Characterization of a small-scale crystallizer using CFD simulations and X-ray CT measurements

Abstract

• Single and multiphase CFD of a small-scale crystallizer with two stirrer types. • Indications when each stirrer is preferably used based on hydrodynamics. • X-ray CT applied in mixing studies used for the validation of the CFD simulations. Although small-scale crystallizers have gained increasing importance in recent years, their hydrodynamic properties have not yet been thoroughly studied. The purpose of this work is to characterize an intensively stirred small-scale crystallizer and to analyze whether its fluid mechanics behavior deviates from being homogeneously well-mixed. To this aim, single and multiphase computational fluid dynamics (CFD) simulations have been conducted. Two types of stirrers, including one overhead stirrer (OS) and one magnetic stirrer (MS), were compared. The single-phase CFD simulations showed that the mixing characteristics of the two stirrers differ significantly, thereby leading to variations in the distribution of solids. The MS is an axial flow type impeller, which is better at handling solid suspensions than the OS. The simulations were complemented by X-ray computed tomography measurements, which confirmed that spatial variations in solid distribution occur and that assuming a homogeneous suspension might lead to errors when modeling crystallization processes.