High-speed Impeller Research Articles

FEM Analysis of the High Pressure Applied to an Impeller Blade During Laser Welding

Finite element analysis was used to predict the distribution of stress and deformation during laser welding of high speed impellers. FEM was used to analyze three cases, a lower tap fixed (Case I), a lower boundary fixed (Case II) and a lower boundary and upper tap fixed (Case III). As the applied pressure increased, the stress and deformation increased gradually for all cases. In Case III, where the restrained portion was large, the stress was much higher than Case I or II, however the maximum deformation in Case III was smaller than the other cases. The analysis determined that stress was reduced by deformation of a blade tab region that was unrestrained when pressure was applied to the blade. In addition, maximum stress was generated around the tabs, and it was found that the stress was concentrated on the shape of the corner portion. Analysis determined that stress and deformation are inversely proportional. Weld design can be optimized by considering these results. Stress and deformation can be minimized by optimizing the shape of the stressed part using the finite element method, and performing blade design and laser welding design accordingly. Key words: Laser welding, Blade analysis, FEM

Experimental Analysis of Conditions of Gas-liquid-floating Particles System Production in an Agitated Vessel Equipped with Two Impellers

The characteristic flow patterns of the three-phase gas-floating particles-liquid system produced in a baffled agitated vessel with two high-speed impellers on the common shaft were experimentally determined. The minimum impeller speeds adequate to obtain loading, complete dispersion and just drawdown (of floating particles) flow patterns for such multiphase system were identified. The results confirmed that there is influence of gas flow rate Vg and particles concentration X on the value of minimum impeller speeds for each flow model (nJD, nL, nCD, nJDG) and gas hold-up ( in analyzed systems.

Numerical study on solid suspension characteristics of a coaxial mixer in viscous systems

Abstract A coaxial mixer consisting of an anchor and a Rushton turbine was selected as the research object, whose solid suspension characteristics were studied with the help of Computational Fluid Dynamics (CFD) method. Based on the Eulerian–Eulerian method and modified Brucato drag model, the just-suspension speed of impeller was predicted, and the simulation results were in good agreement with the experimental data. The quality of solid suspension under different rotation modes was also compared, and the results showed the coaxial mixer operating under co-rotation mode could get the best performance, and a larger anchor speed was beneficial to solid suspension by enhancing the turbulent intensity at the bottom. Compared with the anchor, the inner Rushton turbine played a dominant role in solid suspension due to its high rotational speed, whereas an extremely high inner impeller speed would make the uniformity of solid distributions become worse. Additionally, the effects of solid phase properties were also investigated, the results revealed that the higher the overall solid volume fraction and the smaller the Shields number, the worse the performance of solid suspension, meanwhile the solid suspension was more susceptible to solid density compared with particle diameter within the same Shields number gradient.

Selective flotation of fine-grained pentlandite from low grade polymetallic ore

The main aim of this study is to test a new type of an impeller in selective flotation of a low grade polymetallic Ni-Cu-PGE ore. The effect of impeller type and speed on bubble size and nickel grade and recovery was investigated. It was noticed that bubble size was independent of impeller type and speeds. However, the highest volume of small bubbles was measured using a new type of impeller. The results showed that a pitched blade turbine impeller has a positive effect on nickel grade and recovery at higher impeller speed.

Effect of impeller speed on properties of quiescent zone and entrainment in mechanical flotation cells

Flotation process in mechanical cells is carried out in highly turbulent conditions. In this work, the impact of impeller speed on four characteristics of the quiescent zone, i.e. zone height, turbulence, solid percentage, and gas holdup, and their relationship with the entrainment is investigated, and it is shown why at a higher impeller speed, entrainment is not significant. The height of the quiescent zone and its turbulence are measured using a piezoelectric sensor, while an electrical conductivity sensor measures the gas hold-up. A peristaltic pump is applied to take samples from the pulp to measure the solid percentage. The results obtained showed that with increase in the impeller speed from 750 to 1100 rpm, the entrainment value changed from 2.01% to 5.69%. However, the variations in entrainment were not significant at speeds higher than 1100 rpm. It was found that the height of the quiescent zone was independent from the impeller speed, while raising the impeller speed, as long as the solid percentage, turbulence, and gas hold-up are increased, caused a drastic increase in entrainment. Despite the increase in the solid percentage and turbulence, the gas hold-up decreased at impeller speeds higher than 1100 rpm due to the variation in the bubble distribution pattern, so the entrainment raised with a smaller slope. Finally, a model is presented for the entrainment as a function of the three correlated variables using the Ridge regression. The entrainment is then correlated to the impeller speed, explaining the contradictory results from the literature on the effect of impeller speed on the entrainment.

Detailed modeling and process design of an advanced continuous powder mixer

A vertical in-line continuous powder mixing device (CMT – Continuous Mixing Technology) has been modelled with the discrete element method (DEM) utilizing a calibrated cohesive contact model. The vertical design of the mixing device allows independent control of mean residence time (MRT) and shear rate. The hold-up mass and outlet flow are controlled by an exit valve, located at the bottom of the in-line mixer. A virtual design of experiments (DoE) of DEM simulations has been performed and parameters such as particle velocities, powder bed shape, residence time distribution (RTD), travel distance, and mixing quality are evaluated for the complete operating space. The RTD of the DEM model has been validated with tracer experiments. The resulting RTD has been fitted with an analytical form (generalized cascade of n continuous stirred tank reactors) and utilized to study the downstream response of the continuous mixing device to upstream fluctuations in the inlet material stream. The results indicate a high mixing quality and good filtering properties across the operating space. However, the combination of low hold-up mass and high impeller speeds leads to a reduced filtering capability and wider exit valve openings, indicating a less desirable operating point.

Effects of granulation process variables on the physical properties of dosage forms by combination of experimental design and principal component analysis

The current study was to understand how process variables of high shear wet granulations affect physical properties of granules and tablets. The knowledge gained was intended to be used for Quality-by-Design based process design and optimization. The variables were selected based on the risk assessment as impeller speed, liquid addition rate, and wet massing time. Formulation compositions were kept constant to minimize their influence on granules properties. Multiple linear regression models were built providing understanding of the impact of each variable on granule hardness, Carr's index, tablet tensile strength, surface mean diameter of granules, and compression behavior. The experimental results showed that the impact of impeller speed was more dominant compared to wet massing time and water addition rate. The results also revealed that quality of granules and tablets could be optimized by adjusting specific process variables (impeller speed 1193 rpm, water spray rate 3.7 ml/min, and wet massing time 2.84 min). Overall desirability was 0.84 suggesting that the response values were closer to the target one. The SEM image of granules showed that spherical and smooth granules produced at higher impeller speed, whereas rough and irregular shape granules at lower speed. Moreover, multivariate data analysis demonstrated that impeller speed and massing time had strong correlation with the granule and tablet properties. In overall, the combined experimental design and principal component analysis approach allowed to better understand the correlation between process variables and granules and tablet attributes.

An effect of the tubular baffles configuration in an agitated vessel with a high-speed impeller on the power consumption

The results of the power consumption for an agitated vessel equipped with vertical tubular baffles and high-speed impeller are presented in the paper. Aqueous solutions of CMC were agitated within transitional range of the non-Newtonian liquid flow in the agitated vessel of inner diameter equal to 0.6 m. Eight different types of the impellers were tested: Rushton or Smith turbines, turbine with straight blades, pitched blade turbines and propeller. The J tubular baffles of outer diameter B were located in the position e from the vessel wall. Different configurations of baffles, arranged around the vessel circumference singularly or blocked in the modules, were considered in the study. In total, 180 different tubular baffles–impeller systems were tested. The measurements of the torque were conducted by means of the strain gauges method. Based on the power characteristics obtained for each impeller type, the effect of the geometrical parameters of the vertical tubular baffles on the power number was determined and discussed. The results show that geometry of the tubular baffles mostly affects the power number for the system with radial flow Rushton turbine. Moreover, power numbers decrease with the increase of the clearance between baffle and vessel wall for the systems, in which the radially axial circulation of the liquid is promoted. The dependences of the power number on the geometrical parameters of the vertical tubular baffles arranged singularly around the vessel circumference were described by means of the Eqs. (5)–(16). These equations can be useful in the project computations.

Experimental analysis of gas hold-up for gas-liquid system agitated in a vessel equipped with two impellers and vertical tubular baffles

Abstract The influence of impellers system and type of liquid on the gas hold-up in the vessel has been presented in this paper. The analysis of gas hold-up was conducted on the basis of the data obtained in the vessel of the diameter D = 0.288 m, where the vessel was filled by a liquid up to the height H = 2D. The vessel was equipped in 24 vertical tubular baffles located on the circuit and two high-speed impellers situated on a shaft. Five different configurations of high-speed impellers were employed. The experiments in the gas-liquid system were conducted for setups which differed in capability of gas bubbles coalescence. The results of the experiment of the gas holdup for the five impellers configurations and four gas-liquid systems were presented in the graphic form and they were described mathematically.

Modelling and analysis of a high-speed turbine impeller concerning mistuning

As-manufactured impellers behave significantly different from nominal impellers. There are no identical blades due to geometric and material deviations. In this paper three model updating procedures are discussed with the objective to achieve realistic models of as-manufactured impellers. The techniques are applied to radial inflow turbine wheel of an exhaust gas turbocharger. The first approach creates a model through optical measurement and mesh morphing. The second approach is based on a contactless measurement of blade individual vibration responses. An iterative update process gains the corresponding mistuning pattern and thus the associated model. Third, a model is found by an optimisation, that identified a mistuning pattern, that fits modal characteristics, which are evaluated during experimental modal analysis at vacuum. In-depth analyses of these models are realised to determine advantages and drawbacks of the procedures.

Improving oxygen transfer efficiency by developing a novel energy-saving impeller

Radial flow impeller is the energy-intensive and fundamental component in reactors for the gas–liquid transfer process. A newly designed fan-shaped turbine (FT) assembly with annular-sector-shaped concave blades was characterized and compared with the Rushton turbine (RT) and Bakker turbine (BT). A new surface equation was established to design the blade of the FT impeller. Under turbulence conditions, the FT impeller showed a lower power number and higher relative power demand (RPD) compared with RT and BT impellers. The power number of the FT impeller was 1.7, lower by 26% than that of BT impeller. The RPD of the FT impeller was nearly 0.95 at a high impeller speed. The critical dispersion speed, gas holdup, and volumetric oxygen transfer coefficient of the FT impeller were close to those of BT impeller. Moreover, the oxygen transfer efficiency of the FT impeller was remarkably higher by 35%–66% and 23%–34% than that of RT and BT impellers, respectively. The FT impeller showed competence in a broad operation range, strong robustness, energy-saving feature, and efficient mass transfer characteristics.

Visualization of the Motion of Textiles through a Waste Water Pump at Different Operating Points

In this paper, the motion of textiles through a waste water pump is studied by aid of vision technologies. The steel volute of a commercial pump is replaced with a similar volute made in acrylic glass, which allows recording the motion of textiles inside the pump. Recordings are made at four different operating points to investigate the influence of rotational speed of the impeller and flow rate on the passage of textiles through the pump. The experiments show that the textiles flow rapidly through the pump when the pump is operated near the best efficient point for both high and low impeller speed. The textiles tend to stay inside the pump when the pump is operated at part load for both low and high impeller speed. At low impeller speed, the textiles often stick to the tongue in the pump casing. At higher impeller speed, the textiles flow multiple rounds in the volute. For fail-safe operation, it is recommended not to operate waste water pumps far away from the best efficiency point.

Production of egg white protein hydrolysates with improved antioxidant capacity in a continuous enzymatic membrane reactor: optimization of operating parameters by statistical design.

This study focuses on the influence of operating conditions on Alcalase-catalyzed egg white protein hydrolysis performed in a continuously stirred tank reactor coupled with ultrafiltration module (10kDa). The permeate flow rate did not significantly affect the degree of hydrolysis (DH), but a significant increase in process productivity was apparent above flow rate of 1.9cm3 min-1. By contrast, an increase in enzyme/substrate (E/S) ratio provided an increase in DH, but a negative correlation was observed between E/S ratio and productivity. The relationship between operating conditions and antioxidant properties of the hydrolysates, measured by three methods, was studied using Box-Behnken experimental design and response surface methodology. The statistical analysis showed that each variable (impeller speed, E/S ratio, and permeate flow rate) had a significant effect on the antioxidant capacity of all tested systems. Nevertheless, obtained response functions revealed that antioxidative activity measured by DPPH, ABTS and FRAP methods were affected differently by the same operating conditions. High impeller speeds and low permeate flow rates favor ABTS while high impeller speeds and high permeate flow rates had a positive effect on the DPPH scavenging activity. On the other hand, the best results obtained with FRAP method were achieved under moderate operating conditions. The integration of the reaction and ultrafiltration membrane separation in a continuous manner appears to be a right approach to improve and intensify the enzymatic process, enabling the production of peptides with desired antioxidant activity.

Experimental heat transfer behavior of graphite–water microfluid in a coiled agitated vessel

AbstractAgitation is one of the widely used engineering operations in all of the chemical industries, which involves both material transport and heat transfer in the system. In order to conserve energy spent in heat transfer systems, enhancements to heating and cooling in industrial processes can be achieved by dispersing small‐sized particles having high thermal conductivity in a base fluid. This article reports an experimental study on the heat transfer characteristics of graphite–water microfluid in a coiled agitated vessel equipped with propeller and six bladed disc turbine impellers. The heat transfer coefficient for the graphite–water microfluid is found to be higher than that for the base fluid (water) and increased with higher volume concentrations of graphite and higher impeller speed. Comparison of the graphite–water microfluid and water is found to demonstrate a significant enhancement in the convective heat transfer coefficient. Empirical correlations for the calculation of Nusselt numbers are performed, and the calculated Nusselt number is found to be in good agreement with experimental values within ±10% deviation.

Principle and basic property of the sequential flow pump.

In the emergency care field, early treatment of acute heart or respiratory failure has been a global concern. In severe cases, patients are frequently required to be on an extracorporeal membrane oxygenator (ECMO) life support. To make the ECMO system more compact and portable, we proposed a sequential flow-type centrifugal pump named the sequential flow pump (SFP). In this study, principle and basic properties of this novel blood pump were examined by computational fluid dynamic (CFD) analysis and an experimental model. In the SFP, fluid is given centrifugal force sequentially twice with a single closed impeller. This sequential pressurization mechanism enables high-pressure output without high impeller speed. To realize easy integration of a blood pump with an artificial lung, the inlet and outlet ports are located at lateral side and center of the pump, respectively, which is the reverse configuration of conventional centrifugal pumps. The computational model was composed for CFD analysis and the experimental model was developed for the experiment of the actual pump. For both models, dimension of the impeller and volute was designed to be equal. In the CFD analysis, the SFP could generate higher performance than the single pressurization model with the same rotational speed of the impeller. Basic property of the experimental model was very similar to that of the computational model. The results showed the possibility that the SFP would be more suitable for the compact ECMO system than conventional centrifugal pumps.

Intensification of mixing of shear-thinning fluids possessing yield stress with the coaxial mixers composed of two different central impellers and an anchor

The performance of different configurations of coaxial mixers composed of a wall scraping anchor impeller in combination with two different or identical central high speed impellers in the agitation of the shear-thinning fluids with yield stress (e.g. xanthan gum solution) was investigated. These multi-impeller mixers are more compact for the larger scale of mixing operations. The coaxial mixers employed in this study were the Scaba-Scaba-anchor, Scaba-Rushton-anchor, Rushton-Scaba- anchor, Scaba-pitched blade-anchor, and pitched blade-Scaba-anchor. The quality of mixing achieved by these five coaxial mixers was assessed for the Reynolds numbers in the range of the laminar to the transitional regime in the co-rotating mode through computational fluid dynamic (CFD) and electrical resistance tomography (ERT) techniques. A new correlation was introduced for these complex configurations of the coaxial mixers by incorporating the Metzner-Otto constants (Ks) of the different types of the central impellers into the Reynolds number. The experimental and CFD data were employed to evaluate the mixing intensification attained by these five coaxial mixers in regard to the power consumption, mixing time, velocity profiles, shear strain rate profiles, flow number, power number, and pumping effectiveness. The analysis of the collected data indicated that the intensification of mixing of the highly viscous non-Newtonian fluids achieved by the Scaba-pitched blade-anchor coaxial mixer was the highest among the mixing systems explored in this study.

An effect of the impeller eccentricity on the process characteristics in an agitated vessel—experimental and numerical modeling

An effect of the impeller eccentricity on the process characteristics in an agitated vessel was analyzed on the basis of our own experimental and numerical results obtained within the turbulent range of the Newtonian liquid flow. Mixing time, power consumption, local and mean values of the heat transfer coefficients and distributions of the transport coefficients (shear rate and friction coefficient) at the vicinity of the vessel wall were studied experimentally within the wide range of the operating and geometrical parameters of the agitated vessel equipped with eccentrically located high-speed impeller. Numerical simulations of hydrodynamics in an agitated vessel with eccentrically located axial flow impeller (up-pumping propeller or downpumping HE-3 impeller) were carried out using CFD method.

Development of a discrete element model with moving realistic geometry to simulate particle motion in a Mi-Pro granulator

Abstract This paper presents the implementation of a methodology incorporating a 3D CAD geometry into a 3D discrete element method (DEM) code; discussing some of the issues which were experienced. The 3D CAD model was discretised into a finite element mesh and the finite wall method was employed for contact detection between the elements and the spherical particles. The geometry was based on a lab scale Mi-Pro granulator. Simulations were performed to represent dry particle motion in this piece of equipment. The model was validated by high speed photography of the particle motion at the surface of the Mi-Pro's clear bowl walls. The results indicated that the particle motion was dominated by the high speed impeller and that a roping regime exists. The results from this work give a greater insight into the particle motion and can be used to understand the complex interactions which occur within this equipment.

Numerical simulation on macro-instability of coupling flow field structure in jet-stirred tank

The velocity field macro-instability (MI) can help to improve the mixing efficiency. In this work, the MI features of flow field induced by jet-stirred coupling action is studied by using computational fluid dynamics (CFD) simulations. The numerical simulation method of jet-stirred model was established based on standard turbulent equations, and the impeller rotation was modeled by means of the Sliding Mesh (SM) technology. The numerical results of test fluid (water) power consumption were compared with the data obtained by power test experiments. The effects of jet flow velocity and impeller speed on MI frequency were analyzed thoroughly. The results show that the calculated values of power consumption agree well with the experiment measured data, which validates the turbulent model, and the flow structure and MI frequency distribution are affected by both impeller speed and jet flow rate. The amplitude of MI frequency increases obviously with the increasing rotation speed of impeller and the eccentric jet rate, and it can be enhanced observably by eccentric jet rate, in condition of comparatively high impeller speed. At this time, the MI phenomenon disappears with the overall chaotic mixing.

Design, production and characterisation of granular adsorbent material for arsenic removal from contaminated wastewater

The objective of this research was to design granulated iron oxide for the adsorption of heavy metals from wastewater. Polyvinyl acetate (PVAc) was chosen as a suitable binder; as it is water insoluble. Initial experiments on selection of suitable solvent of the polymer were carried out using three solvents namely; methanol, acetone and toluene. Based on the initial tests on product yield and mechanical strength, acetone was selected as the solvent for the polyvinyl acetate binder. Design of experiment was then used to investigate the influence of granulation process variables; impeller speed, binder concentration and liquid to solid ratio on the properties of the granular materials. The response variables in the study were granules mean size, stability in water and granule strength. The results showed that the combination of high impeller speed and high binder concentration favour the formation of strong and stable granules. Results also showed that leaching of the binder into the simulated was water was negligible. Trial adsorption experiments carried out using the strongest and most stable iron oxide granules produced in this work showed removal efficiency of around 70% of synthetic arsenic solutions with initial concentration of 1000ppb.