Turbulence characteristics in a rushton dorr oliver stirring vessel a numerical investigation
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Turbulence Characteristics in a Rushton & Dorr-Oliver Stirring Vessel: A numerical investigation. Vasileios N Vlachakis 06/16/2006. Outline of the Presentation. Introduction/Motivation Background of the Flotation process Mechanically agitated vessels

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Turbulence characteristics in a rushton dorr oliver stirring vessel a numerical investigation

Turbulence Characteristics in a Rushton & Dorr-Oliver Stirring Vessel: A numerical investigation

Vasileios N Vlachakis

06/16/2006


Outline of the presentation
Outline of the Presentation Dorr-Oliver Stirring Vessel: A numerical investigation

  • Introduction/Motivation

  • Background of the Flotation process

  • Mechanically agitated vessels

  • The Rushton Stirring Tank

    • Computational Model

    • Comparisons between them

  • The Dorr-Oliver Stirring Tank

  • Conclusions

  • Future Work


I ntroduction motivation
I Dorr-Oliver Stirring Vessel: A numerical investigationntroduction/Motivation

The objectives of the thesis are to:

  • study the hydrodynamics of two stirring tanks

    • The Rushton mixing tank

    • The Dorr-Oliver

  • estimate accurately the velocity distribution

  • discuss which turbulent model is the most suitable for this type of flow (validation with the experiments)

  • determine the effect of the clearance of the impeller on the turbulence characteristics

    • Vorticity

    • Turbulent kinetic energy

    • Dissipation rate


Significance of the dissipation rate
Significance of the Dissipation rate Dorr-Oliver Stirring Vessel: A numerical investigation

  • Dissipation rate controls:

    • Collisions between particles and bubbles in flotation cells

    • bubble breakup

    • coalescence of drops in liquid-liquid dispersions

    • agglomeration in crystallizers


Background
Background Dorr-Oliver Stirring Vessel: A numerical investigation

Flotation is carried out using

Mechanically agitated cells

Widely Used in Industries to

separate mixtures

  • Mining

  • Chemical

  • Environmental

  • Pharmaceutical

  • Biotechnological

Principles of Froth-Flotation


The flotation process
The flotation process Dorr-Oliver Stirring Vessel: A numerical investigation

  • The flotation technique relies on the surface properties of the different particles

  • Two types of particles:

    • hydrophobic (needs to be separated and floated)

    • hydrophilic

  • Particles are fed from a slurry located in the bottom

  • While the impeller rotates air is passing through the hollow shaft to generate bubbles

  • Some particles attach to the surface of the air bubbles and some others fall on the bottom of the tank

  • The floated particles are collected from the froth layer


The rushton stirring tank
The Rushton Stirring Tank Dorr-Oliver Stirring Vessel: A numerical investigation

Cylindrical Tank

Diameter of the Tank

Diameter of the Impeller

Four equally spaced baffles with width

Thickness of the baffles

Blade height

Blade width

Liquid Height = Height of the Tank


Governing equations
Governing Equations Dorr-Oliver Stirring Vessel: A numerical investigation

Unsteady 3D Navier-Stokes equations

Continuity

Momentum

Decomposition of the total velocity and pressure

Averaging rules

Time-averaged Navier-Stokes equations

Continuity

Momentum


Dimensionless parameters scaling laws
Dimensionless Parameters Dorr-Oliver Stirring Vessel: A numerical investigationScaling Laws

The Reynolds number:

Laminar flow: Re<50

Transitional: 50<Re<5000

Turbulent: Re>10000

The Power number:

Where a=5 and b=0.8 in the case of radial-disk impellers

In our case where

This Power number is hold for unbaffled tanks


Power number versus re number
Power number versus Re number Dorr-Oliver Stirring Vessel: A numerical investigation


Dimensionless parameters scaling laws1
Dimensionless Parameters Dorr-Oliver Stirring Vessel: A numerical investigationScaling Laws

Froude number:

The Froude number is important for unbaffled tanks

It is negligible for baffled tanks or unbaffled with Re<300

In unbaffled tanks for Re>300

Flow number:

In the case of the radial-disk impellers

In our case (Rushton turbine) : Fl=1.07


Computational grid
Computational Grid Dorr-Oliver Stirring Vessel: A numerical investigation

The computational grid consists of 480,000 cells

Grid surrounding the impeller (The unsteady Navier - Stokes equations are solved)

Outside grid (The steady Navier - Stokes equations are solved)

Two frames of reference:

The first is mounted on the

Impeller and the second is

stationary (MRF)

View from the top

3Dimensional View

The grid surrounding the impeller is more dense from the outside


Simulation test matrix
Simulation Test matrix Dorr-Oliver Stirring Vessel: A numerical investigation

Three different configurations

Three turbulent models

Five Reynolds numbers


Normalized radial velocity contours
Normalized radial velocity contours Dorr-Oliver Stirring Vessel: A numerical investigation

The flow for the first two cases can be described as a radial jet with two recirculation regions in each side of the tank

In the case of the low clearance, a low speed jet and only one large

recirculation area is observed


Normalized dissipation rate contours
Normalized dissipation rate contours Dorr-Oliver Stirring Vessel: A numerical investigation

In the first two cases the dissipation rate has high values around and next

to the impeller’s blade while in the last is extended to the region below them too


Normalized tke contours
Normalized TKE contours Dorr-Oliver Stirring Vessel: A numerical investigation

Slices that pass through the middle plane of the impeller

The TKE is lower in the case of the low configuration


Normalized x vorticity contours
Normalized X-vorticity contours Dorr-Oliver Stirring Vessel: A numerical investigation

Re=35000

In the first two cases the tip vortices that form at the end of the moving blades

can be observed while in the third case only one big vortex ring forms.


Y vorticity
Y- Vorticity Dorr-Oliver Stirring Vessel: A numerical investigation

Time-averaged experimental

results

Trailing vortices at the next blade

Trailing vortices at the 1st blade

Trailing Vortices at y/Dtank=0.167

(exactly at the end of the blades)


Vorticity superimposed with streamlines for re 35000
Vorticity superimposed with Dorr-Oliver Stirring Vessel: A numerical investigationstreamlines for Re=35000

Flow can be described as a radial jet with convecting tip vortices


Normalized z vorticity contours
Normalized Z-vorticity contours Dorr-Oliver Stirring Vessel: A numerical investigation

In the first two cases the presence of the trailing vortices that form behind

the rotating blades can be seen.

In all cases small vortices also form behind the baffles


Grid study
Grid Study Dorr-Oliver Stirring Vessel: A numerical investigation


Radial plots for re 35000 along the centerline of the impeller
Radial Plots for Re=35000 along the centerline of the impeller

Normalized radial velocity

Normalized velocity magnitude

The velocity magnitudes consists only of the axial and radial components

in order to be validated by the experimental results where the tangential

component Is not available.

The low speed jet in the case of the low configuration is confirmed but a

strong axial component is present as it is shown in the second plot


Radial plots for re 35000 along the centerline of the impeller1
Radial Plots for Re=35000 along the centerline of the impeller

Normalized tangential velocity

Re=35000

Normalized X-Vorticity

Experimental vorticity seems to be oscillating due to the periodicity and due

to the fact that trailing vortices are present.

Clearly none of the turbulent models can capture what is happening


Radial plots for re 35000 along the centerline of the impeller2
Radial Plots for Re=35000 along the centerline of the impeller

Normalized Dissipation rate

Normalized Turbulent Kinetic Energy

The RNG k-e model has a superior behavior among the studied

turbulent models in predicting the Turbulent Dissipation Rate (TDR)

The apparent discrepancy in TKE is due to the periodicity that characterizes

the flow, since with every passage of a blade strong radial jet is created.


Normalized maximum dissipation rate
Normalized Maximum Dissipation rate impeller

For C/T=1/2 and C/T=1/15

For C/T=1/3

As the Re number increases the maximum TDR decreases for the first two

configurations (agreement with the experimental data)

For case of the low clearance configuration the line of the maximum dissipation

levels off.


Velocity profiles
Velocity Profiles impeller

r/T=0.256

r/T=0.19

r/T=0.315


Dissipation rate profiles
Dissipation rate profiles impeller

r/T=0.256

r/T=0.19

r/T=0.315


Reynolds stresses isosurfaces
Reynolds Stresses & Isosurfaces impeller

C/T=1/3

u’w’ normalized component of the RS

Isosurfaces of vorticity

The higher the helicity the more the vorticity

vector is closer to the velocity vector (swirl)

Helicity

Isosurfaces of helicity


Conclusions
Conclusions impeller

  • The turbulent kinetic energy and dissipation have the highest values in the immediate neighborhood of the impeller

  • Good agreement with the experimental data is succeed

  • Most of the times the Standard k-e model predicts better the flow velocities and the turbulent quantities while in some others has poor performance and the RNG k-e is better

  • In the case of the low configuration model:

    • there is a strong tendency to skew the contours downward

    • the dominant downward flow is diverting the jet-like flow that leaves the tip of the impeller downward, and it convects with the turbulent features of the flow.

    • The axial component of the velocity has high values


Future work
Future Work impeller

  • Experimental predictions for the Dorr-Oliver Flotation cell

  • Comparisons of the studied cases with the experiments

  • More Re numbers and clearances for the Dorr-Oliver Cell

  • Higher Re numbers for both Tanks (100000-300000)

  • Unsteady calculations

  • Extension to two-phase or three phase flows


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