Impeller Speed Research Articles

Study on the influence degree of variables of gangue entrainment in low-rank coal flotation

ABSTRACT In high-ash low-rank coal flotation, often the entrainment of kaolinite (a gangue mineral) seriously affects the quality of the concentrate. Entrainment in flotation is a complex process. Literature suggests that operating conditions have a significant impact on the degree of entrainment. In this study, a factorial batch flotation experiment, using a mixture of low-rank coal and pure kaolinite, was performed to investigate the effects of each factor and the interaction between two factors of these variables (including air rate, impeller speed, pulp density and frother dosage) on the entrainment of gangue mineral. The results show that both the air rate and impeller speed highly significantly affect the gangue entrainment and water recovery. Pulp density interacted with both the impeller speed and frother dosage, having a statistically significant effect on the degree of entrainment. Moreover, the interaction between pulp density and frother dosage had a significant impact on gangue entrainment recovery. Besides, water recovery was significantly influenced by the interaction between the air rate and frother dosage.

Nanoparticle deagglomeration driven by a high shear mixer and intensification of low-speed stirring in a viscous system

High shear mixers (HSMs), with their unique advantages of high shear forces and a wide operational range, are commonly used in nanoparticle deagglomeration. This study explores a novel approach to intensifying nanoparticle deagglomeration in a 100 mPa‧s viscous system using HSMs combined with low-speed stirring. The effects of main operating and structural parameters were experimentally investigated. The results show that the teethed HSM outperforms the blade-screen HSM, achieving a smaller attainable size (114 nm vs. 210 nm) and a higher fine particle generation fraction (46.08% vs. 18.77%). Increasing HSM size directly affects the energy input (from 6.478 MJ/kg to 31.879 MJ/kg), which influences the deagglomeration mechanism and kinetics but does not affect the smallest attainable size (117 nm). Higher solid contents improve energy efficiency, while low-speed stirring, though not altering the deagglomeration mechanism, enhances its kinetics. The process intensification factor (S) and energy efficiency factor (εm) were defined to evaluate the intensification of low-speed stirring. Increasing the impeller speed enhances this effect. The PBT impeller with a diameter ratio of 0.35 is identified as the ideal structure in this study, improving deagglomeration performance by 8.26% while reducing energy consumption by 8.3%. These results provide guidance for optimizing processes and improving deagglomeration performance through the combination of low-speed stirring in viscous systems for process industries.

Characterisation of a continuous blender: Impact of physical properties on mass holdup behaviour

Continuous blenders are a key unit operation in Continuous Direct Compaction, a route to solid oral dosage forms that is receiving significant interest. Mass holdup in these blenders is a crucial variable; understanding how it is influenced by material properties, equipment configuration and process settings is key. The present work evaluated a Gericke GCM-450 blender for range of outlet weir aperture geometries (angled or horizontal), material properties (pure components and blends) and process settings (throughput and impeller speed). Results show opposing mass holdup behaviour depending on weir choice, material density and flowability, likely linked to the propensity of the material to form an inclined powder surface that matches – or does not – the chosen weir geometry. The present work underscores the need for fundamental process phenomena understanding, especially when insight is sought for how blender performance varies across multiple dimensions (throughput, impeller speed, material properties) and discrete equipment choices (weir geometry).

Investigation of gas-liquid mass transfer in slurry systems driven by the coaxial mixer

The coaxial mixer was applied to the gas-liquid mass transfer process in slurry systems containing up to 8 vol% solids. The effects of impeller type, impeller speed, solid content, and gas flow rate were examined, and a correlation for the volumetric mass transfer coefficient was established. The findings indicate that at identical impeller speeds, the combination of an anchor and Rushton turbine exhibited the highest volumetric mass transfer coefficient and gas hold-up among coaxial mixers. However, when the pitched blade turbine with a down-pumping direction was utilized as the inner impeller, the coaxial mixer demonstrated superior performance under the same power consumption conditions. Additionally, the lower anchor speed was found to improve gas-liquid mass transfer, whereas a higher speed would lead to poor dispersion of gas phase, thereby deteriorating the performance of coaxial mixers. Increasing solid content caused a continuous decline in both the volumetric mass transfer coefficient and gas hold-up, while a rise in gas flow rate had the positive effect. Finally, the correlation developed for the volumetric mass transfer coefficient in slurry systems showed a deviation of less than 20% between predicted and measured values.

Understanding of Wetting Mechanism Toward the Sticky Powder and Machine Learning in Predicting Granule Size Distribution Under High Shear Wet Granulation.

The granulation of traditional Chinese medicine (TCM) has attracted widespread attention, there is limited research on the high shear wet granulation (HSWG) and wetting mechanisms of sticky TCM powders, which profoundly impact the granule size distribution (GSD). Here we investigate the wetting mechanism of binders and the influence of various parameters on the GSD of HSWG and establish a GSD prediction model. Permeability and contact angle experiments combined with molecular dynamics (MD) simulations were used to explore the wetting mechanism of hydroalcoholic solutions with TCM powder. Machine learning (ML) was employed to build a GSD prediction model, feature importance explained the influence of features on the predictive performance of the model, and correlation analysis was used to assess the influence of various parameters on GSD. The results show that water increases powder viscosity, forming high-viscosity aggregates, while ethanol primarily acted as a wetting agent. The contact angle of water on the powder bed was the largest and decreased with an increase in ethanol concentration. Extreme Gradient Boosting (XGBoost) outperformed other models in overall prediction accuracy in GSD prediction, the binder had the greatest impact on the predictions and GSD, adjusting the amount and concentration of adhesive can control the adhesion and growth of granules while the impeller speed had the least influence on granulation. The study elucidates the wetting mechanism and provides a GSD prediction model, along with the impact of material properties, formulation, and process parameters obtained, aiding the intelligent manufacturing and formulation development of TMC.

Influence of energy-saving devices on the hydrodynamic characteristics of a waterjet-propelled ship: Experimental and numerical investigation

Installing stern energy-saving devices can help conserve energy and enhance ship speed, particularly for medium-to-high-speed ships. This study focuses on a waterjet-propelled ship and examines the performance of two energy-saving devices: the interceptor and stern flap. The investigation involves conducting a comparative analysis through towing-tank experiments and utilising Reynolds-averaged Navier–Stokes (RANS) numerical methods. The findings suggest that incorporating energy-saving devices alters the capture flow of the waterjet-propelled ship. Furthermore, these devices reduce ship resistance, resulting in a maximum decrease in the impeller speed of the self-propulsion point up to 5%. Following the installation of energy-saving devices, the propulsion efficiency of the waterjet-propelled ship demonstrates an enhancement ranging from 0.5% to 5.7%. This increase in propulsion efficiency emerges as a principal factor contributing to the energy savings facilitated by the stern energy-saving device. Upon comparison, it was found that within the Fr range of 0.3–0.5, the stern flap exhibited a superior energy-saving effect. Conversely, when Fr exceeded 0.5, the interceptor demonstrated a more pronounced energy-saving effect. Finally, the mechanisms of the stern energy-saving devices are elucidated based on the momentum velocity coefficient, thrust deduction fraction, and changes in the internal and external flow fields of the waterjet-propelled ship.

Gas–liquid mixing performance of a non‐Newtonian fluid in a multiple‐impeller agitated tank

AbstractBACKGROUNDThis target is to decide power input and gas hold‐up for gas–liquid mixing aqueous CMC solutions. The analysis considers the impact by varying the impeller speed and gas flow rates in a stirred tank bioreactor of three kinds of multiple impellers. The effects of the impeller type, rheology, and operating conditions were investigated on power drawn, relative power demand (RPD), gas holdup, and volumetric mass transfer coefficient.RESULTCompared to the Rushton turbine (6RT) and 4‐pitch blade (4PBT) impeller, the propeller (3PP) impeller presented a minimal event of the gassing on the RPD. 4PBT impeller has shown a higher gas hold‐up compared to the Rushton turbine and propeller impellers. The aerated agitated tank was established a dimensionless correlation for the RPD as a function of flow number and web number. Besides, the gas–liquid agitated system was also introduced a dimensionless correlation to compute the overall gas hold‐up as a function of specific power consumption. For the maximum dispersion mixing intensity, the impeller structure with low RPD looks to be more adequate. Further, maximizing gas holdup in the structures with high RPD is advantageous. The effects of impeller speed, gas superficial velocity, and rheology on the volumetric mass transfer coefficient were examined.CONCLUSIONThe volumetric mass transfer coefficient increased with an increase in impeller speed, gas superficial velocity, and power consumption per unit volume and decreased as rheology increased. The averaged kLa for each multiple‐impeller was correlated well with the specific gassed power consumption and gas superficial velocity. © 2024 Society of Chemical Industry (SCI).

A four-way coupled numerical investigation of draft tube baffled crystallizer

In the present paper, the liquid–solid two-phase turbulent flow in a Draft Tube Baffled crystallizer has been simulated using Computational Fluid Dynamics. In this respect, multiphase Eulerian model along with population balance equations were applied. To implement four-way coupling, aggregation and breakage were considered. The RNG k-ε and RSM turbulence models were employed to conduct numerical simulation of two phase turbulent flow. Results demonstrated that applying RNG k-ε and RSM turbulence models, a significant difference in axial velocity profiles along the x-axis is observed, while those along the z-axis exhibit less difference. Moreover, a significant difference in volume fraction between the two models was observed which mostly concerns the region within the draft tube and the distance between the baffle and crystallizer wall. Furthermore, changing the propeller speed from 165 to 495 rpm, the speed of 330 rpm showed to be optimal in terms of particles residence time. The results also showed that a rise in impeller speed is one of the major contributors to mass exchange enhancement between the liquid and the solid phases. Accordingly, as the impeller speed rises, the rate of mass exchange increases from 9.92 kg/h for 165 rpm to 29.07 kg/h for 495 rpm.

The effect of process parameters on a continuous blending process monitored in-line by near-infrared spectroscopy

The continuous feeding-mixing system ensures the composition uniformity down to the tableting continuous manufacturing line so that a quality end-product is consistently delivered. Near-infrared spectroscopy (NIRS) enables in-line assessment of the blend's critical quality attributes in real-time. In this study, the effect of total feed rate and impeller speed on the continuous blending process monitored in-line by NIRS was examined by principal component analysis (PCA), ANOVA simultaneous component analysis (ASCA) and partial least squares (PLS) regression. Process data were generated by a factorial experimental design with process parameters and a constant formulation comprised of: 30 % (wt/wt) ibuprofen, 67.5 % (wt/wt) microcrystalline cellulose, 2 % (wt/wt) of sodium starch glycolate and 0.5 % (wt/wt) of magnesium stearate. The PCA hinted at the prevalence of impeller speed effect on ibuprofen concentration due to path length variation of the NIR light caused by the fluidized behaviour in the powder blend as a result of high speed ranges (>300 rpm). The ASCA model indicated that while both impeller speed and total feed rate effects were statistically significant (p-value=0.004), the impeller speed was the factor that contributed the most to the spectral variance (55.5 %). The PLS regression model for the ibuprofen content resulted in a RMSECV of 1.3 % (wt/wt) and showed that impeller speed was yet again the factor that exerted the major influence on spectral variance, owing to its wavelength-dependent effect that prevents common pre-processing techniques from eliminating it across the entire NIR range. The best sample presentation to the NIR probe was achieved at low impeller speed ranges (<600 rpm) and low total feed rates (<15 kg/h), such that it enhanced the PLS model ability to predict the ibuprofen concentration in the blend.

Research of Bubble Breakup and Influencing Factors in Flotation Machine

As the core factor of flotation, bubbles have an important effect on flotation. The rotor speed, initial gas parameters and impeller structure of the flotation machine will affect the formation and movement of bubbles. It is very important to study the influence mechanism of operating parameters of flotation machine on the bubble breakup process for flotation machine design and structure optimization. This paper takes KYF-0.2m&amp;lt;sup&amp;gt;3&amp;lt;/sup&amp;gt; flotation machine as the research object, establishes a single bubble analysis model, adopts the VOF (Volume of Fluid) method to analyze the influence of different initial positions of bubbles on the bubble breakup behavior, and studies the influence of impeller speed and initial position of bubbles on the bubble breakup. Result show that the breakup of bubbles mainly occurs near the stator region. With the increase of rotational speed of the impeller, the centrifugal force and the disturbance of the convection field will become greater, the time of the bubble breakup become shorter, more bubbles breakup and generate more smaller ones. With the bubble position is closer to the rotating axis of the impeller, the impact of reflow becomes stronger and the bubble breakup effect will be better, and if the bubble initial position closer to the impeller cover, the influence of impeller on the bubbles become greater and the distribution of bubbles will be more uniform.

Influence of gate cutoff effect on flow mode conversion and energy dissipation during power-off of prototype tubular pump system

Understanding the cutoff effect of gates is essential for enhancing the overall quality of the pump system's power-off process, minimizing energy losses, and reducing potential risks associated with hydraulic transients. In this study, both numerical simulations and experimental investigations were conducted on the power-off process of a tubular pump system, considering scenarios with and without gate functionality. The simulations utilized a dynamic mesh method to model gate movement, incorporated the torque balance equation to determine the real-time impeller speed, and applied the 3D-VOF method for free surface modeling in reservoirs. Power-off experiments were performed on a model pump system and a prototype pump system to validate the numerical simulation results. To elucidate the mechanism of the gate's cutoff effect, flow modes during the power-off process were categorized based on the four-quadrant static test results of the pump, revealing the deviations between transient and static characteristics. By comparing the transient flow structures of the pump system under different gate operating states, specific energy dissipation behaviors during gate cutoff were analyzed. The research findings enhance the understanding of hydraulic transients, which is essential for developing more sustainable and resilient energy systems.

块茎收获物清选机的设计与模拟分析

In this paper, a screening machine was designed to remove the impurities in the tuber harvest, which integrates the functions of vibration screening, air separation, and flexible polishing. Discrete element simulation analysis was carried out to investigate the movement of tuber harvest and soil in the machine and the effect of polishing and removing impurities, the rationality of the structure, and the size were verified. Orthogonal tests were designed and carried out, with the rate of impurity, loss, and crushing as indicators and crank speed, impeller speed, and polishing roller speed as factors. The optimum working parameters were obtained: crank speed 280.12 r/min, impeller speed 1056.27 r/min, polishing roller speed 405.02 r/min, the impurity content was 0.29%, the loss rate was 1.01%, and the breakage rate was 0.11%. Through experimental verification, the actual value and theoretical value are basically the same, which verifies the rationality.

Numerical simulation study of the influence of stirred vessel structure on particle suspension characteristics in dilute solutions

The Euler-Euler/RANS approach has been used to simulate the particle suspension in solid–liquid stirred vessels, with experimental validation conducted through the Electrical Sensing Zone Method (ESZ). An innovative evaluation method has been introduced to quantify the critical impeller speed Nc required for particles to achieve a specific uniform suspension state in dilute solutions. The impact of different vessel bottom shapes (flat, round, and W-shaped) on particle suspension characteristics is examined. The results indicate that optimizing the bottom shape to align with flow streamlines markedly enhances particle suspension, a conclusion supported by the Online Micro-sized Particle Analyzer (OMiPA). Further analysis shows baffle configurations transform the tangential and radial velocities into the axial velocity, which is not conducive to providing initial conditions for particle suspension but improves overall suspension uniformity. Overall, effective particle suspension relies on the interaction between main flow and turbulent fluctuations, with tangential and radial flows playing critical roles.

Experimental investigation of hydrodynamics and suspension characteristics in a boiling stirred tank reactor with helical coils

The boiling stirred tank reactor (BSTR) is widely used in the chemical industry, while the relevant basic data of hydrodynamics and suspension characteristics for reactor design are quite limited. In this work, the hydrodynamics and suspension characteristics in a BSTR with helical coils (BSTR@HC) were studied using three types of impellers. Particle image velocimetry and visualization experiments reveal different flow fields and nucleation processes of three impellers. Suspension experiments show that superficial vapor velocity, solid loading, and particle size play an important role for just-suspension impeller speed Njsv and power consumption Pjsv, while cloud height is mainly determined by superficial vapor velocity. Among the three impellers, radial impeller shows the best suspension performance in BSTR@HC. Correlations of Njsv and Pjsv were developed with relative mean deviations of 2.7% and 4.6%, respectively. Furthermore, a model for the estimation of energy efficiency was developed by evaluate specific power consumption εjsv.

Impact of Impeller Speed Adjustment Interval on Hemolysis Performance of an Intravascular Micro-Axial Blood Pump.

In recent years, intravascular micro-axial blood pumps have been increasingly used in the treatment of patients with cardiogenic shock. The flow rate of such blood pumps requires adjustment based on the patient's physiological condition. Compared to a stable flow state with fixed rotation speed, adjusting the speed of blood pump impeller to alter flow rate may lead to additional hemolysis. This study aimed at elucidating the relationship between adjusting interval of a blood pump's impeller speed and the hemolysis index. By comparing simulation results with P-Q characteristic curves of the blood pump measured by experiments, the accuracy of the blood pump flow field simulation model was confirmed. In this study, a drainage tube was employed as the device analogous to an intravascular micro-axial blood pump for achieving similar shear stress levels and residence times. The hemolysis finite element prediction method based on a power-law model was validated through hemolysis testing of porcine blood flow through the drainage tube. The validated models were subsequently utilized to investigate the impact of impeller speed adjusting intervals on hemolysis in the blood pump. Compared to steady flow, the results demonstrate that the hemolysis index increased to 6.3% when changing the blood pump flow rate from 2 L/min to 2.5 L/min by adjusting the impeller speed within 0.072 s. An adjustment time of impeller speed longer than 0.072 s can avoid extra hemolysis when adjusting the intravascular micro-axial blood pump flow rate from 2 L/min to 2.5 L/min.

Study on the Transient Flow Characteristics of Multistage Centrifugal Pumps during the Startup Process before System Operation

Multistage pumps are essential in emergency water supply, irrigation, and other systems undergoing unavoidable hydraulic transitions like pump startup and valve operations. These transitions cause rapid changes in impeller speed, flow rate, and pressure, destabilizing the internal flow field and impacting system reliability. To study transient flow characteristics, a numerical analysis of a three-stage pump was conducted, focusing on vortex identification, entropy production, and time–frequency pressure pulsation. Using the SST turbulence model, the simulation analyzed different start times and flow rate variations. Findings revealed that shorter startup times intensified transient effects, with the head increasing rapidly initially and then stabilizing. Vortex structures showed periodic development and dissipation. Entropy production rose with impeller speed, peaking higher with shorter startups. Blade passing frequency dominated pressure pulsations, with increased low-frequency pulsations as speed rose. During valve opening, flow stabilization accelerated with increasing flow rates, reducing amplitude and eliminating low-frequency components. This research aids the reliable operation of high-pressure pumping systems in energy storage.

Enhancing ECG readability in LVAD patients: A comparative analysis of Denoising techniques with an emphasis on discrete wavelet transform.

BackgroundElectrocardiograms (ECGs) are vital for diagnosing cardiac conditions but obtaining clean signals in Left Ventricular Assist Device (LVAD) patients is hindered by electromagnetic interference (EMI). Traditional filters have limited efficacy. There is a current need for an easy and effective method. MethodsRaw ECG data obtained from 5 patients with LVADs. LVAD types included HeartMate II, III at multiple impeller speeds, and a case with HeartMate III and a ProtekDuo. ECG spectral profiles were examined ensuring the presence of diverse types of EMI in the study. ECGs were then processed with four denoising techniques: Moving Average Filter, Finite Impulse Response Filter, Fast Fourier Transform, and Discrete Wavelet Transform. ResultsDiscrete Wavelet Transform proved as the most promising method. It offered a one solution fits all, enabling automatic processing with minimal user input while preserving crucial high-frequency components and reducing LVAD EMI artifacts. ConclusionOur study demonstrates the practicality and efficiency of Discrete Wavelet Transform in obtaining high-fidelity ECGs in LVAD patients. This method could enhance clinical diagnosis and monitoring.

Investigation of the Electrokinetic Potential of Granules and Optimization of the Pelletization Method Using the Quality by Design Approach.

The preparation of pellets using a high-shear granulator in a rapid single-step is considered a good economic alternative to the extrusion spheronization process. As process parameters and material attributes greatly affect pellet qualities, successful process optimization plays a vital role in producing pellet dosage forms with the required critical quality attributes. This study was aimed at the development and optimization of the pelletization technique with the Pro-CepT granulator. According to the quality by design (QbD) and screening design results, chopper speed, the volume of the granulating liquid, binder amount, and impeller speed were selected as the highest risk variables for a two-level full factorial design and central composite design, which were applied to the formula of microcrystalline cellulose, mannitol, and with a binding aqueous polyvinylpyrrolidone solution. The design space was estimated based on physical response results, including the total yield of the required size, hardness, and aspect ratio. The optimized point was tested with two different types of active ingredients. Amlodipine and hydrochlorothiazide were selected as model drugs and were loaded into an optimized formulation. The kinetics of the release of the active agent was examined and found that the results show a correlation with the electrokinetic potential because amlodipine besylate can be adsorbed on the surface of the MCC, while hydrochlorothiazide less so; therefore, in this case, the release of the active agent increases. The research results revealed no significant differences between plain and model drug pellets, except for hydrochlorothiazide yield percent, in addition to acceptable content uniformity and dissolution enhancement.

A Study on the Transient Characteristics of the Power-Off Transition Process of a Double-Volute Centrifugal Pump

A double-volute centrifugal pump is a very important pump type; the internal flow field of a centrifugal pump will change drastically during the transition process of power failure, which will affect the safety and stability of the pump’s operation. In this paper, the CFD numerical simulation method is used, and the UDF procedure is developed to realize the continuous update of the impeller speed at each time step. The working parameters, such as the torque and flow rate at the instantaneous moment, are obtained through the sequential iteration of each small step, and a numerical simulation of the power-off transient is carried out on a double-volute centrifugal pump; additionally, the changes in the external characteristic parameters and the internal flow field of the centrifugal pump are analyzed in detail. The results show that the double-volute centrifugal pump experienced four different modes after power failure, namely pump mode, braking mode, turbine mode, and runaway mode, and the absolute values of the runaway speed and runaway flow rate are 1.465 times and 1.21 times the initial values, respectively. Through the analysis of the flow field in different regions, the change processes of the generation, development, and disappearance of the vortex at each position of the centrifugal pump are obtained, and the change and development processes of the internal velocity gradient of the centrifugal pump are obtained. In addition, it is found that the high-speed area located in the second volute runner is larger than that of the first volute runner because the second volute runner is shorter and narrower than the first volute runner.

Heat transfer coefficient evaluated for a designed jacketed vessel for parameter optimization in coal water slurry preparation using dual impellers

ABSTRACT This study examines the heat transfer coefficient during coal water slurry preparation in a jacketed vessel, focusing on key parameters influencing heat transfer. A dual impeller system is utilized to enhance mixing and heat transmission capacity. Using the Ant Colony Optimization (ACO) method, the equipment is designed, comprising a cylindrical flat-bottom tank with an impeller diameter of 0.079 m, a height of 0.3 m, and four uniformly positioned detachable flat baffles around the vessel’s perimeter. Experiments are conducted using the L27 orthogonal array at three different levels, varying impeller speed, clearance height to tank diameter ratio, slurry height to tank diameter ratio, and distance between the two impellers. Two categories of dual impeller experiments, propeller and Rushton, are examined. Statistical analysis indicates that impeller speed and Z/T ratio significantly influence heat transfer coefficient, while C/T ratio and distance between impellers have a lesser impact. In both propeller and Rushton experiments, impeller speed and Z/T ratio have the most substantial effect on heat transfer coefficient, contributing 62.907% and 59.47%, respectively, in propeller and Rushton experiments. These findings underscore the importance of impeller speed and Z/T ratio in enhancing heat transfer coefficient during coal water slurry preparation in a jacketed vessel.