The focus of this thesis is the study of turbulent solid-liquid stirred suspensions, which are involved in many common unit operations in the chemical, pharmaceutical and food industries. The studies of two-phase flows present a big challenge to researchers due to the complexity of experiments; hence there is a lack of quantitative solid and liquid hydrodynamic measurements. Therefore, an investigation of turbulence modulation by dispersed particles on the surrounding fluid in stirred vessels has been carried out, via two-phase fluorescent Particle Image Velocimetry (FPIV) and micromixing experiments. The main property of interest has been the local dissipation rate, as well as root-mean-square (rms) velocities and turbulent kinetic energy (TKE) of the fluid. Initially a single-phase PIV study was conducted to investigate the flow field generated by a sawtooth (EkatoMizer) impeller. The purpose of this study was to gain insight into various PIV techniques before moving on to more complex two-phase flows. Subsequently stereo-, highspeed and angle-resolved measurements were obtained. The EkatoMizer formed a good case study as information regarding its hydrodynamics is not readily available in literature, hence knowledge has been extended in this area. An analysis of the mean flow field elucidated the general structure of fluid drawn into the impeller region axially and discharged radially; the latter characterised the impeller stream. The radial rms velocity was considered to represent best the system turbulence, even though the tangential rms velocity was greater close to the blade; however the radial component was more prevalent in the discharge stream. Due to differences in rms velocities, TKE estimates obtained from two and three velocity components deviated, being greater in the latter case. Integral (1-D and 2-D) length scales were overestimated by the quantity W / 2 in the impeller region. Ratios of longitudinal-to-lateral length scales also indicated flow anisotropy (as they deviated from 2:1). The anisotropy tensor showed that the flow was anisotropic close to the blade, and returned to isotropy further away from the impeller. Instantaneous vector plots revealed vortices in the discharge stream, but these were not associated with flow periodicity. Alternatively, the vortex structures were interpreted as low frequency phenomena between 0-200 Hz; macro-instabilities were found to have a high probability of occurrence in the discharge stream. Dissipation is the turbulent property of most interest as it directly influences micromixing processes, and its calculation is also the most difficult to achieve. Its direct determination from definition requires highly resolved data. Alternative methods have been proposed in the literature, namely dimensional analysis, large eddy simulation (LES) analogy and deduction from the TKE balance. All methods were employed using 2-D and 3-D approximations from stereo-PIV data. The LES analogy was deemed to provide the best estimate, since it accounts for three-dimensionality of the flow and models turbulence at the smallest scales using a subgrid scale model. (Continues...).

Este trabalho estudou a aplicação de oito métodos clássicos de escalonamento de tanques condicionadores, testando sua validade para dois tanques de geometria semelhante, mas com diferentes volumes (V1=10 e V2=49 decímetros cúbicos). No interior dos tanques, operavam impulsores (diâmetro D1=0,078m x D2=0,132m) que exibiam três distintos desenhos (2 pás versus 4 pás inclinadas em 45 graus versus turbina de Rushton). Sua rotação (N1 no tanque menor x N2 no tanque maior) visava à suspensão de partículas grossas de apatita (diâmetro médio = 254 micrometros) em polpas com 40% de sólidos em massa. Para balizar o escalonamento, adotou-se como variável de controle a mínima rotação do impulsor (Njs) que é capaz de fazer com que nenhuma partícula repouse no fundo do tanque por mais do que 1 ou 2 segundos (Critério 1-s), além de perfis axiais de distribuição de sólidos e a extensão da Zona Turbulenta versus Zona Quiescente no interior dos tanques. A diferença entre o valor previsto de Njs para o tanque de 49 decímetros cúbicos (N2) pelos métodos de escalonamento versus o valor de Njs (N2) determinado experimentalmente foi expressa como erro percentual (E). Consideraram-se como adequados para a aplicação que constitui o objetivo desta dissertação todos os métodos que exibiram E menor que 10%. Para o impelidor de 2 pás inclinadas, a adequação do método baseado na constância da razão potência/volume (E=2%) e também do método empírico de Rautzen (E=6%), indica a expressão N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros variando entre 0,67 e 0,75 para a aplicação desejada. Considerando o impulsor de 4 pás inclinadas, a adequação do método da constância da razão potência/volume (E=4%); assim como dos métodos empíricos de Rautzen (E=0%) e Zwietering (5%), sugere o uso da expressão N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros variando entre 0,67 e 0,85. Para a turbina de Rushton, o único método que exibiu E menor que 10% foi o da constância da relação potência/volume (E=8%), cuja expressão é N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros igual a 0,67. Uma vez que a determinação do valor real de N2 foi baseada numa técnica experimental influenciada pelas limitações do observador, pode-se inferir que uma expressão geral de escalonamento do tipo N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros igual a 0,75 atende aos propósitos desta aplicação. Por outro lado, o uso da relação P/V provê um critério mais objetivo para se balizar o escalonamento, haja vista que ele se adequou a todos os três tipos de impelidores contemplados por este estudo. / This work has studied the application of eight classical methods appointed by literature to accomplish the scale-up of stirred tanks which aimed to suspend slurries of 40% of solids, containing coarse (mean diameter=254 micrometers) apatite particles. The validity of the methods was accomplished by using two tanks of similar geometry but different capacity (V1=10 e V2=49 cubic decimeter), together with impellers of different diameter (D1=0,078m versus D2=0,132m) and design (turbine of 2 or 4 blades inclined at 45 degrees and Rushton turbine). To assist the process of validation, the impeller speed (Njs) under which no particle rests on the bottom of the tank for more than 1-2 seconds (1-s Criterium) was used together with the axial profile of solids percent distribution plus the extension of the turbulent versus quiescent zones within the two tanks. For any of the eight scale-up methods, the difference between the predicted value of Njs (N2) for the 49 cubic decimeter tank and the actual value (experimental) of the same variable was determined and its magnitude was expressed in terms of the percent error (E). The methods that yielded E less than 10% were considered as suitable for the aimed application. Considering the 2-inclined blade impeller, low value of E yielded by the method based on the constancy of the ratio power/volume (E=2%) and also by the empiric method of Rautzen (E=6%) indicate that the expression N2=N1.(D1/D2) with its exponent of the relation between diameters ranging between 0,67 and 0,75 is suitable for the desired application. Regarding the 4-inclined blade impeller, because the method based on the constancy of the ratio power/volume (E=4%) and also the empiric methods of Rautzen (E=0%) and Zwietering (E=5%) yielded the lowest values of E, the expression N2=N1.(D1/D2) with its exponent of the relation between diameters ranging between 0,67 and 0,85 is suitable for the aimed application. Moreover, for the Rusthon turbine, only the method based on the constancy of the ratio power/volume (E=8%) was adequate for the aimed application and, thus, the expression N2=N1.(D1/D2) with its exponent of the relation between the diameters equal to 0,67 is suitable for the purpose of this dissertation. Once the actual value of N2 is determined by visual observation, it is not possible to get very accurate results. This way, a generic scale-up expression is proposed: N2=N1.(D1/D2) with its exponent of the relation between the diameters equal to 0,75. On the other hand, the ratio P/V may provide a more objective criterium for scale-up, because the three sort of impellers used in this study yielded E less than 10% when the power/volume method was applied for the purpose of scale-up.

Este trabalho estudou a aplicação de oito métodos clássicos de escalonamento de tanques condicionadores, testando sua validade para dois tanques de geometria semelhante, mas com diferentes volumes (V1=10 e V2=49 decímetros cúbicos). No interior dos tanques, operavam impulsores (diâmetro D1=0,078m x D2=0,132m) que exibiam três distintos desenhos (2 pás versus 4 pás inclinadas em 45 graus versus turbina de Rushton). Sua rotação (N1 no tanque menor x N2 no tanque maior) visava à suspensão de partículas grossas de apatita (diâmetro médio = 254 micrometros) em polpas com 40% de sólidos em massa. Para balizar o escalonamento, adotou-se como variável de controle a mínima rotação do impulsor (Njs) que é capaz de fazer com que nenhuma partícula repouse no fundo do tanque por mais do que 1 ou 2 segundos (Critério 1-s), além de perfis axiais de distribuição de sólidos e a extensão da Zona Turbulenta versus Zona Quiescente no interior dos tanques. A diferença entre o valor previsto de Njs para o tanque de 49 decímetros cúbicos (N2) pelos métodos de escalonamento versus o valor de Njs (N2) determinado experimentalmente foi expressa como erro percentual (E). Consideraram-se como adequados para a aplicação que constitui o objetivo desta dissertação todos os métodos que exibiram E menor que 10%. Para o impelidor de 2 pás inclinadas, a adequação do método baseado na constância da razão potência/volume (E=2%) e também do método empírico de Rautzen (E=6%), indica a expressão N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros variando entre 0,67 e 0,75 para a aplicação desejada. Considerando o impulsor de 4 pás inclinadas, a adequação do método da constância da razão potência/volume (E=4%); assim como dos métodos empíricos de Rautzen (E=0%) e Zwietering (5%), sugere o uso da expressão N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros variando entre 0,67 e 0,85. Para a turbina de Rushton, o único método que exibiu E menor que 10% foi o da constância da relação potência/volume (E=8%), cuja expressão é N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros igual a 0,67. Uma vez que a determinação do valor real de N2 foi baseada numa técnica experimental influenciada pelas limitações do observador, pode-se inferir que uma expressão geral de escalonamento do tipo N2=N1.(D1/D2) com seu expoente da relação entre os diâmetros igual a 0,75 atende aos propósitos desta aplicação. Por outro lado, o uso da relação P/V provê um critério mais objetivo para se balizar o escalonamento, haja vista que ele se adequou a todos os três tipos de impelidores contemplados por este estudo. / This work has studied the application of eight classical methods appointed by literature to accomplish the scale-up of stirred tanks which aimed to suspend slurries of 40% of solids, containing coarse (mean diameter=254 micrometers) apatite particles. The validity of the methods was accomplished by using two tanks of similar geometry but different capacity (V1=10 e V2=49 cubic decimeter), together with impellers of different diameter (D1=0,078m versus D2=0,132m) and design (turbine of 2 or 4 blades inclined at 45 degrees and Rushton turbine). To assist the process of validation, the impeller speed (Njs) under which no particle rests on the bottom of the tank for more than 1-2 seconds (1-s Criterium) was used together with the axial profile of solids percent distribution plus the extension of the turbulent versus quiescent zones within the two tanks. For any of the eight scale-up methods, the difference between the predicted value of Njs (N2) for the 49 cubic decimeter tank and the actual value (experimental) of the same variable was determined and its magnitude was expressed in terms of the percent error (E). The methods that yielded E less than 10% were considered as suitable for the aimed application. Considering the 2-inclined blade impeller, low value of E yielded by the method based on the constancy of the ratio power/volume (E=2%) and also by the empiric method of Rautzen (E=6%) indicate that the expression N2=N1.(D1/D2) with its exponent of the relation between diameters ranging between 0,67 and 0,75 is suitable for the desired application. Regarding the 4-inclined blade impeller, because the method based on the constancy of the ratio power/volume (E=4%) and also the empiric methods of Rautzen (E=0%) and Zwietering (E=5%) yielded the lowest values of E, the expression N2=N1.(D1/D2) with its exponent of the relation between diameters ranging between 0,67 and 0,85 is suitable for the aimed application. Moreover, for the Rusthon turbine, only the method based on the constancy of the ratio power/volume (E=8%) was adequate for the aimed application and, thus, the expression N2=N1.(D1/D2) with its exponent of the relation between the diameters equal to 0,67 is suitable for the purpose of this dissertation. Once the actual value of N2 is determined by visual observation, it is not possible to get very accurate results. This way, a generic scale-up expression is proposed: N2=N1.(D1/D2) with its exponent of the relation between the diameters equal to 0,75. On the other hand, the ratio P/V may provide a more objective criterium for scale-up, because the three sort of impellers used in this study yielded E less than 10% when the power/volume method was applied for the purpose of scale-up.

Emulsion explosives have become the preferred choice as blasting agents for numerous industries including mining, agriculture, and construction. One of the most important components in such an emulsion is an emulsifier, which controls the emulsification properties of the explosive. The present study involves the production of one such emulsifier, which is produced by reacting two immiscible liquids, PIBSA (polyisobutylene succinic anhydride) and MEA (monoethanolamine). The study examines the effect of design variable such as the impeller speed, impeller type and the dispersed phase volume fraction on interfacial area. Experiments were carried out in a 0.15 m diameter fully baffled stirred tank using a 6-bladed Rushton turbine impeller and a marine propeller. Drop size was determined using a microscope with a video camera and image processing system. The transient concentration of PIBSA was determined using FTIR analysis and used to estimate the volume fraction of the dispersed phase (ƒÖ). The effective interfacial area was calculated using the Sauter mean drop diameter, d32 and ƒÖ. Impeller speeds ranging from 150 to 600 rpm and dispersed phase volume fractions, ƒÖ ranging from 0.01 to 0.028 were examined in the experimental study. It was found that that the evolution of Sauter mean drop diameter, d32 has four different trends depending on ƒÖ and impeller speed. At high impeller speeds and high ƒÖ, d32 values decrease initially and reach constant values after a long period of time. This trend is consistent with the findings in previous investigations. Under certain operating conditions, d32 values increase initially with stirring time to reach a maximum value and then decrease to reach a steady state value. The presence of these trends has been attributed to the effect of changing physical properties of the system as a result of chemical reaction. Results indicate that, in general, Sauter mean drop diameter d32 decreases with an increase in agitation intensity. However a decrease in the dispersed phase volume fraction is found to increase d32. These trends are found to be the same for both impeller types studied. Comparing the drop size results produced by the two impellers, it appears that low-power number propeller produces s ignificantly smaller drops than the Rushton turbine. It was found that the concentrations of reactants decrease with time for all impeller speeds thereby leading to a decrease in interfacial area with the progress of the reaction. Interfacial area values obtained at higher impeller speeds are found to be lower in spite of lower d32 values at these speeds. Also, these values decrease with time and become zero in a shorter duration indicating the rapid depletion of MEA. The interfacial area values obtained with the propeller at a given impeller speed are lower as compared to those for Rushton turbine. They also decrease and become zero in a shorter duration as compared to those for Rushton turbine suggesting propeller¡¦s performance is better in enhancing the reaction rate.

No description available.