Abstract Unbaffled stirred tanks are increasingly recognized as a viable alternative to common baffled tanks for a range of processes where the presence of baffles is undesirable for some reason. For instance, in the case of shear sensitive cell cultivation (e.g. human cells), unbaffled tanks have been recently found to be able to provide sufficient mass transfer through the free surface vortex. As a consequence the need for bubble formation and subsequent bursting, along with relevant cells damage, is conveniently avoided. In this work the influence of impeller geometry on mass transfer performance and power demand of an unbaffled stirred vessel operating both in sub-critical conditions (t…

Modeling and simulation of dense cloud dispersion in urban areas by means of computational fluid dynamics

Abstract The formation of toxic heavy clouds as a result of sudden accidental releases from mobile containers, such as road tankers or railway tank cars, may occur inside urban areas so the problem arises of their consequences evaluation. Due to the semi-confined nature of the dispersion site simplified models may often be inappropriate. As an alternative, computational fluid dynamics (CFD) has the potential to provide realistic simulations even for geometrically complex scenarios since the heavy gas dispersion process is described by basic conservation equations with a reduced number of approximations. In the present work a commercial general purpose CFD code (CFX 4.4 by Ansys®) is employe…

CFD prediction of bubbles local gas hold-up in 2-dimensional gas-solid fluidized beds

ADVANCED STATISTICAL ANALYSIS OF LOCAL BUBBLE SIZE DISTRIBUTIONS IN 2D GAS FLUIDIZED BEDS

The principal difficulty in analysing fluidization quality and bubble dynamics is related to the possibility of measuring or predicting the physical and geometrical properties of gas bubbles rising in a granular medium. Even the development of detailed experimental correlations gives poor results, being necessary a fully statistical approach. On the above basis, the present work focuses on the statistical analysis of the behaviour of a 2-D fluidized bed operating under bubbling and slugging conditions, performing measurements of Local Bubble Size Distributions (BSD) along the bed. The analysis allowed to observe a characteristic bimodal shape of BSDs for different particles dimension and fl…

Analysis of bubbling fluidization dynamics

Experimental Analysis of bubbling dynamics in bidisperse gas-solid 2D fluidized beds

Modelling and Simulation of Gas–liquid Hydrodynamics in a Rectangular Air-lift Reactor

Abstract Computational Fluid Dynamics is a quite well established tool for carrying out realistic simulations of process apparatuses. However, as a difference from single phase systems, for multiphase systems the development of CFD models is still in progress. Among the two-phase systems, gas–liquid systems are characterised by an additional complexity level, related to the fact that bubble sizes are not known in advance, being rather the result of formation and breakage-coalescence dynamics and therefore of complex phenomena related to flow dynamics and interfacial effects. In the present work, Euler–Euler Reynolds-averaged flow simulations of an air-lift reactor are reported. All bubbles …

Modeling of Magnetic-Field-Assisted Fluidization: Model Development and CFD Simulation of Magnetically Stabilized Fluidized Beds

Magnetic-field-assisted fluidization is starting to be considered as a viable alternative to standard fluidized beds for those operations (such as particle separations, filtration, adsorption) in which the solid phase can be made of magnetic particles or, alternatively, the fluidizing agent is a ferro-fluid; thus the fluid bed responds to the action of magnetic fields, and stabilized fluidization regimes can be generated. One of the major difficulties to be tackled is the development of a predictive model capable of estimating the stabilized-to-bubbling transition velocity for a given magnetic field or, on the other hand, the magnetic field intensity required to stabilize the bed to a quies…

Measurement techniques and modelling of multiphase systems.

Multiphase systems are often encountered in process industry. Widely diffused applications and operations involve the contact between different phases (gas-solid, gasliquid, solid liquid, etc.) for different purposes, such as chemical reactions of physical operations (heat transfer, mass transfer). Multiphase flows are therefore one of the most frequent applied fields in chemical engineering. The present thesis is aimed at the development of experimental techniques for the investigation of multiphase flow in general, with particular focus on the analysis of gas-solid and gas-liquid systems. Notably, the development of image analysis techniques is the central thread of the present contributi…

On the bubbling dynamics of binary mixtures of powders in 2D gas-solid fluidized beds

Abstract The bubbling behavior of fluidized beds has been thoroughly investigated in the last decades by means of several techniques (e.g. X-ray, Inductance, Resistance and Impedance based techniques). In recent years, Digital Image Analysis Techniques have shown their potential for accurate and cost effective measurements. Most of the works related to the experimental analysis of bubble behavior in the field of gas-solid fluidization actually deal with monodispersed particles although almost all industrial equipments operate with mixtures of particles. Among the works available in literature dealing with mixtures of particles having different diameters and/or densities, most of them aim at…

A probabilistic approach to radiant field modeling in dense particulate systems

Radiant field distribution is an important modeling issue in many systems of practical interest, such as photo-bioreactors for algae growth and heterogeneous photo-catalytic reactors for water detoxification.In this work, a simple radiant field model suitable for dispersed systems showing particle size distributions, is proposed for both dilute and dense two-phase systems. Its main features are: (i) only physical, independently assessable parameters are involved and (ii) its simplicity allows a closed form solution, which makes it suitable for inclusion in a complete photo-reactor model, where also kinetic and fluid dynamic sub-models play a role. A similar model can be derived by making us…

Experimental analysis of bubble size distributions in 2D gas fluidized beds

Abstract The present work focuses on the development of a novel statistical approach for the analysis of the behavior of a 2D fluidized bed operating under bubbling and slugging conditions. Experimental data were collected by means of a purposely built lab-scale 2D fluidized bed and an original digital image analysis technique (DIAT), allowing the acquisition of a number of data sufficient to perform a statistical analysis of bubble dynamics. In particular, measurements of bubble size distributions (BSD) along the bed were performed. The analysis allowed to characterize the shape of BSD for different particle systems and fluidization gas velocities; interestingly a bimodal shape of BSD is o…

Free surface oxygen transfer in large aspect ratio unbaffled bio-reactors, with or without draft-tube

Abstract It is widely accepted that animal cell damage in aerated bioreactors is mainly related to the bursting of bubbles at the air–liquid interface. A viable alternative to sparged bioreactors may be represented by uncovered unbaffled stirred tanks, which have been recently found to be able to provide sufficient mass transfer through the deep free surface vortex which takes place under agitation conditions. As a matter of fact, if the vortex is not allowed to reach impeller blades, no bubble formation and subsequent bursting at the free-surface, along with relevant cells damage, occurs. In this work oxygen transfer performance of large aspect ratio unbaffled stirred bioreactors, either e…

Lagrangian simulation of bubbling dynamics in a lab-scale 2D fluidized bed

The present work focuses on the development of a novel computational code able to predict with a reasonable level of accuracy the bubble behavior in gas fluidized beds with minimum computational demands. The code simulates the bubble chaotic rise motion and coalescence along bed height via simple lagrangian tracking of bubbles. An original empirical model for the assessment of bubble-bubble interactions is developed. The code is used to simulate a lab-scale unit in bubbling and slugging mode. On this basis, fast simulations are performed to successfully predict bubble population and fluxes within the bed. The main aim of this code is to be embedded within CAPE codes for the process simulati…

A Digital Image Analysis Technique for 2-D Gas-Solid Fluidized Beds

On the measurement of bubble size distribution in gas–liquid contactors via light sheet and image analysis

Abstract Particle image velocimetry techniques coupled with advanced image processing tools are receiving an increasing interest for measuring flow quantities and local bubble-size distributions in gas–liquid mechanically agitated vessels. When trying to analyze image information the problem arises that bubble sizes are generally underestimated, due to the fact that the laser sheet used for lighting the system randomly cuts bubbles over non-diametrical planes, leading to an apparent bubble size distribution even in the ideal case of single sized bubbles. Clearly in the case of bubbles with a size distribution the experimental information obtained is affected by the superposition of effects.…

Free-surface shape in unbaffled stirred vessels: Experimental study via digital image analysis

There is a growing interest in using unbaffled stirred tanks for addressing a number of processing needs such as low shear damage (sensitive biocultures), low attrition (solid–liquid applications), deep-cleaning/sterilization (pharmaceutical applications). The main feature of uncovered, unbaffled stirred tanks is highly swirling motion of the fluid that results in a deformation of the free liquid surface. At sufficiently high agitation speeds the resulting whirlpool reaches the impeller and gives rise to a gas–liquid dispersion, so leading to the formation of a dispersion without the use of gas-sparger; the so-called self-inducing operation of the vessel. In this work, digital image analysi…

CFD prediction of bubble behavior in two-dimensional gas-solid fluidized beds

This work focuses on the computational fluid dynamics (CFD) simulation of a laboratory-scale, two-dimensional fluidized bed and the relevant experiments in order to validate the prediction capability of the adopted codes and models. Both experimental and computational quantitative data were analyzed by means of an original digital image analysis technique, allowing for coherent comparison of computational and experimental results. In particular, this work analyzes the capability of the CFD simulations in predicting the fluctuating behavior of bubbling fluidized beds by means of frequency analysis of bubble-related phenomena.

Analysis of the bubbling behaviour of 2-D gas solid fluidized beds part II: Comparison between experiments and numerical simulations via Digital Image Analysis Technique

In the field of gas–solid fluidization, bubbles, and all features regarding them, have a very great importance, as they significantly affect the process performance. Numerous experimental studies on bubbles, and their formation, evolution, and properties, have been performed in the past. These investigations appear particularly difficult, due to the nature of these systems, since the gas phase is distributed in both the bubble and the emulsion phase. Several experimental approaches have been developed to tackle this study. Among these, the Digital Image Analysis Technique purposely developed in Part I of the present work, based on the use of a video camera for monitoring the phenomenon coup…

CFD PREDICTION OF BUBBLES BEHAVIOUR IN 2-DIMENSIONAL GAS-SOLID FLUIDIZED BEDS

In recent years the use of Computational Fluid Dynamics (CFD) is significantly increasing to simulate multi-phase flows. It is invariably emphasized that a necessary step towards the development of reliable fully predictive CFD models is an extensive experimental validation of the simulation results. This work in particular focuses on the CFD simulation of a lab-scale 2D fluidized bed and the relevant experiments, in order to validate the prediction capability of the used codes and models. It must be emphasized that both experimental and computational quantitative data have been obtained by means of an original Digital Image Analysis Technique, that allows coherent comparison of computation…

Simplified dynamic pressure method for kLa measurement in aerated bioreactors

Abstract A simplified version of the dynamic pressure method for measuring mass-transfer coefficients in gas–liquid systems is proposed. With this method oxygen concentration in the liquid phase is monitored after a sudden change of total pressure is applied to the system. With respect to the original technique introduced by Linek [14] the simplified version here proposed greatly simplifies the data treatment, yet resulting in good accuracy for most practical purposes. In practice, with the help of a simple mathematical model, it is found that the dynamic oxygen concentration response, when plotted as residual driving force versus time in a semi-log diagram, should be expected to finally se…

Experimental investigation of fluidization dynamics at various flow regimes

Power Consumption in Uncovered Unbaffled Stirred Tanks: Influence of the Viscosity and Flow Regime

Notwithstanding the increasing industrial interest toward unbaffled tanks, available experimental information on their behavior is still scant, even for basic quantities such as the mechanical power drawn. In this work, the influence of the Reynolds and Froude numbers on the power consumption characteristics is presented for unbaffled stirred tanks operating both in nonaerated conditions (subcritical regime) and in aerated conditions (supercritical regime), i.e., when the free surface vortex has reached the impeller and the gas phase is ingested and dispersed inside the reactor. Experimental results obtained at various liquid viscosities show that power numbers obtained in subcritical condi…

On the measurement of local gas hold-up and interfacial area in gas–liquid contactors via light sheet and image analysis

Abstract Particle image velocimetry techniques coupled with advanced image processing tools are receiving an increasing interest for measuring flow quantities and local bubble-size distributions in gas–liquid contactors. Aim of this work is that of providing a numerical procedure able to reconstruct local gas hold-up and specific interfacial area from images obtained by laser sheet illumination. A correction for measured quantities accounting for laser sheet thickness is proposed and tested by means of Monte Carlo simulations. The algorithms proposed are robust and independent of any measured parameters of the actual bubble size distribution.

Gas-Fluidization Characteristics of Binary Mixtures of Particles in 2D Geometry

The bubbling behaviour of fluidized beds has been thoroughly investigated in the last decades by means of several techniques, e.g. X-ray, Inductance, Resistance and Impedance based techniques, PIV. In recent years, Digital Image Analysis Techniques have shown their potential for accurate and cost effectively measurements.Most of the work related to bubble behaviour analysis deals with single-sized particles, while almost all industrial equipment operates with multi-sized particles. Although considerable work has been done in the past with focus on the analysis of the mixing-segregation behaviour and predictions of fluid dynamics regime transitions, a lack of knowledge still exists in the an…

Gas-liquid-solid Operation of a High Aspect Ratio Self-ingesting Reactor

Gas-liquid stirred vessels are widely employed to carry out chemical reactions involving a gas reagent and a liquid phase. The usual way for introducing the gas stream into the liquid phase is through suitable distributors placed below the impeller. An interesting alternative is that of using “self ingesting” vessels where the headspace gas phase is injected and dispersed into the vessel through suitable surface vortices. In this work the performance of a Long Draft Tube Self-ingesting Reactor (LDTSR) dealing with three-phase (gas-liquid-solid) systems, is investigated. Preliminary experimental results on the effectiveness of this contactor for particle suspension and gas-liquid mass transf…

Oscillation dynamics of free vortex surface in uncovered unbaffled stirred vessels

Abstract The main feature of unbaffled stirred tanks is the highly swirling liquid motion, which leads to the formation of a central vortex on the liquid free surface, when the vessel is operated without top-cover (Uncovered Unbaffled Stirred Tanks, UUST). One of the main drawbacks of such vessels, that limits their industrial applicability, is the possible onset of low-frequency sloshing of the free surface. In this work, original data on oscillation dynamics in UUST are presented. In particular, data focus on the oscillation amplitude as well as on their frequency. Data were obtained by means of a novel experimental technique based on digital image analysis. The effect of impeller geometr…

ON THE PERFORMANC E OF A TAYLOR-COUETTE REACTOR FOR NANO-PARTICLE PRECIPITATION

Numerical simulations of bubbling fluidized beds

Lagrangian simulation of bubbling behaviour in gas fluidized beds and validation with experimental data

On the measurement of local gas hold-up, interfacial area and bubble size distribution in gas–liquid contactors via light sheet and image analysis: Imaging technique and experimental results

Abstract In this work a novel experimental technique for measuring local gas hold-up, interfacial area and bubble size distribution, in gas–liquid systems is proposed. The technique is based on advanced Image Processing coupled with experimental set-ups typically available for Particle Image Velocimetry. A fluorescent dye dissolved in the liquid phase allows to identify in-plane bubbles among all visible bubbles in the images. To this end, a suitable algorithm is proposed. The raw data so obtained are processed by previously developed statistical methods that result in a reliable reconstruction of actual dispersion properties. The technique is applied to the case of a gas-dispersed mechanic…

Study of bubbling fluidization dynamics via Digital Image Analysis Technique

Measurement of Multiphase Flow Characteristics Via Image Analysis Techniques: The Fluidization Case Study

In this chapter, an overview on some imaging-based experimental techniques for the analysis of complex multiphase systems is reported. In particular, some techniques aimed at the study of fluidization dynamics will be analyzed and discussed, as developed by our research group

Analysis of the bubbling behaviour of 2D gas solid fluidized beds

Abstract In the field of gas–solid fluidization, bubbles, and all features regarding them, have a very great importance, as they significantly affect the process performance. Numerous experimental studies on bubbles, and their formation, evolution, and properties, have been performed in the past. These investigations appear particularly difficult, due to the nature of these systems, since the gas phase is distributed in both the bubble and the emulsion phase. Several experimental approaches have been developed to tackle this study. Among these, the Digital Image Analysis Technique purposely developed in Part I of the present work, based on the use of a video camera for monitoring the phenom…

ON THE BUBBLING DYNAMICS OF BINARY MIXTURES OF PARTICLES IN 2D GAS-SOLID FLUIDIZED BEDS

The bubbling behaviour of fluidized beds has been thoroughly investigated in the last decades by means of several techniques, e.g. X-ray, Inductance, Resistance and Impedance based techniques, PIV. In recent years, Digital Image Analysis Techniques have shown their potential for accurate and cost effectively measurements. Most of the work related to bubble behaviour analysis deals with monodispersed particles, while almost all industrial equipment operates with mixtures of particles. Although considerable work has been done in the past with focus on the analysis of the mixing-segregation behaviour and predictions of fluid dynamics regime transitions, a lack of knowledge exists in the analys…

Unbaffled, Stirred Bioreactors for Animal Cell Cultivation

One of the main features of animal cell bioreactors is that the cultured cells lack a strong membrane and are therefore more prone to shear damage. It is widely accepted that animal cell damage in aerated bioreactors is mainly related to burst bubbles at the air–liquid interface. A viable alternative to sparged bioreactors, aimed at minimizing cell damage, may be represented by uncovered, unbaffled, stirred tanks, which are able to provide sufficient mass transfer through the deep free surface vortex that takes place under agitation. As a consequence the need for bubble formation and subsequent bursting accompanied by cell damage is conveniently avoided. In this chapter, mass transfer perfo…

Bubble formation at single nozzles

Study of bubble size distribution in bubbling fluidized beds via Digital Image Analysis Technique

Bubble formation at variously inclined nozzles

Bubble formation at variously inclined submerged nozzles, fed with a continuous gas flow rate, is investigated. Results confirm previous findings, such as a substantial independence of bubble size of nozzle diameter and its dependence on the cubic root of gas flow rate at sufficiently high values of this parameter. Nozzle inclination in the range between 0 and 135° from the vertical upward orientation is found to have a negligible effect on bubble size. Observed bubble rise velocities lead to an estimation of the average liquid velocity induced by bubbles motion, leading in turn to a very simple correlation for the estimation of the liquid velocities induced by the repeated passage of bubbl…

Solid–Liquid Suspensions in Top-Covered Unbaffled Vessels: Influence of Particle Size, Liquid Viscosity, Impeller Size, and Clearance

Particle suspension in liquids is a unit operation commonly encountered in the process industry. Although it is usually carried out in baffled stirred tanks, there are some specific applications where the presence of baffles may be undesirable. In the present work solid-liquid suspensions are investigated in a radially stirred unbaffled tank provided with a top cover. The minimum impeller speed at which all solid particles get suspended (Njs) and the relevant power requirements (Pjs) are assessed. The dependence of these two parameters on physical properties (liquid viscosity, particle concentration, and size) and system geometrical configurations (impeller diameter and clearance) is invest…

Analysis of the bubbling behaviour of 2-D gas solid fluidized beds - Part I Digital Image Analysis Technique

Bubble characteristics are very important in the design of fluidized beds because they govern hydrodynamics and efficiency of the operation for which the bed is used. In this work, a digital image analysis technique has been developed to study the fluidization dynamics of a lab-scale two-dimensional bubbling bed. Digital image analysis may supply a great quantity of information; it is non-intrusive, capable of securing several properties simultaneously and cost effective. The image analysis method here developed allows for the simultaneous measurements of various significant bubble properties, i.e. bubble size and bubble velocity distributions, bed height and bubble-phase hold-up, by means …

Reattore per la precipitazione di micro e nano-particelle

Particle image velocimetry in a gas-sparged stirred tank

Free vortex shape in Uncovered Unbaffled Stirred Tanks (UUST) agitated by Rushton turbines

The main feature of unbaffled stirred tanks is the highly swirling liquid motion, which leads to the formation of a central vortex on the liquid free surface, when the vessel is operated without top-cover (Uncovered Unbaffled Stirred Tanks, UUST). In this work, original data on fluid dynamics characteristics of (UUST) agitated by a Rushton turbine are presented. In particular, digital image analysis is employed to accurately assess vortex shape and validate an original model for its description. The model describes vortex shape in the case of sub-critical systems (when vortex bottom is placed above the impeller plane) as well as in the case of super-critical systems (when vortex bottom fall…

Linear stability analysis of gas-fluidized beds for the prediction of incipient bubbling conditions

Abstract This work focuses on the development of a novel linear stability criterion for the state of homogeneous fluidization regime, based on a new mathematical model for gas-fluidized beds. The model is developed starting from the well-known particle bed model. A mono-dimensional momentum balance is derived leading to a set of equations which explicitly include voidage-gradient dependent terms (elastic force) for both solid and fluid phases. A fully predictive criterion for the stability of homogeneous fluidization state is here proposed, based on the well-known Wallis’ linear stability analysis. The criterion requires the choice of an appropriate averaging distance, which in the present …

AREA-TO-VOLUME DATA TRANSLATION IN THE MEASUREMENT OF BUBBLE SIZE DISTRIBUTIONS VIA LASER SHEET AND IMAGE ANALYSIS

Not available.

Mathematical Model and Stability analysis of Multiphase Flow in Fluidized Beds