Impeller Type Research Articles

Improving grinding efficiency and performance of new impeller type ball mill using discrete element method simulations and Taguchi method

Improving grinding efficiency and performance of new impeller type ball mill using discrete element method simulations and Taguchi method

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.

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).

CHO stable pool fed-batch process development of SARS-CoV-2 spike protein production: Impact of aeration conditions and feeding strategies.

Technology scale-up and transfer are a fundamental and critical part of process development in biomanufacturing. Important bioreactor hydrodynamic characteristics such as working volume, overhead gas flow rate, volumetric power input (P/V), impeller type, agitation regimen, sparging aeration strategy, sparger type, and kLa must be selected based on key performance indicators (KPI) to ensure a smooth and seamless process scale-up and transfer. Finding suitable operational setpoints and developing an efficient feeding regimen to ensure process efficacy and consistency are instrumental. In this investigation, process development of a cumate inducible Chinese hamster ovary (CHO) stable pool expressing trimeric SARS-CoV-2 spike protein in 1.8 L benchtop stirred-tank bioreactors is detailed. Various dissolved oxygen levels and aeration air caps were studied to determine their impact on cell growth and metabolism, culture longevity, and endpoint product titers. Once hydrodynamic conditions were tuned to an optimal zone, various feeding strategies were explored to increase culture performance. Dynamic feedings such as feeding based on current culture volume, viable cell density (VCD), oxygen uptake rate (OUR), and bio-capacitance signals were tested and compared to standard bolus addition. Increases in integral of viable cell concentration (IVCC) (1.25-fold) and protein yield (2.52-fold), as well as greater culture longevity (extension of 5 days) were observed in dynamic feeding strategies when compared to periodic bolus feeding. Our study emphasizes the benefits of designing feeding strategies around metabolically relevant signals such as OUR and bio-capacitance signals.

Interpretable machine learning-based analysis of coal fly ash flotation by conditioning process intensification

ABSTRACT Conditioning process intensification is necessary for improving the fly ash flotation effect. Understanding the relationship between conditioning parameters and flotation results is crucial for optimizing the conditioning-flotation process. This study developed a machine learning framework for predicting the yield, loss on ignition, and removal rate of unburned carbon using data from conditioning-flotation experiments. Feature variables of conditioning speed, impeller type, stirred tank diameter, collector dosage, and frother dosage were employed to develop five machine learning models. After tuning the hyper-parameters with GridSearchCV technique, it was found that Random Forest Regression model, eXtreme Gradient Boosting Regression model, and Gradient Boosting Regression model demonstrated good agreements between the predicted data and test data for the yield, loss on ignition, and removal rate of unburned carbon. The maximum R2 values were 0.9184, 0.8339, and 0.9434, respectively, while the minimum MSE values were 3.30, 5.82, and 20.59, respectively. The interpretable analysis using SHapley Additive exPlanations (SHAP) method indicated that conditioning speed was the most significant feature variable affecting the yield, loss on ignition, and removal rate of unburned carbon, while impeller type had a secondary impact. This investigation is expected to reveal the important role of conditioning process intensification in optimizing fly ash flotation.

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.

Enhancing Pump as Turbine (PAT) performances: A numerical investigation into the impact of impeller leading edge rounding

Pump As Turbine (PAT) utility represents a major advance in the field of hydraulic engineering. This work aims to improve the PAT performance characteristics. The sharp impeller leading edge (original impeller) was revealed by flow analysis as exhibiting negative effects on the PAT performances due to flow separation and flow misalignment. The performances of rounded and original impeller leading edge were studied by Computational Fluid Dynamic (CFD) method carried out on ANSYS CFX. Although impeller leading edge rounding has notably improved the performances in off design conditions, the difference of efficiency between the both impeller types was decreasing when increasing the discharge. The hydraulic head generated by the rounded impeller leading edge was also slightly higher at part load conditions, but when increasing the discharge, the difference between the both heads became negligible. It appeared from numerical simulations that the impeller leading edge rounding allows to decrease the hydraulic losses of the individual sub-domains except the outlet pipe. For the seek of a comprehensive analysis, the significant losses were computed for the two impeller geometries. It was observed that the shock losses and swirling losses of the rounded impeller leading edge were lower at part load conditions, but when increasing the discharge, the both losses were lower for the original impeller geometry. The rounded impeller leading edge exhibited as well lower wall frictional losses for the entire operating range of discharge.

Impact of impeller design on anaerobic digestion: Assessment of mixing dynamics, methane yield, microbial communities and digestate dewaterability

The efficiency of anaerobic digestion (AD) processes is intricately tied to mixing quality. This research investigates the influence of two impeller types, namely a helical ribbon impeller (HRI) and a pitched-blade impeller (PBI), on key aspects of AD. The investigation encompassed mixing dynamics, methane production, microbial communities, and the previously unexplored impact on digestate dewaterability. Results show that agitation with the PBI exhibited stratification, with bottom layer total solids (TS) values of 3.1% for the PBI and 2.6% for the HRI. Nevertheless, methane yield remained unchanged, averaging 286 LN/kg volatile solids (VS)added. Slower mixing with the HRI achieved more uniform mixing and reduced energy requirements. Additionally, impeller type significantly affected digestate dewaterability, leading to a 3.8% increase in TS of the dewatered sludge when using the PBI. These findings highlight the importance of considering mixing not only for methane production and reduced maintenance but also for achieving optimal digestate dewaterability.

Development of new correlation for the prediction of power number for closed clearance impellers using machine learning methods trained on literature data

AbstractThe accurate estimation of the power number for closed clearance impellers holds significant importance in industries such as chemical, biochemical, paper and pulp, as well as paints, pigments, and polymers. Existing state‐of‐the‐art correlations for predicting power numbers, however, are inaccurate for impeller Reynolds number . In this study, we compiled a dataset of 1470 data points from 15 research articles in the open literature, covering five types of impellers: (i) anchor; (ii) gate; (iii) single helical ribbon; (iv) double helical ribbon; and (v) helical ribbon with screw. Six machine learning models, namely artificial neural networks (ANN), CatBoost regressor, extra tree regressor, support vector regressor, random forest, and XGBoost regressor, were developed and compared. The results revealed that ANN emerged as the most efficient model, demonstrating the highest testing R2 value of 0.99 and the lowest testing MAPE of 7.3%. Further, we used the ANN model to develop a novel set of process correlations to estimate impeller power numbers for the industrially important anchor and double helical ribbon impellers: which significantly outperform the existing state‐of‐the‐art correlations available in literature.

CFD modeling of H2S removal from liquid sulfur in a pilot-scale gas-liquid contactor

Removal of hydrogen sulfide (H2S) from liquid sulfur is essential to product quality and safe operation in sulfur processing recovery. This paper presents computational fluid dynamics (CFD) models of sulfur degassing performance in a pilot-scale gas-liquid contactor. Two mass transfer models with and without considering the decomposition of hydrogen polysulfide (H2Sx) to H2S are established. They are then used to explore the effects of various operating parameters, including residence time, injected liquid sulfur flow rate, impeller type, and agitation speed, on degassing efficiency. Results show that the relative errors between calculation and experimental data are within ±6.2 %. Furthermore, the impeller geometry is optimized, and the efficiencies of three degasser shapes are compared using the verified CFD tool. The optimized impeller structure can increase degassing efficiency by about 9 % compared to the original one. The CFD model can be further improved to guide the design and scale-up of diverse H2S degassers.

Numerical validation of a novel cuttings bed impeller for extended reach horizontal wells

To reduce the risk of downhole accidents resulting from poor wellbore cleaning during the drilling of extended reach horizontal wells, a new cuttings bed impeller is developed. The performance of existing cuttings bed impellers on wellbore cleaning efficiency is analyzed by multiphase numerical simulation. Based on this analysis, a new type of cuttings bed impeller is proposed, and its key structure parameters are optimized. Its cuttings removal performance under different working conditions is verified. The results show that the spiral impellers have the highest annular velocity, promoting the movement of the cuttings bed. Increasing the rotation speed of the impeller causes the cuttings bed to move further from the low side of the wellbore, facilitating the cuttings removal. Two major improvements are introduced to the new cuttings bed impeller: a positive displacement motor that enables the self-rotation of the impeller, and the elastic contacts on the spiral blades that stir cuttings bed and reduce friction with the wellbore. The optimized parameters of the new impeller are: helix angle of 60°, 4 blades, elastic contacts arranged in crossed pattern, and self-rotation speed of 60 r/min. It is also demonstrated that the new impeller achieves satisfactory cleaning results in both rotary drilling (84.71%) and sliding drilling (71.07%) conditions. This work provides a new solution for the efficient removal of cuttings in extended reach horizontal wells.

Design and experiment of impeller seed guide device for rice internal suction hole direct seeding device

Multi-grain hole-forming sowing and uniform hole spacing are important agronomic requirements for precise hole-direct seeding of rice.This paper designs a kind of impeller type seed guiding device. The main structural parameters of the impeller seed guide device were analyzed by constructing the kinematics model of the rice seed in the impeller seed guide process. The experiment analysis were carried out with the long-grain rice variety Chuangliangyou 4418 as the seeding object. The optimal structural parameter combination of seeding-guiding device was determined as inner impeller radius 56 mm, blade offset angle 11° and seeding angle 36°. On this basis, the seeding performance test of different seed guiding devices of internal suction seed-metering device was carried out by using rice seeds with different external dimensions. The test results show that the impeller has better cavitation and hole spacing uniformity than the seed guide tube. The average hole diameter is not higher than 21.7 mm, the qualified rate of hole diameter is not lower than 96.1%, and the coefficient of variation of hole spacing is not higher than 10.1%. Compared with the seed guide tube, which is increased by 32%, 16% and 34% respectively, and the average hole distance is about 200 mm in theory.

Kinetics of hydrate formation by CO2 and mixture of CO2–C3H8 in concentrated NaCl solution: Effect of impellers

Hydrate-based desalination (HBD) can apply directly to high-salinity water produced with crude oils and gases. For HBD technology to be commercialized, the slow kinetics of hydrate formation must be overcome. This study investigates the effects of type, diameter, number and clearance of impellers on kinetics, i.e. nucleation and growth, of hydrates of pure CO2 and mixture of CO2–C3H8 in a stirred vessel. Concentrated saline solution (8 wt%) was applied to form hydrates at constant temperatures (271.15–279.15 K) and pressures (1.73–3.6 MPa). Single pitched blade (PB) and straight blade (SB) impellers and also dual combinations of them were applied. With both SB and PB impellers at single mode, lower clearance improved nucleation rates (lower induction times) and higher clearance improved growth rates. The growth rate with SB was higher than that with PB under similar conditions, showing that radial flow is in favor of growth rate. With dual combination of PB and SB, higher nucleation and growth rates were observed compared to single impellers. The presence of PB in dual configuration influenced only the nucleation rate. Using a large diameter SB impeller, resulted in higher growth rate and gas consumption in dual mode. The results with CO2–C3H8 mixture were the same as pure CO2. Due to the promoting effect of propane on nucleation and growth rates, the effects of variation in propeller characteristics became minor in the presence of propane.

Investigation of effects of impeller geometry on the spatial distribution of turbulent field and micro-mixing performance in a stirred reactor equipped with multiple impellers

There are few studies on the effects of spatial distribution of hydrodynamics on the micro-mixing in stirred reactors. In this work, a statistical approach is introduced to quantitatively assess the spatial distributions of hydrodynamic parameters, using the turbulent dissipation rate as an example. According to the results, the effects of impeller geometry and angular velocity on the turbulent dissipation rate can be well described in terms of the volume-averaged values and spatial distribution functions. In the present study, a more uniform distribution of the turbulent dissipation rate is achieved by the multiple impellers with an inclinational angle of 15° at the same rotational speed. However, increasing the inclinational angle can decrease the volume-averaged value. The cumulative percentage of area-averaged turbulent dissipation rate is well modeled by an exponential function. The effects of impeller types on the meso- and micro-mixing processes are also investigated. It is found that the micro-mixing process has more significant influences than the meso-mixing process in the bottom region and near the free surface. The effects of impeller types on the micro-mixing performance are further investigated using the Villermaux–Dushman reaction system, both experimentally and numerically. An empirical correlation that considers the spatial distribution of turbulent parameters for the reaction rate of I2 synthesis is proposed. The results show that the predictions of segregation index, which represents micro-mixing performance, are improved by a numerical model coupled with the new reaction rate model.

Satellite Thermal Management Pump Impeller Design and Optimization

This study presents a numerical approach to the design and optimization of centrifugal impellers used in the pumps of active thermal control systems of spacecraft. Although launch costs have shrunk in the last decade, the performance requirements, such as efficiency and reliability, have increased, as such systems are required to work up to 15 years, depending on the mission. To that effect, our paper deals with the first step in this pump design, namely the hydraulic optimization of the impeller. Constructively, this type of impeller allows for certain balancing systems and labyrinth seals to be applied in a more effective way, as well as allowing for additive manufacturing methods to be used—however, details regarding these aspects are beyond the scope of the current paper. By combining empirical formulas, computational fluid dynamics (CFD) analysis, and artificial neural networks (ANNs), the research focuses on achieving high efficiency and fast manufacturing. A series of geometries have been sized and validated using steady-state RANS (Reynolds Averaged Navier-Stokes) simulations, leading to the identification of the most efficient configuration. Subsequent optimization using an ANN resulted in a refined impeller design with notable improvements in hydraulic performance: a 3.55% increase in efficiency and a 7.9% increase in head. Key parameters influencing impeller performance, including blade number, incidence, and backsweep angles, are identified. This approach offers a comprehensive method to address the evolving requirements of space missions and contributes to the advancement of centrifugal pump technology in the space domain.

Design and scale up of a mixing process for a novel automotive coating

The study reported here was performed as part of a larger project aiming to develop a high performance automotive coating and the associated manufacturing process to enable large scale manufacture of the new product. We report from the process development aspect of the project which aimed at establishing the comparative blending performance of two types of impeller- one currently in use and an alternative- at different scales. Mixing time measurements compared on the basis of volumetric power input were comparable for the sawtooth impeller and pitched blade turbine over the turbulent and transitional regimes at formulation (T= 0.13 m, ∼2 l) and pilot scales (T= 0.30 m, ∼ 20 l). At the largest scale of ∼ 160 l, it took a lot longer to blend when using the sawtooth impeller. Measured mixing time results were in agreement with predicted values using the well-established correlation for both impellers in T= 0.30 m and also for the PBT at large scale, For the sawtooth impeller the correlation underpredicted at large scale unless a higher value for the constant in the mixing time correlation (about twice) was used. This deviation in the performance at large scale has highlighted the complexity of design and scale up using a sawtooth impeller.

Synthesis and characterization of coprecipitated layered NCM oxide as cathode for sodium-ion batteries: Kinetics and hydrodynamics studies

Interest in the development of high-performance sodium-ion batteries (SIBs) as a sustainable alternative to lithium-ion batteries (LIBs) for emerging energy storage systems has motivated to delve into a novel approach for the synthesis of layered transition metal oxide (LTMO) type cathode for SIBs batteries. In this study, we introduce novel chemical synthesis method that diverges from traditional methodologies reported till date. Rather than relying on sulfur, nitrate, or acetate metal precursor salts, we employ metal carbonate salt coupled with oxalic acid as a chelating agent, and sodium carbonate as a precipitating agent. This novel chemistry enhances the microstructure of the cathode material inherited from its precursor exhibiting spherical morphology, influence on the electrochemical properties, bestowing the material with high specific capacity, extended cycle life, and an elevated charge–discharge rate. The primary focus of this work centers on a comprehensive investigation of the hydrodynamic and kinetics aspects of the co-precipitation reaction, guided by the principles of chemical engineering. The effects of key parameters such as impeller speed, impeller type, and scale-up effects on the co-precipitation process have been systematically explored. This research introduces insights into optimizing reaction conditions such as pH, reaction temperature, metal precursor salt ratio, precipitating agent, through rigorous experimentation and characterization reports. The notable effect of precipitating agent on morphology has been demonstrated by electron microscopy images. The kinetics study shows the activation energy of 8.9 kJ mol−1 depicts the reaction is controlled by mass transfer resistance and to overcome this effect, impeller type and speed plays significant role and experimentation results shows the axial mixing pattern created by pitched blade impeller is effective to improvise electrochemical properties. The synthesized cathode material exhibits remarkable electrochemical properties, including tap density of approximately 1.3 g cc−1 with reversible capacity of 215 mAh g−1, along with excellent cyclic stability (90 %) over 60 cycles. Furthermore, it shows the high energy density up to 1300 Wh/L and a rapid charge–discharge rate. These findings contribute to the advancement of SIBs technology and offer promising prospects for future researchers to efficient development of high-performance energy storage solutions.

Synthesis of layered double hydroxides: Investigating the impact of stirring conditions and reactor design parameters

The synthesis by coprecipitation of Layered Double Hydroxides (LDHs) is governed by the stages of nucleation and crystal growth associated with the efficiency of the mixing and dispersion process of the reagents. Mixing efficiency is related to process variables, such as agitation speed, type of impeller and baffles presence, among others. In this context, this work proposes an analysis of these variables in a batch reactor, using a 23 factorial design employing the factors: acceleration speed (200 and 1000 rpm), mixing time (2 and 18 h) and presence or absence of baffles. The results were evaluated quantitatively (amount of LDH produced, time and amount of base for the formation of LDHs to begin) and qualitatively (mixing aspects, sedimentation ad grinding). The significant factors affecting the amount of LDH produced (51.94–80.81 g) were agitation speed and aging time. These factors were also correlated with the structural characteristics of the materials produced, such as crystallinity, crystallite size (70.99–174.79 nm), surface area (69.81–97.62 m2/g), pore volume (0.28–0.59 cm3/g), and pore diameter (11.40–34.66 nm). LDHs produced at higher agitation rates (1000 rpm) and longer aging times (18 h) yielded higher quantities of materials (80.81 g) with improved structural characteristics. The study highlights the importance of systematically exploring the synergistic effect between process variables, emphasizing the research potential in this area.

Analyzing of hydrodynamic stress and mass transfer requirements of a fermentation process carried out in a coaxial bioreactor: a scale-up study.

Fluid hydrodynamic stress has a deterministic effect on the morphology of filamentous fungi. Although the coaxial mixer has been recognized as a suitable gas dispersion system for minimizing inhomogeneities within a bioreactor, its performance for achieving enhanced oxygen transfer while operating at a reduced shear environment has not been investigated yet, specifically upon scale-up. Therefore, the influence of the impeller type, aeration rate, and central impeller retrofitting on the efficacy of an abiotic coaxial system containing a shear-thinning fluid was examined. The aim was to assess the hydrodynamic parameters, including stress, mass transfer, bubble size, and gas hold-up, upon conducting a scale-up study. The investigation was conducted through dynamic gassing-in, tomography, and computational fluid dynamics combined with population balance methods. It was observed that the coaxial bioreactor performance was strongly influenced by the agitator type. In addition, coaxial bioreactors are scalable in terms of shear environment and oxygen transfer rate.

Diseño de un sistema de agitación para un biorreactor de 1m3 de capacidad para la producción de ácido glicérico a partir de glicerol por fermentación microbiana de Acetobacter tropicalis

This work presents the design of an agitation system for a 1m3 capacity bioreactor intended to produce glyceric acid (GA) through microbial fermentation of A. tropicalis using 20% v/v glycerol as the primary substrate. Building on previous studies that evaluated ideal conditions for glyceric acid production, initial data were utilized to identify the impeller type and perform subsequent calculations, including impeller Reynolds number, power consumption, and mixing time. Once the agitator type was specified, standard geometric relationships were employed to size components of the agitation system, such as tank size, baffle plates, and agitator dimensions. Power consumption calculations were compared with results from other studies on fermentation media with similar rheological characteristics. The agitator's power consumption for mixing 1m3 of medium was determined to be 8.35 kW, achieving 95% homogenization in 5.14 seconds, with a mixing time error of approximately 10%, operating at an agitation speed of 500 rpm. Keywords: agitation system; glyceryc acid; bioreactor