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International Journal of Food Engineering

Volume 4, Issue 2 2008 Article 3

Simulation of an Effect of a Bafe Length on the Power Consumption in an Agitated Vessel


Palani Sivashanmugam S. Prabhakaran

National Institute of Technology, Tiruchirappalli-620015, India, psiva@nitt.edu National Institute of Technology, Tiruchirappalli-620015, India, cla0515@nitt.edu

Copyright c 2008 The Berkeley Electronic Press. All rights reserved.

Simulation of an Effect of a Bafe Length on the Power Consumption in an Agitated Vessel


Palani Sivashanmugam and S. Prabhakaran

Abstract
Agitated vessels are often used for homogenization of the miscible liquids in chemical, biochemical, and food industries. Computational uid dynamics (CFD) is a useful tool for studying uid ows, including those of mixing systems. It is particularly powerful where the ability exists to corroborate model results with available data. The CFD simulation was carried out for Rushton and Smith turbines agitators. The standard k- model has been used for turbulence modeling. The data obtained by simulation are matching with the literature experimental value for standard bafe with the discrepancy of less than + 4.5% for power number. The simulated results for agitated vessel with short bafe (non-standard) are agreeing with the literature values within plus or minus 5% for Power Number. KEYWORDS: agitated vessel, power consumption, short bafes, CFD, turbine agitators

Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

1.

INTRODUCTION

Agitators are used widely for mixing of miscible and immiscible fluid, dispersion of gas in liquid, suspension of solids in liquid as it is done in hydrogenation of oils. Various types of agitators are used for different applications of mixing and agitation. Among these turbine type agitator is used widely for dispersing gas into liquid, which is very much required in fermentation and effluent treatment application. Prior to 1970s, researchers recognized that the angle of impeller blade, vessel geometry, baffle were plays the major role in agitated vessel and postulated that an impeller with more baffle can perform better in terms of power consumption. Since then, impellers with angle of blades have been discarded, and the 6-blade disk turbine impeller with 4- baffle has become the most popular impeller. The power consumption depends on the geometrical parameters of the agitator, baffles and vessel. The power curves for different agitators working in the vessel equipped with standard baffles (i.e. baffle length L is equal to liquid height H in the vessel) were reported by Joanna Karcz, Marta Major, 1998. During recent years, the studies on power consumption for the impeller-vessel systems of different geometry have been continued by many research workers. Using CFD, one can understand the mechanism of mixing of fluids in mixing tanks with much easier and economical than the use of experiments. Also CFD simulation is useful for predicting the vessel hydrodynamics in a wide range of operational conditions or various geometries. Computational Fluid Dynamics (CFD) has already been used in many studies to predict flow patterns and local gas volume fractions in the stirred gas-liquid vessels (Bakker and Van Den Akker,1994; Morud and Hjertager,1996; Derksen, 2002; Van Den Akker, 2007). CFD has reached a level that gives reliable and accurate results for predicting the flow field in stirred vessels (Sommerfeld and Decker,2003). Several methods had been successfully developed to simulate the flow in a stirred vessel, where good agreement of the mean flow field with experimental data was achieved. Threedimensional steady-state predictions based on this approach were presented by Vlaev, and. Staykov, 2001. Mavros and Mann extended this approach to simulate two-phase flow in a Rushton stirred vessel. This paper presents the simulation results of an effect of a baffle length on the power consumption in the agitated vessel with different high-speed agitators and the results were compared with the experimentally reported literature value.

Published by The Berkeley Electronic Press, 2008

International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

2.

TECHNICAL DETAILS OF AGITATED VESSEL

The simulation were carried out in the agitated vessel of inner diameter D = 0.6 m, filled with the water up to height H= D. Four planar baffles of width B = 0.1D and different length L were mounted in the vessel with the flat bottom. The geometrical parameter L/H was varied within the range L/H<0; 1>. Six series of the measurements were conducted in the literature for the L/H <0; 0.33; 0.5; 0.67; 0.83 and 1> i.e. p/H = 1; 0.67; 0.5; 0.33; 0.17 and 0. The Rushton and Smith turbines of diameter d = 0.33D, placed at the height h = 0.33D from the bottom of the vessel, were used in the simulation. Agitated vessel with arrangement of baffles used for simulation is shown in Figure 1. Geometrical parameters of the agitators are given in Table 1. The diagram of the agitator is shown in Figure.2.

Figure 1. Arrangement of baffles in the agitated vessel; (a) p/H=0; (b) p/H=0.5

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

Table 1. Geometrical parameters of the agitators No 1 2 Agitator Rushton Turbine Smith Turbine 0.33 6 0.25 0.2 R = b/2 d/D 0.33 Z 6 a/d 0.25 b/d 0.2 Remarks

(a) Rushton turbine

(b) Smith turbine Figure 2. Diagram of agitators

3.

CFD SIMULATION METHODS

Three main generalized approaches namely multiple reference frame (MRF), computational snapshot, and sliding mesh approach are used to predict the flow field in an agitated vessel. The first two approaches involve steady state computation producing time average flow filed and the third involves transient computation to produce time accurate flow filed. The computational domain
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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

representing mixer is divided into two non-overlapping regions one surrounding the impeller and the other representing the rest of the vessel. In this paper MRF approach has been tried. The brief description of this approach is as follows: initially simulation of flow is done for inner domain surrounding the impeller in a reference frame rotating with impeller. The flow field separating (interface) the inner and outer domain serves as boundary conditions for simulation of flow field in the outer domain of the frame reference model. This results in the revised boundary conditions for flow field inner domain. The procedure is repeated till suitable numerical convergence criterion is achieved. CFD simulation can be carried out by solution of continuity equation and time averaged Navier-stroke equations;
div{U} = 0

(1)

{U}+ div{UU} = p + div{U}+ div u' u' + F. t

(2)

Several turbulence models such as k-epsilon, k-omega, etc are available for carrying out simulation. Among these models k-epsilon is very widely used because of its reasonable accuracy for a wide range of turbulent condition in an agitated vessel. The following two equations have to be solved along with the above equation for k- turbulence model. 1 {k}+ div{Uk} = div (3) k + 21Eij t k" 2 1 {}+ div{U} = div 1 1 ij ij 2 + E E (4) 2 C C k k t Where 1 Ui Uj + Eij = (5) 2 xj xi Solution of Eqs (3) and (4) give spatial variation of k and which in turn can be used to find out spatial variation of turbulent viscosity or eddy viscosity t using the Prandtl-Kolmogorov relation k2 t = C (6) Once t is known, expression of turbulent stresses appearing in Eq.(2) can be given as 2 (7) u' iu' j = 2tEij kij 3

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

The standard values of different constants appearing in Eqs (3),(4) and (6) are C = 0.09, k=1.00, = 1.3, C 1 =1.44 and C 2 =1.92 Commercial CFD software FLUENT was used to perform simulation. To start with several exploratory simulations were carried out using MRF approach to finalize the geometry and to conduct grid independent test and the result is shown in Figure 3. From this figure it is observed that accuracy of the result increases with increase in mesh (cell) volume and became constant at 176550 cells. Final CFD simulations were done at this cell number. Figure 4 presents the typical appearance of the vessel with meshed condition.

6 Power Number 4 2 0 0 200000 400000 600000 800000 1E+06 1E+06 Mesh Volume

Mesh volume Vs Power Number


Figure 3. Effect of mesh volume number on simulated power number

Figure 4. Diagram of the meshed agitated vessel

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

4.

RESULTS AND DISCUSSION

The Figures 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, and 15 depict that the simulated power number obtained for the agitated vessels equipped with standard baffles against experimentally reported value1. The power number for standard baffle is higher than that for nonstandard baffle owing to high degree of inertial force experienced in standard baffle. It is also observed that as p/H increases the power required for agitation decreases as reported in the literature due to fact that as the distance from baffle edge to bottom vessel increases the inertial force required for running the agitator decreases resulting in reduced power consumption. Also for a given p/H ratio, the power required for Rushton turbine is more than that for Smith turbine agitator due to high inertia experienced by Rushton turbine agitator. The data obtained by simulation are matching with the literature experimental value for standard baffle with the discrepancy of less than 4.5%. The simulated results for agitated vessel with short baffle (nonstandard) are agreeing with the literature values within plus or minus 5% for power number. Figures 16a and 16c present the radial velocity component vector for p/H =0 (Figure 16 a) and for p/H=0.5 (Figure 16c). From these figures, it is observed that the intensity of mixing decreases with increasing radius and the mixing of fluids more uniform both in radial and axial direction in the outer domain of the agitator. Figures 16b and 16d depict the turbulent kinetic energy distribution for p/H =0 (Figure 16b) and for p/H=0.5 (Figure 16d). From these figures, it is observed that the intensity of the turbulent kinetic energy decreases with increasing radius, and the distribution of turbulent kinetic energy is more uniform both in radial and axial direction corresponding to the mixing of fluids in the outer domain of the agitator. This more uniform mixing of fluids, and the corresponding uniform distribution of kinetic energy may be the reason for reduced power consumption in nonstandard baffle compared to standard baffle. This similar behavior only has been reported by Joanna Karcz, Marta Major, 1998.

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

7 6

Power Number

5 4 3 2 1 0 10000

Simulation value literature Value

100000

1000000

Reynolds Number

Figure 5. Simulated and Experimental power Number for Rushton Turbine p/H=0
6 5 Simulation Value :iterature Value

Power Number

4 3 2 1 0 10000

100000

1000000

Reynolds Number

Figure 6. Simulated and Experimental power number for smith turbine p/H= 0

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

8 Simulation Value 6 Literature value

Power Number

0 10000

100000

1000000

Reynolds Number

Figure 7. Simulated and Experimental power numberfor Rushton Turbine p/H = 0.17
8

6 Power Number

Simulation Value Literature Value

0 10000

100000 Re ynolds Numbe r

1000000

Figure 8. Simulated and Experimental power number for Smith Turbine p/H = 0.17

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

8 Simulation Value 6 Literature Value

Power Number

0 10000

100000

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Figure 9. Simulated and Experimental power number for Rushton Turbine p/H = 0.33
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Power Number

0 10000

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Figure 10. Simulated and Experimental power number for Smith Turbine p/H = 0.33

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

Simulation Value
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Literature value

Power Nuber

0 10000

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Reynolds Number

Figure 11. Simulated and Experimental power number for Rushton Turbine p/H = 0.5
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Figure 12. Simulated and Experimental power nmuber for Smith Turbine p/H = 0.5

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

8 Simulation Result 6 Literature Value

Power Number

0 10000

100000

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Figure13. Simulated and Experimental power number for Rushton Turbine p/H = 0.67
8 Simulation value Literature Value 6

Power Number

0 10000

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Figure 14. Simulated and Experimental power number for Smith Turbine p/H = 0.67

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

Simulation Result
6

Literature value

Power Nuber

0 10000

100000

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Reynolds Number

Figure 15. Simulated and Experimental power number for Rushton Turbine p/H = 1

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

a)

b)

Figure 16. Radial velocity for Rushton turbine (a) p/H = 0, and Turbulent Kinetic energy for Rushton Turbine (b) p/H = 0

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

c)

d)

Figure 16. Radial velocity for Rushton turbine (c) p/H = 0.5, and Turbulent Kinetic energy for Rushton Turbine, (d) p/H = 0.5

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Sivashanmugam and Prabhakaran: Simulation of an Effect of a Baffle Length on the Power Consumption in an Agitated Vessel

5.

CONCLUSION

CFD simulation for the power consumption in agitator vessel with varying baffle length p/H = 1; 0.67; 0.5; 0.33; 0.17 and 0 in turbulent flow conditions has been explained in this paper using Fluent version 6.2.16. The data obtained by simulation are matching with the literature experimental value for standard baffle with the discrepancy of less than 4.5% for power number. The simulated results for agitated vessel with short baffle (non-standard) are agreeing with the literature values within plus or minus 5% for power number. The reason for reduced power consumption in nonstandard baffle has been evidenced from more uniform distribution of turbulent kinetic energy both in radial and axial direction as observed from turbulent kinetic energy distribution profile around the turbine agitator. NOMENCLATURE
a length of the agitator blade, m B width of the baffles, m b width of the agitator blade, m D inner diameter of the agitated vessel, m d diameter of the agitator, m H liquid height in the vessel, m h distance between agitator and bottom of the vessel, m J number of baffles k specific turbulent kinetic energy, m2/s L length of the baffle, m n agitator speed, s-1 P power consumption, W Power number = P / n3 d 5 Reynolds number = n d 2/ p distance between lower edge of the baffle and bottom of the vessel, m R radius of the agitator blade, m Z number of agitator blade Greek letter specific turbulent energy dissipation rate, m2/s dynamic viscosity of the liquid, kg/ms t turbulent viscosity or eddy viscosity , kg/ms liquid density, kg

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International Journal of Food Engineering, Vol. 4 [2008], Iss. 2, Art. 3

REFERENCES 1. Joanna Karcz *, Marta Major An Effect of a Baffle Length on the Power Consumption in an Agitated Vessel Chemical Engineering and Processing,1998, 37 249256. 2. Bakker, A., Van Den Akker., H.E.A., A computational model for the gasliquid flow in stirred reactors, Trans. IchemE, 1994, A72, 594-606. 3. Morud, K.E., Hjertager, B.H., LDA, Measurements and CFD modeling of gasliquid flow in a stirred vessel, Chem. Eng. Sci, 1996, 51(2), 233-249. 4. Derksen, J.J., Venneker, B.C.H., Van Den Akker, H.E.A., Population balance modeling of aerated stirred vessels based on CFD,2002, AIChE J, 48(4), 673685. 5. Van Den Akker., H.E.A., The details of turbulent mixing process and their simulation, Advances in Chemical Engineering,2006, 31,151-229. 6. Sommerfeld, M., Decker, S. State of the art trends in CFD simulation of stirred vessels, Proceedings of the 11th European Conference on Mixing, Bamberg, 2003.p. 1 7. Vlaev, S.D., P. Staykov, R. Mann, H. Hristov and P. Mavros, Experimental and CFD Characterization of a New Energy-saving Mixing Impeller for the Process Industries, Paper presented at 18th North American Mixing Conference, Pocono Manor, PA, 2001,June 24-29. 8. Mavros, P., R. Mann, S.D. Vlaev and J. Bertrand, Experimental Visualization and CFD Simulation of Flow Patterns Induced by a Novel Energy-Saving Dual-Configuration Impeller in Stirred Vessels, Trans. I. Chem. E,2001, 79A, 857866.

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