Mixer Module

Application Library Manual

Mixer Module Application Library Manual
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Part number: CM023303

 Created in COMSOL Multiphysics 5.3

Modular Mixer

This model is licensed under the COMSOL Software License Agreement 5.3.
All trademarks are the property of their respective owners. See www.comsol.com/trademarks.
Introduction
This model uses the Part Libraries to build a variety of mixers by combining two common
types of vessels with two types of impellers. The mixers are baffled flat and dished bottom
vessels with either pitched blade impellers or Rushton turbines. By changing the
parameters in the model, you can modify the geometry to fit your applications. In case
your mixer components cannot be built from the Geometry sequences available in the Part
Libraries, you can add your own ones. The model includes three examples using the
Rotating Machinery, Fluid Flow branch with the frozen-rotor study type. The first
example solves a laminar mixing problem in a flat bottom mixer with a Rushton turbine.
The second and third examples solve for turbulent mixing in a dished bottom mixer with
a pitched blade impeller using the k-ε and k-ω turbulence models.

Model Definition
A typical mixer principally consists of two physical components — a vessel with or without
baffles and an impeller structure. Baffles are used to suppress the main vortex formation in
the bulk and thereby improve the mixing. The radial baffles, consisting of flat vertical solid
strips set radially along the vessel wall, are evenly distributed around the perimeter of the
vessel wall. Figure 1 shows the two combinations of vessels and impellers used in the
simulations.

Figure 1: A baffled flat bottom mixer with a Rushton turbine (left) and a baffled dished
bottom mixer with a pitched four blade impeller (right).

The Part Libraries contains geometry subsequences for building the mixer components
shown in the figure. The types of components and their respective properties can be
specified and varied by changing their parameters. The vessel used for mixers and reactors
typically consists of a vertical cylinder with a dish-shaped or flat bottom. The vessel
dimensions are defined by prescribing the vessel height H and diameter T. For the dished

2 | MODULAR MIXER
bottom vessel, the bottom minor radius Rd must also be specified. The mixer geometries
and dimensions are shown in Figure 2.

Rd
T

Figure 2: Side view of a flat bottom mixer (top) and a dished bottom mixer (bottom). The
specified geometric properties are the vessel height (H), diameter (T), and for the dished
bottom vessel, the bottom minor radius (Rd).

The rotation of the impeller drives the mixing of the fluid in the vessel. Due to the rotation
and the design of the impeller, the liquid is discharged in the axial and radial directions by
the impeller. Many types of impellers, with a variety of purposes, are used in industrial
applications. Impellers used for mixing are commonly classified as radial or axial impellers
corresponding to the predominant discharge direction. The impellers included in this
example are the pitched blade impeller and the six-blade Rushton disc turbine. The

3 | MODULAR MIXER
pitched blade impeller is a so-called general purpose impeller discharging the fluid both
radially and axially whereas the Rushton turbine is a radial impeller used for high-shear
mixing of liquid solutions. The impellers are shown in Figure 3. Other types of impellers
can be found in the Part Libraries.

Figure 3: A four-blade pitched impeller (left) and a six-blade Rushton disc turbine (right).

Table 1 shows the parameters used to build the mixer components, along with their
default values. The clearance C is defined as the vertical distance between the lowest point
on the cylindrical wall of the vessel and the mean vertical position of the impeller blades.
For the dished bottom vessel, the bottom is joint to the cylindrical wall by a fillet. The fillet
is ignored in the definition of the clearance.

The geometry subsequences to build the impellers and vessels are imported from the Part
Libraries: Rushton Impeller, Pitched Blade Impeller, Impeller Shaft, Flat Bottom Tank
and Dished Bottom Tank. An assembly for the mixer geometry is formed under the main
geometry node. The subsequences also define selections, such as Rotating Wall, Rotating
Interior Wall, Interior Wall, or Symmetry to facilitate setting up the physics features.

You can modify the geometry to fit your own application. In case your mixer components
cannot be built from the supplied geometry subsequences, you can add your own
subsequences to the geometry file using the existing ones as templates.
TABLE 1: MIXER GEOMETRY PARAMETERS

H 0.5[m] Vessel height

T H Vessel diameter
C 1/3*H Clearance

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TABLE 1: MIXER GEOMETRY PARAMETERS

B 4 Number of baffles
bw T/12 Baffle width
Boz 0 Baffle offset from bottom
Rd T/10 Minor radius of dished bottom
Da 1/2*T Impeller diameter
shaft_diameter 1/10*Da Shaft diameter
blade_length Da/4 Blade length for Rushton turbine
blade_lengthA 1/2*Da Blade length for pitched blade impeller
blade_width Da/5 Width of impeller blade
alpha -45[deg] Pitch angle
N_blades 4 Number of blades for pitched blade impeller

Laminar Mixing
The first example is a simulation of Silicon oil in a flat bottom mixer with a six-blade
Rushton turbine rotating at 40 rps. The simulation is set up using a Rotating Machinery,
Laminar Flow interface with the Frozen Rotor study type. The geometry is built from the
supplied geometry file: modular_mixer_geom.mph using the following parameters: vessel
diameter T = 0.0805 m, vessel height H = T, clearance C = T/3, impeller diameter
Da = T/3, blade length lb = T/4, blade width hb = T/5, and baffle width bw = T/10. The
fluid in the mixer is Silicon oil Si1000 with a density of 972 kg/m3 and a dynamic viscosity
of 1.0 Pa·s.

The example is taken from Ref. 1 which also includes comparisons with experiments from
Ref. 2. In Ref. 1, results are presented for three different rotation rates. The mixer
simulation in this example is for the highest of the three rotation rates. You can adjust the
rotation rate to simulate the other two cases. This example uses the frozen-rotor study type
whereas time-dependent (sliding-mesh) studies are performed in Ref. 1. Due to the
topology variations resulting from the relative motion between the rotating impeller and
baffled vessel, the flow field is really time dependent. The frozen-rotor solution should in
this case be viewed as a quasi-steady approximation to the flow field. The solution gives a
general idea of the circulation pattern set up in the mixing vessel, and may produce good
approximations of certain averaged flow quantities, such as the power draw. You can use
the results of the frozen-rotor simulation as initial conditions for a time-dependent study.
It is straightforward to add a time-dependent study and set the initial conditions to the
frozen-rotor solution.

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Results and Discussion
Figure 4 shows the velocity magnitude in the xz-plane and a projection of the velocity
vectors on the yz-plane for the laminar-mixing simulation.

Figure 4: Velocity magnitude and in-plane velocity vectors (yz-plane) for laminar mixing of
Silicon oil in a flat bottom mixer with a Rushton turbine.

The Rushton turbine discharges the fluid radially outward, whereby two zonal vortices are
created. Mixing occurs between the top and bottom vortices but less intensely than within
each vortex. This phenomenon is referred to as compartmentalization and is a
characteristic feature of radial impellers.

The torque on the impeller, given by


M = ẑ ⋅ r × T dA
A

where A is the surface area of the impeller and T is the total stress, is 0.011 Nm. The power
draw is obtained from

6 | MODULAR MIXER
 
P = Ω ⋅ r × T dA = Ω M
A

where Ω is the angular-velocity vector. The power draw is 2.8 W in this case. In Ref. 1, a
flow number is defined as

Q
N q = ------------3-
ND a

where Q is the radial flux through a cylindrical surface with a radius of 0.186T, extending
axially from the bottom to the top of the impeller blades. The surface defined for the
evaluation of the flow number is shown in Figure 5.

Figure 5: The surface defined for the evaluation of the flow number.

The value obtained from the simulation is 0.56, which is very close to the experimental
value presented in Ref. 2. This illustrates how the frozen-rotor simulation, in addition to
giving a general idea of the circulation pattern set up in the mixing vessel, can give good
approximations of averaged flow quantities.

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References
1. M.J. Rice, High Resolution Simulation of Laminar and Transitional Flows in a
Mixing Vessel, PhD thesis, Virginia Polytechnic Institute and State University, 2011.

2. J. Hall, Study of Viscous and Visco-elastic Flows with Reference to Laminar Stirred
Vessels, PhD thesis, Department of Mechanical Engineering, King’s College London,
2005.

Application Library path: Mixer_Module/Tutorials/modular_mixer

Modeling Instructions
Begin by loading the geometry file.

From the File menu, choose Open.

Browse to the model’s Application Libraries folder and double-click the file
modular_mixer_geom.mph.

COMPONENT 1 (COMP1)
On the Home toolbar, click Windows and choose Add Physics.

ADD PHYSICS
1 Go to the Add Physics window.
2 In the tree, select Fluid Flow>Single-Phase Flow>Rotating Machinery, Fluid Flow>
Rotating Machinery, Laminar Flow (rmspf).
3 Click Add to Component in the window toolbar.

R O T A T I N G M A C H I N E R Y, L A M I N A R F L O W ( R M S P F )
1 In the Model Builder window, under Component 1 (comp1) click Rotating Machinery,
Laminar Flow (rmspf).
2 In the Settings window for Rotating Machinery, Laminar Flow, locate the Physical Model
section.
3 From the Compressibility list, choose Incompressible flow.

Fluid Properties 1
Add the values for Silicon oil Si1000.

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1 In the Model Builder window, under Component 1 (comp1)>Rotating Machinery,
Laminar Flow (rmspf) click Fluid Properties 1.
2 In the Settings window for Fluid Properties, locate the Fluid Properties section.
3 From the ρ list, choose User defined. In the associated text field, type 972.
4 From the μ list, choose User defined. In the associated text field, type 1.

Use the predefined selections to set up the physics features.

Rotating Domain 1
1 On the Physics toolbar, click Domains and choose Rotating Domain.
2 In the Settings window for Rotating Domain, locate the Domain Selection section.
3 From the Selection list, choose Rotating domain (Flat Bottom Tank 1).
4 Locate the Rotating Domain section. In the f text field, type 40.

Rotating Wall 2
1 On the Physics toolbar, click Boundaries and choose Rotating Wall.
2 In the Settings window for Rotating Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Wall.

Rotating Interior Wall 1

1 On the Physics toolbar, click Boundaries and choose Rotating Interior Wall.
2 In the Settings window for Rotating Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Interior Wall.

Interior Wall 1
1 On the Physics toolbar, click Boundaries and choose Interior Wall.
2 In the Settings window for Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Interior Wall.

Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 In the Settings window for Symmetry, locate the Boundary Selection section.
3 From the Selection list, choose Symmetry.

Pressure Point Constraint 1

1 On the Physics toolbar, click Points and choose Pressure Point Constraint.
2 In the Settings window for Pressure Point Constraint, locate the Point Selection section.
3 From the Selection list, choose Pressure Point Constraint.

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DEFINITIONS
Load postprocessing variables for the torque and power draw.

Variables 1
1 On the Home toolbar, click Variables and choose Local Variables.
2 In the Settings window for Variables, locate the Variables section.
3 In the table, enter the following settings:

Name Expression Unit Description

tau_riw x*(rmspf.T_stress_uy+ N/m Torque per area
rmspf.T_stress_dy)-y* (interior walls)
(rmspf.T_stress_ux+
rmspf.T_stress_dx)
tau_rw x*(rmspf.T_stressy)-y* N/m Torque per area
(rmspf.T_stressx) (rotating walls)
P_riw tau_riw*rmspf.wrd1 W/m² Power draw per area
(rotating interior
walls)
P_rw tau_rw*rmspf.wrd1 W/m² Power draw per area
(rotating walls)

Integration 1 (intop1)
Define an integration operator on Rotating Interior Wall to evaluate its contributions to the
torque and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Interior Wall.

Integration 2 (intop2)
Define an integration operator on Rotating Wall to evaluate its contributions to the torque
and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Wall.

10 | MODULAR MIXER
MESH 1
1 In the Model Builder window, under Component 1 (comp1) right-click Mesh 1 and choose
Build All.
2 Click the Zoom Extents button on the Graphics toolbar.

ADD STUDY
1 On the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select Preset Studies>Frozen Rotor.
4 Click Add Study in the window toolbar.
5 On the Home toolbar, click Add Study to close the Add Study window.

STUDY 1
On the Home toolbar, click Compute.

RESULTS

Cut Plane 1
1 On the Results toolbar, click Cut Plane.
2 In the Settings window for Cut Plane, locate the Plane Data section.
3 From the Plane list, choose xz-planes.

Cut Plane 2
On the Results toolbar, click Cut Plane.

Define the surface used to calculate the flow number.

Parameterized Surface 1
1 On the Results toolbar, click More Data Sets and choose Parameterized Surface.
2 In the Settings window for Parameterized Surface, locate the Parameters section.
3 Find the First parameter subsection. In the Maximum text field, type 2*pi.
4 Find the Second parameter subsection. In the Minimum text field, type -Da/10.
5 In the Maximum text field, type Da/10.
6 Locate the Expressions section. In the x text field, type 0.186*T*cos(s1).
7 In the y text field, type 0.186*T*sin(s1).
8 In the z text field, type s2.

11 | MODULAR MIXER
9 Click Plot.
The surface for the calculation of the flow number is now visualized in the Graphics
window.

Downside Pressure
Use the vessel and impeller surface plots set up under the Pressure (rmspf) results node to
create a plot of the velocity magnitude and in-plane velocity vectors.

In the Model Builder window, expand the Results>Pressure (rmspf) node.

Upside Pressure
Right-click Downside Pressure and choose Delete.

Pressure (rmspf)
1 In the Model Builder window, under Results>Pressure (rmspf) right-click Upside Pressure
and choose Delete.
2 Right-click Pressure and choose Delete.
3 Right-click Pressure (rmspf) and choose Rename.
4 In the Rename 3D Plot Group dialog box, type Velocity: Magnitude and Vectors in
the New label text field.
5 Click OK.

Surface 2
1 Right-click Results>Velocity: Magnitude and Vectors and choose Surface.
2 In the Settings window for Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 1.
4 Locate the Coloring and Style section. From the Color table list, choose RainbowLight.

Arrow Surface 1
1 Right-click Velocity: Magnitude and Vectors and choose Arrow Surface.
2 In the Settings window for Arrow Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 2.
4 Locate the Expression section. In the x component text field, type 0.
5 Locate the Coloring and Style section. From the Arrow length list, choose Logarithmic.
6 Select the Scale factor check box.
7 In the associated text field, type 0.005.
8 In the Number of arrows text field, type 1000.

12 | MODULAR MIXER
9 From the Color list, choose White.

Velocity: Magnitude and Vectors

1 In the Model Builder window, under Results click Velocity: Magnitude and Vectors.
2 In the Settings window for 3D Plot Group, click to expand the Title section.
3 From the Title type list, choose Manual.
4 In the Title text area, type Velocity: magnitude and in-plane vectors.
5 On the Velocity: Magnitude and Vectors toolbar, click Plot.

Evaluate the torque on the impeller and the power draw using the imported
postprocessing variables.

Global Evaluation 1
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 1 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Torque in the New label text field.
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

abs(intop1(tau_riw)+intop2(tau_rw)) N*m

7 Click Evaluate.

Global Evaluation 2
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 2 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Power Draw in the New label text field.
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

abs(intop1(P_riw)+intop2(P_rw)) W

7 Click Evaluate.

Evaluate the flow number.

13 | MODULAR MIXER
Surface Integration 1
1 On the Results toolbar, click More Derived Values and choose Integration>
Surface Integration.
2 In the Model Builder window, right-click Surface Integration 1 and choose Rename.
3 In the Rename Surface Integration dialog box, type Flow Number in the New label text
field.
4 Click OK.
5 In the Settings window for Surface Integration, locate the Data section.
6 From the Data set list, choose Parameterized Surface 1.
7 Locate the Expressions section. In the table, enter the following settings:

Expression Unit Description

(u*cos(s1)+v*sin(s1))/40[1/s]/Da^3 1

8 Click Evaluate.

Turbulent Mixing, k-ε model

In the second example, turbulent mixing of water is simulated in a dished bottom mixer
with a pitched four blade impeller rotating at 20 rpm. This simulation is set up using a
Rotating Machinery, Turbulent Flow, k-ε interface with the frozen-rotor study type. The
geometry is built from the supplied geometry file:
modular_mixer_turbulent_geom.mph using the default parameters in Table 1 for a
dished bottom vessel with a pitched blade impeller except that the clearance is reduced to
C = H/4. Periodicity is utilized to reduce the computational time and hence a quarter of
the domain is simulated in this case.

This example uses the frozen-rotor study type. Due to the topology variations resulting
from the relative motion between the rotating impeller and baffled vessel, the flow field is
really time dependent. The frozen-rotor solution should in this case be viewed as a quasi-
steady approximation to the flow field. The solution gives a general idea of the circulation
pattern set up in the mixing vessel, and may produce good approximations of certain
averaged flow quantities, such as the power draw.

14 | MODULAR MIXER
Results
Figure 6 shows a surface plot of the velocity magnitude and a projection of the velocity
vectors on the yz-plane for the turbulent simulation with the k-ε turbulence model.

Figure 6: Velocity magnitude and in-plane velocity vectors (yz-plane) for turbulent mixing in
a dished bottom mixer with a pitched blade impeller using the k-ε turbulence model.

The pitched blade impeller expels the fluid axially as well as radially, and a large zonal
vortex, extending from the bottom to the top of the vessel, is formed. A smaller zonal
vortex forms below the impeller and may in certain cases cause aggregation of heavy
dispersed particles at the bottom center of the vessel.

The torque on the impeller, given by


M = ẑ ⋅ r × T dA
A

where A is the surface area of the impeller and T is the total stress, is 0.016 Nm. The power
draw is obtained from

15 | MODULAR MIXER
 
P = Ω ⋅ r × T dA = Ω M
A

where Ω is the angular-velocity vector. The power draw is 0.033 W in this case.

The process of setting up a time-dependent study with the results of the frozen-rotor
simulation as initial conditions is a bit more involved in this case because of the geometry
reduction. You can either use general extrusions to define the solution on the remaining
three quarters of the domain, or, you can recompute the frozen-rotor simulation on the
full domain.

Modeling Instructions
Begin by loading the geometry file.

From the File menu, choose Open.

Browse to the model’s Application Libraries folder and double-click the file
modular_mixer_turbulent_geom.mph.

COMPONENT 1 (COMP1)
On the Home toolbar, click Windows and choose Add Physics.

ADD PHYSICS
1 Go to the Add Physics window.
2 In the tree, select Fluid Flow>Single-Phase Flow>Rotating Machinery, Fluid Flow>
Rotating Machinery, Turbulent Flow, k-ε (rmspf).
3 Click Add to Component in the window toolbar.
4 On the Home toolbar, click Add Physics to close the Add Physics window.

ADD MATERIAL
1 On the Home toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Built-In>Water, liquid.
4 Click Add to Component in the window toolbar.
5 On the Home toolbar, click Add Material to close the Add Material window.

16 | MODULAR MIXER
R O T A T I N G M A C H I N E R Y, TU R B U L E N T F L O W, K - ε ( R M S P F )
1 In the Model Builder window, under Component 1 (comp1) click Rotating Machinery,
Turbulent Flow, k-ε (rmspf).
2 In the Settings window for Rotating Machinery, Turbulent Flow, k-ε, locate the
Physical Model section.
3 From the Compressibility list, choose Incompressible flow.

Use the predefined selections to set up the physics features.

Rotating Domain 1
1 On the Physics toolbar, click Domains and choose Rotating Domain.
2 In the Settings window for Rotating Domain, locate the Domain Selection section.
3 From the Selection list, choose Rotating domain (Dished Bottom Tank 1).
4 Locate the Rotating Domain section. In the f text field, type 20[rpm].

Rotating Wall 2
1 On the Physics toolbar, click Boundaries and choose Rotating Wall.
2 In the Settings window for Rotating Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Wall.

Rotating Interior Wall 1

1 On the Physics toolbar, click Boundaries and choose Rotating Interior Wall.
2 In the Settings window for Rotating Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Interior Wall.

Interior Wall 1
1 On the Physics toolbar, click Boundaries and choose Interior Wall.
2 In the Settings window for Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Interior Wall.

Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 In the Settings window for Symmetry, locate the Boundary Selection section.
3 From the Selection list, choose Symmetry.

Use a Periodic Flow Condition to account for the excluded domain.

Periodic Flow Condition 1

1 On the Physics toolbar, click Boundaries and choose Periodic Flow Condition.

17 | MODULAR MIXER
2 Select Boundaries 2, 6, 22, and 23 only.

Pressure Point Constraint 1

1 On the Physics toolbar, click Points and choose Pressure Point Constraint.
2 In the Settings window for Pressure Point Constraint, locate the Point Selection section.
3 From the Selection list, choose Pressure Point Constraint.

DEFINITIONS

Variables 1
1 On the Home toolbar, click Variables and choose Local Variables.
Add postprocessing variables for the torque and power draw.
2 In the Settings window for Variables, locate the Variables section.

18 | MODULAR MIXER
3 In the table, enter the following settings:

Name Expression Unit Description

tau_riw x*(rmspf.T_stress_uy+ N/m Torque per area
rmspf.T_stress_dy)-y* (interior walls)
(rmspf.T_stress_ux+
rmspf.T_stress_dx)
tau_rw x*(rmspf.T_stressy)-y* N/m Torque per area
(rmspf.T_stressx) (rotating walls)
P_riw tau_riw*rmspf.wrd1 W/m² Power draw per area
(rotating interior
walls)
P_rw tau_rw*rmspf.wrd1 W/m² Power draw per area
(rotating walls)

Integration 1 (intop1)
Define an integration operator on Rotating Interior Wall to evaluate its contributions to the
torque and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Interior Wall.

Integration 2 (intop2)
Define an integration operator on Rotating Wall to evaluate its contributions to the torque
and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Wall.

MESH 1
In the Model Builder window, under Component 1 (comp1) right-click Mesh 1 and choose
Edit Physics-Induced Sequence.

Size
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size.
2 In the Settings window for Size, locate the Element Size section.

19 | MODULAR MIXER
3 Click the Custom button.
4 Locate the Element Size Parameters section. In the Maximum element size text field, type
0.02.

Size 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size 1.
2 Select Boundaries 1, 15, 16, and 25 only.

3 In the Settings window for Size, locate the Element Size section.
4 From the Predefined list, choose Finer.
5 Click Build Selected.

Size 2
1 In the Model Builder window, right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.

20 | MODULAR MIXER
4 Select Boundaries 3 and 17 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Fine.
7 Click the Custom button.
8 Click Build Selected.
Refine the mesh in the domain defined by the control surfaces.

Size 3
1 Right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Domain.

21 | MODULAR MIXER
4 Select Domain 3 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Finer.
7 Click the Custom button.
8 Locate the Element Size Parameters section. Select the Maximum element size check box.
9 In the associated text field, type 0.0114.
10 Select the Minimum element size check box.
11 In the associated text field, type 0.00123.
12 Select the Maximum element growth rate check box.
13 In the associated text field, type 1.08.
Refine the mesh further near the blade’s surface.

Size 4
1 Right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.

22 | MODULAR MIXER
4 Select Boundary 9 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Extra fine.
7 Click Build All.
8 Click the Zoom Extents button on the Graphics toolbar.

ADD STUDY
1 On the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select Preset Studies>Frozen Rotor.
4 Click Add Study in the window toolbar.
5 On the Home toolbar, click Add Study to close the Add Study window.

STUDY 1
On the Home toolbar, click Compute.

RESULTS

Cut Plane 1
1 On the Results toolbar, click Cut Plane.

23 | MODULAR MIXER
2 In the Settings window for Cut Plane, locate the Plane Data section.
3 From the Plane type list, choose General.
4 In row Point 1, set x to -0.2 and y to -0.2.
5 In row Point 2, set x to -0.2, y to -0.2, and z to 0.2.
6 In row Point 3, set y to 0.
7 Click Plot.

Cut Plane 2
1 On the Results toolbar, click Cut Plane.
2 Click Plot.

Use the vessel and impeller surface plots set up under the Pressure (rmspf) results node to
create a plot of the velocity magnitude and in-plane velocity vectors.

Downside Pressure
In the Model Builder window, expand the Results>Pressure (rmspf) node.

Upside Pressure
Right-click Downside Pressure and choose Delete.

Pressure (rmspf)
1 In the Model Builder window, under Results>Pressure (rmspf) right-click Upside Pressure
and choose Delete.
2 Right-click Pressure and choose Delete.
3 Right-click Pressure (rmspf) and choose Rename.
4 In the Rename 3D Plot Group dialog box, type Velocity: Magnitude and Vectors in
the New label text field.
5 Click OK.

Surface 2
1 Right-click Results>Velocity: Magnitude and Vectors and choose Surface.
2 In the Settings window for Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 1.
4 Locate the Coloring and Style section. From the Color table list, choose RainbowLight.

Arrow Surface 1
1 Right-click Velocity: Magnitude and Vectors and choose Arrow Surface.
2 In the Settings window for Arrow Surface, locate the Data section.

24 | MODULAR MIXER
3 From the Data set list, choose Cut Plane 2.
4 Locate the Expression section. In the x component text field, type 0.
5 Locate the Coloring and Style section. From the Arrow length list, choose Logarithmic.
6 Select the Scale factor check box.
7 In the associated text field, type 0.26.
8 In the Number of arrows text field, type 500.
9 From the Color list, choose White.

Velocity: Magnitude and Vectors

1 In the Model Builder window, under Results click Velocity: Magnitude and Vectors.
2 In the Settings window for 3D Plot Group, click to expand the Title section.
3 From the Title type list, choose Manual.
4 In the Title text area, type Velocity: magnitude and in-plane vectors.
5 On the Velocity: Magnitude and Vectors toolbar, click Plot.
6 In the Model Builder window, click Velocity: Magnitude and Vectors.
7 In the Settings window for 3D Plot Group, locate the Plot Settings section.
8 From the View list, choose View 5.

Evaluate the torque on the impeller and the power draw using the imported
postprocessing variables.

Global Evaluation 1
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 1 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Torque in the New label text field.
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

4*abs(intop1(tau_riw)+intop2(tau_rw)) N*m

Multiply by 4 to get the torque on the whole impeller.

7 Click Evaluate.

25 | MODULAR MIXER
Global Evaluation 2
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 2 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Power Draw in the New label text field.
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

4*abs(intop1(P_riw)+intop2(P_rw)) W

Multiply by 4 to get the full power draw.

7 Click Evaluate.

Turbulent Mixing, k-ω model

In the third example, similarly to the second example, turbulent mixing of water is
simulated in a dished bottom mixer with a pitched four blade impeller rotating at 20 rpm.
Here, the simulation is set up using a Rotating Machinery, Turbulent Flow, k-ω interface
with the frozen-rotor study type. The k-ω model is better suited for flows with
recirculation regions but, due to the strong nonlinearity in the turbulence coefficients,
takes longer to converge than the k-ε model. The geometry is built from the supplied
geometry file: modular_mixer_turbulent_geom.mph using the default parameters in
Table 1 for a dished bottom vessel with a pitched blade impeller except that the clearance
is reduced to C = H/4. Periodicity is utilized to reduce the computational time and hence
a quarter of the domain is simulated in this case.

This example uses the frozen-rotor study type. Due to the topology variations resulting
from the relative motion between the rotating impeller and baffled vessel, the flow field is
really time dependent. The frozen-rotor solution should in this case be viewed as a quasi-
steady approximation to the flow field. The solution gives a general idea of the circulation
pattern set up in the mixing vessel, and may produce good approximations of certain
averaged flow quantities, such as the power draw.

26 | MODULAR MIXER
Results
Figure 7 shows a surface plot of the velocity magnitude and a projection of the velocity
vectors on the yz-plane for the turbulent simulation with the k-ω turbulence model.

Figure 7: Velocity magnitude and in-plane velocity vectors (yz-plane) for turbulent mixing in
a dished bottom mixer with a pitched blade impeller using the k-ω turbulence model.

Similarly to the k-ε simulation, the flow pattern is dominated by a large zonal vortex but
its core appears to be more stretched in the vertical direction. The smaller zonal vortex
below the impeller appears to be stretched in the radial direction.

The torque on the impeller, given by


M = ẑ ⋅ r × T dA
A

where A is the surface area of the impeller and T is the total stress, is 0.025 Nm. The power
draw is obtained from


P = Ω ⋅ r × T dA = Ω M
A

27 | MODULAR MIXER
where Ω is the angular-velocity vector. The power draw is 0.052 W in this case. These
values are higher than the corresponding results from the k-ε simulation. Although the k-
ω model is better suited for these types of flows, experimental results are needed to
determine whether these results are indeed more accurate.

The process of setting up a time-dependent study with the results of the frozen-rotor
simulation as initial conditions is a bit more involved because of the geometry reduction.
You can either use general extrusions to define the solution on the remaining three
quarters of the domain, or, you can recompute the frozen-rotor simulation on the full
domain.

Modeling Instructions
Begin by loading the geometry file.

From the File menu, choose Open.

Browse to the model’s Application Libraries folder and double-click the file
modular_mixer_turbulent_geom.mph.

COMPONENT 1 (COMP1)
On the Home toolbar, click Windows and choose Add Physics.

ADD PHYSICS
1 Go to the Add Physics window.
2 In the tree, select Fluid Flow>Single-Phase Flow>Rotating Machinery, Fluid Flow>
Rotating Machinery, Turbulent Flow, k-ω (rmspf).
3 Click Add to Component in the window toolbar.
4 On the Home toolbar, click Add Physics to close the Add Physics window.

ADD MATERIAL
1 On the Home toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Built-In>Water, liquid.
4 Click Add to Component in the window toolbar.
5 On the Home toolbar, click Add Material to close the Add Material window.

28 | MODULAR MIXER
R O T A T I N G M A C H I N E R Y, TU R B U L E N T F L O W, K - ω ( R M S P F )
1 In the Model Builder window, under Component 1 (comp1) click Rotating Machinery,
Turbulent Flow, k-ω (rmspf).
2 In the Settings window for Rotating Machinery, Turbulent Flow, k-ω, locate the
Physical Model section.
3 From the Compressibility list, choose Incompressible flow.

Use the predefined selections to set up the physics features.

Rotating Domain 1
1 On the Physics toolbar, click Domains and choose Rotating Domain.
2 In the Settings window for Rotating Domain, locate the Domain Selection section.
3 From the Selection list, choose Rotating domain (Dished Bottom Tank 1).
4 Locate the Rotating Domain section. In the f text field, type 20[rpm].

Rotating Wall 2
1 On the Physics toolbar, click Boundaries and choose Rotating Wall.
2 In the Settings window for Rotating Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Wall.

Rotating Interior Wall 1

1 On the Physics toolbar, click Boundaries and choose Rotating Interior Wall.
2 In the Settings window for Rotating Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Rotating Interior Wall.

Interior Wall 1
1 On the Physics toolbar, click Boundaries and choose Interior Wall.
2 In the Settings window for Interior Wall, locate the Boundary Selection section.
3 From the Selection list, choose Interior Wall.

Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 In the Settings window for Symmetry, locate the Boundary Selection section.
3 From the Selection list, choose Symmetry.

Use a Periodic Flow Condition to account for the excluded domain.

Periodic Flow Condition 1

1 On the Physics toolbar, click Boundaries and choose Periodic Flow Condition.

29 | MODULAR MIXER
2 Select Boundaries 2, 6, 22, and 23 only.

Pressure Point Constraint 1

1 On the Physics toolbar, click Points and choose Pressure Point Constraint.
2 In the Settings window for Pressure Point Constraint, locate the Point Selection section.
3 From the Selection list, choose Pressure Point Constraint.

DEFINITIONS

Variables 1
1 On the Home toolbar, click Variables and choose Local Variables.
Add postprocessing variables for the torque and power draw.
2 In the Settings window for Variables, locate the Variables section.

30 | MODULAR MIXER
3 In the table, enter the following settings:

Name Expression Unit Description

tau_riw x*(rmspf.T_stress_uy+ N/m Torque per area
rmspf.T_stress_dy)-y* (interior walls)
(rmspf.T_stress_ux+
rmspf.T_stress_dx)
tau_rw x*(rmspf.T_stressy)-y* N/m Torque per area
(rmspf.T_stressx) (rotating walls)
P_riw tau_riw*rmspf.wrd1 W/m² Power draw per area
(rotating interior
walls)
P_rw tau_rw*rmspf.wrd1 W/m² Power draw per area
(rotating walls)

Integration 1 (intop1)
Define an integration operator on Rotating Interior Wall to evaluate its contributions to the
torque and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Interior Wall.

Integration 2 (intop2)
Define an integration operator on Rotating Wall to evaluate its contributions to the torque
and power draw.

1 On the Definitions toolbar, click Component Couplings and choose Integration.

2 In the Settings window for Integration, locate the Source Selection section.
3 From the Geometric entity level list, choose Boundary.
4 From the Selection list, choose Rotating Wall.

MESH 1
In the Model Builder window, under Component 1 (comp1) right-click Mesh 1 and choose
Edit Physics-Induced Sequence.

Size
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size.
2 In the Settings window for Size, locate the Element Size section.

31 | MODULAR MIXER
3 Click the Custom button.
4 Locate the Element Size Parameters section. In the Maximum element size text field, type
0.02.

Size 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size 1.
2 Select Boundaries 1, 15, 16, and 25 only.

3 In the Settings window for Size, locate the Element Size section.
4 From the Predefined list, choose Finer.
5 Click Build Selected.

Size 2
1 In the Model Builder window, right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.

32 | MODULAR MIXER
4 Select Boundaries 3 and 17 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Fine.
7 Click the Custom button.
8 Click Build Selected.
Refine the mesh in the domain defined by the control surfaces.

Size 3
1 Right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Domain.

33 | MODULAR MIXER
4 Select Domain 3 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Finer.
7 Click the Custom button.
8 Locate the Element Size Parameters section. Select the Maximum element size check box.
9 In the associated text field, type 0.0114.
10 Select the Minimum element size check box.
11 In the associated text field, type 0.00123.
12 Select the Maximum element growth rate check box.
13 In the associated text field, type 1.08.
Refine the mesh further near the blades surface.

Size 4
1 Right-click Mesh 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.

34 | MODULAR MIXER
4 Select Boundary 9 only.

5 Locate the Element Size section. From the Calibrate for list, choose Fluid dynamics.
6 From the Predefined list, choose Extra fine.
7 Click Build All.
8 Click the Zoom Extents button on the Graphics toolbar.

ADD STUDY
1 On the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select Preset Studies>Frozen Rotor.
4 Click Add Study in the window toolbar.
5 On the Home toolbar, click Add Study to close the Add Study window.

STUDY 1
On the Home toolbar, click Compute.

RESULTS

Cut Plane 1
1 On the Results toolbar, click Cut Plane.

35 | MODULAR MIXER
2 In the Settings window for Cut Plane, locate the Plane Data section.
3 From the Plane type list, choose General.
4 In row Point 1, set x to -0.2 and y to -0.2.
5 In row Point 2, set x to -0.2, y to -0.2, and z to 0.2.
6 In row Point 3, set y to 0.
7 Click Plot.

Cut Plane 2
1 On the Results toolbar, click Cut Plane.
2 Click Plot.

Use the vessel and impeller surface plots set up under the Pressure (rmspf) results node to
create a plot of the velocity magnitude and in-plane velocity vectors.

Downside Pressure
In the Model Builder window, expand the Results>Pressure (rmspf) node.

Upside Pressure
Right-click Downside Pressure and choose Delete.

Pressure (rmspf)
1 In the Model Builder window, under Results>Pressure (rmspf) right-click Upside Pressure
and choose Delete.
2 Right-click Pressure and choose Delete.
3 Right-click Pressure (rmspf) and choose Rename.
4 In the Rename 3D Plot Group dialog box, type Velocity: Magnitude and Vectors in
the New label text field.
5 Click OK.

Surface 2
1 Right-click Results>Velocity: Magnitude and Vectors and choose Surface.
2 In the Settings window for Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 1.
4 Locate the Coloring and Style section. From the Color table list, choose RainbowLight.

Arrow Surface 1
1 Right-click Velocity: Magnitude and Vectors and choose Arrow Surface.
2 In the Settings window for Arrow Surface, locate the Data section.

36 | MODULAR MIXER
3 From the Data set list, choose Cut Plane 2.
4 Locate the Expression section. In the x component text field, type 0.
5 Locate the Coloring and Style section. From the Arrow length list, choose Logarithmic.
6 Select the Scale factor check box.
7 In the associated text field, type 0.26.
8 In the Number of arrows text field, type 500.
9 From the Color list, choose White.

Velocity: Magnitude and Vectors

1 In the Model Builder window, under Results click Velocity: Magnitude and Vectors.
2 In the Settings window for 3D Plot Group, click to expand the Title section.
3 From the Title type list, choose Manual.
4 In the Title text area, type Velocity: magnitude and in-plane vectors.
5 On the Velocity: Magnitude and Vectors toolbar, click Plot.

Evaluate the torque on the impeller and the power draw using the imported
postprocessing variables.

Global Evaluation 1
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 1 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Torque in the New label text field.
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

4*abs(intop1(tau_riw)+intop2(tau_rw)) N*m

Multiply by 4 to get the torque on the whole impeller.

7 Click Evaluate.

Global Evaluation 2
1 On the Results toolbar, click Global Evaluation.
2 In the Model Builder window, right-click Global Evaluation 2 and choose Rename.
3 In the Rename Global Evaluation dialog box, type Power Draw in the New label text field.

37 | MODULAR MIXER
4 Click OK.
5 In the Settings window for Global Evaluation, locate the Expressions section.
6 In the table, enter the following settings:

Expression Unit Description

4*abs(intop1(P_riw)+intop2(P_rw)) W

Multiply by 4 to get the full power draw.

7 Click Evaluate.

38 | MODULAR MIXER
 Created in COMSOL Multiphysics 5.3

Non-Isothermal Flow in a 2D Mixer

This model is licensed under the COMSOL Software License Agreement 5.3.
All trademarks are the property of their respective owners. See www.comsol.com/trademarks.
Introduction
This model demonstrates how to investigate the temperature distribution in a simplified
table-top lab mixer using the Rotating Machinery, Non-Isothermal Flow interface in the
Mixer Module. The key instructive element is to demonstrate the Frozen Rotor method
which substantially speeds up the computation time for a mixing study.

General Description
The model geometry is shown in Figure 1. It represents a cross-section view of a table-top
lab mixer. Small mixers are not always baffled. Instead, one or several rods are inserted
through the mixer lid and function as baffles. The rods typically contain measurement
equipment to measure for example temperature or pH level. In this model, the mixer is
baffled by a simplified immersion heater which has a constant surface a temperature of 60
°C.

Immersion heater

Rotational
direction

Figure 1: Model geometry.

2 | NON-ISOTHERMAL FLOW IN A 2D MIXER

The mixer tank is filled with water which is agitated by the impeller that rotates clockwise
(as indicated in Figure 1) with 20 rotations per minute (rpm). The impeller blades are
modeled as infinitely thin blades.

The tank is made of steel and subject to cooling by natural convection that takes place on
the outside of the mixer. The surrounding conditions are standard conditions
(temperature equal to 20 °C and pressure equal to 1 atmosphere) and the reactor is 0.2 m
high. These latter is needed as input in the natural convection correlations used to calculate
the heat transfer coefficient from the tank wall to the surrounding.

Model Setup
The Reynolds number for a mixer is commonly calculated as

ND a2
Re = ------------- (1)
ν

where N is the number of rotations per second, Da the impeller diameter and ν the
kinematic viscosity. A high Reynolds number means that the flow has a tendency to
become turbulent. Evaluating Equation 1 using ν at 60 °C gives Re= 6944.This Reynolds
number would warrant the use of a turbulence model, if the model was three-dimensional.
But the restriction to two dimensions means that a laminar flow model works at higher
Reynolds number and this model does not employ any turbulence model. A possible
extension of the model is to apply a turbulence model and recalculate the result to
investigate the effect of possible turbulent structures in the flow.

The objective of this model is to obtain the temperature distribution at operating

conditions. One way to get there would be to start from zero velocity and a homogeneous
temperature distribution and simulate the start-up of the mixer. This approach is simple,
but can require relatively long computation time.

A computationally more efficient method is to first simulate the flow using the frozen
rotor approach. The Frozen rotor approach is a modeling concept that treats the rotor as
fixed, or frozen in space. The flow in the rotating domain is assumed to be stationary in
terms of a rotating coordinate system. The effect of the rotation is then accounted for by
Coriolis and centrifugal forces. The flow in the non-rotating parts is also assumed to be
stationary, but in a non-rotating coordinate system. See Frozen Rotor in the CFD Module
User’s Guide for more information. The result of a frozen rotor simulation is an
approximation to the flow at operating conditions. The result depends on the angular
position of the impeller and cannot represent transient effects. It is still a very good starting
condition to reach operating conditions.

3 | NON-ISOTHERMAL FLOW IN A 2D MIXER

The frozen rotor result is used as input in a time dependent simulation and the progress
towards the operating conditions is monitored using probe plots.

Results and Discussion

Figure 2 shows the velocity distribution obtained from the frozen rotor simulation. As
expected, the highest velocity magnitude is found at the tip of the mixer blades. There are
three recirculation zones: One downstream of the immersion heater, one along the top
wall and one along the bottom wall.

Figure 2: Velocity field obtained from the frozen rotor simulation.

Figure 3 shows the temperature distribution obtained from the frozen rotor simulation.
Streamlines are also included to visualize the flow field. The temperature is relatively
homogeneous through the mixer. There are some cold spots in connection to the
recirculation zones. This is expected since the fluid there has a longer residence time close
to the solid wall and is thereby in less contact with the heated fluid closer to the center of
the mixer.

4 | NON-ISOTHERMAL FLOW IN A 2D MIXER

 Probe point

Figure 3: Temperature distribution obtained from the frozen rotor simulation.

To monitor the progress towards steady state, the velocity magnitude and temperature are
probed a (x,y) = (−0.05,0.065). The location is indicated in Figure 3. As can be seen, it is
located just outside the recirculation zone along the top wall.

The probe plots produced during the time dependent simulation are shown in Figure 4.
Both plots show that the flow pattern and temperature distribution drift slowly from the
frozen rotor solution towards the operating conditions. The drift in the velocity value is
significant, but the temperature does not shift much.

It can be noticed that the velocity probe plot clearly shows the frequency that corresponds
to the passing of the blades. The temperature value does not display those rapid variations
but changes smoothly.

5 | NON-ISOTHERMAL FLOW IN A 2D MIXER

Figure 4: Probe plots of velocity and temperature.

6 | NON-ISOTHERMAL FLOW IN A 2D MIXER

A more complete picture of the progress from the frozen rotor solution towards operating
conditions can be obtained by making an animation. Figure 5 shows four snapshots from
such an animation. The time runs from top left to bottom right. The most notable changes
occur in the recirculation zones. The recirculation zone behind the immersion heater
shows a periodic shedding pattern typical for flow around a cylinder at moderate Reynolds
numbers.

Looking at Figure 3, it can be seen that the recirculation zone along the top wall contains
a single, large vortex. Early on during the time-dependent simulation, this vortex splits
into several (t=10 s). As the simulation progresses (t=20 s to t=40 s), the size and strength
of the vortices varies as a result of the interaction between the disturbance, produced by
the immersion heater, and the outer wall.

Figure 5: Evolution of the temperature field from frozen rotor solution towards operating
conditions.

The results obtained in this model are typical for rotating machinery models: The frozen
rotor approach can at a minimal computation effort deliver a decent approximation of the
flow and temperature fields. But transient effects can only be captured by a time dependent
simulation and these effects can change local temperature and velocity values significantly.

7 | NON-ISOTHERMAL FLOW IN A 2D MIXER

Application Library path: Mixer_Module/Tutorials/nonisothermal_mixer

Modeling Instructions
From the File menu, choose New.

NEW
In the New window, click Model Wizard.

MODEL WIZARD
1 In the Model Wizard window, click 2D.
2 In the Select Physics tree, select Fluid Flow>Nonisothermal Flow>Rotating Machinery,
Nonisothermal Flow>Laminar Flow (rmnitf).
3 Click Add.
4 Click Study.
5 In the Select Study tree, select Preset Studies>Frozen Rotor.
6 Click Done.

GEOMETRY 1

Circle 1 (c1)
1 On the Geometry toolbar, click Primitives and choose Circle.
2 In the Settings window for Circle, locate the Size and Shape section.
3 In the Radius text field, type 0.1.

Circle 2 (c2)
1 On the Geometry toolbar, click Primitives and choose Circle.
2 In the Settings window for Circle, locate the Size and Shape section.
3 In the Radius text field, type 0.101.

Union 1 (uni1)
1 On the Geometry toolbar, click Booleans and Partitions and choose Union.
2 Click in the Graphics window and then press Ctrl+A to select both objects.

Circle 3 (c3)
1 On the Geometry toolbar, click Primitives and choose Circle.

8 | NON-ISOTHERMAL FLOW IN A 2D MIXER

2 In the Settings window for Circle, locate the Size and Shape section.
3 In the Radius text field, type 0.01.
4 Locate the Position section. In the x text field, type 0.05.
5 In the y text field, type 0.05.

Difference 1 (dif1)
1 On the Geometry toolbar, click Booleans and Partitions and choose Difference.
2 Select the object uni1 only.
3 In the Settings window for Difference, locate the Difference section.
4 Find the Objects to subtract subsection. Select the Active toggle button.
5 Select the object c3 only.

Circle 4 (c4)
1 On the Geometry toolbar, click Primitives and choose Circle.
2 In the Settings window for Circle, locate the Size and Shape section.
3 In the Radius text field, type 0.05.

Difference 2 (dif2)
1 On the Geometry toolbar, click Booleans and Partitions and choose Difference.
2 Select the object dif1 only.
3 In the Settings window for Difference, locate the Difference section.
4 Find the Objects to subtract subsection. Select the Active toggle button.
5 Select the object c4 only.
6 Select the Keep input objects check box.

Delete Entities 1 (del1)

1 In the Model Builder window, right-click Geometry 1 and choose Delete Entities.
2 In the Settings window for Delete Entities, locate the Entities or Objects to Delete section.
3 From the Geometric entity level list, choose Object.
4 Select the object dif1 only.

Bézier Polygon 1 (b1)

1 On the Geometry toolbar, click Primitives and choose Bézier Polygon.
2 In the Settings window for Bézier Polygon, locate the Polygon Segments section.
3 Find the Added segments subsection. Click Add Linear.
4 Find the Control points subsection. In row 1, set y to -0.04.

9 | NON-ISOTHERMAL FLOW IN A 2D MIXER

5 In row 2, set y to 0.04.

Bézier Polygon 2 (b2)

1 On the Geometry toolbar, click Primitives and choose Bézier Polygon.
2 In the Settings window for Bézier Polygon, locate the Polygon Segments section.
3 Find the Added segments subsection. Click Add Linear.
4 Find the Control points subsection. In row 1, set x to -0.04.
5 In row 2, set x to 0.04.

Union 2 (uni2)
1 On the Geometry toolbar, click Booleans and Partitions and choose Union.
2 Select the objects b1, c4, and b2 only.

Form Union (fin)

The boundary between the rotating and non-rotating domain must be an assembly
boundary so that the parts can move relative to each other.

1 In the Model Builder window, under Component 1 (comp1)>Geometry 1 click

Form Union (fin).
2 In the Settings window for Form Union/Assembly, locate the Form Union/Assembly section.
3 From the Action list, choose Form an assembly.
4 On the Geometry toolbar, click Build All.
5 Click the Zoom Extents button on the Graphics toolbar.

ADD MATERIAL
1 On the Home toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Built-In>Water, liquid.
4 Click Add to Component in the window toolbar.

ADD MATERIAL
1 Go to the Add Material window.
2 In the tree, select Built-In>Steel AISI 4340.
3 Click Add to Component in the window toolbar.

10 | NON-ISOTHERMAL FLOW IN A 2D MIXER

MATERIALS

Steel AISI 4340 (mat2)

1 In the Model Builder window, under Component 1 (comp1)>Materials click
Steel AISI 4340 (mat2).
2 Select Domain 1 only.
3 On the Home toolbar, click Add Material to close the Add Material window.

R O T A T I N G M A C H I N E R Y, N O N I S O T H E R M A L F L O W ( R M N I T F )

Heat Transfer in Solids 1

1 On the Physics toolbar, click Domains and choose Heat Transfer in Solids.
2 Select Domain 1 only.

Rotating Domain 1
1 On the Physics toolbar, click Domains and choose Rotating Domain.
2 Select Domain 3 only.
3 In the Settings window for Rotating Domain, locate the Rotating Domain section.
4 In the f text field, type 20[1/min].

Rotating Interior Wall 1

1 On the Physics toolbar, click Boundaries and choose Rotating Interior Wall.
2 Select Boundaries 17–20 only.

Heat Continuity 1
1 On the Physics toolbar, in the Boundary section, click Pairs and choose Heat Continuity.
2 In the Settings window for Heat Continuity, locate the Pair Selection section.
3 In the Pairs list, select Identity Boundary Pair 1 (ap1).

Flow Continuity 2
1 On the Physics toolbar, in the Boundary section, click Pairs and choose Flow Continuity.
2 In the Settings window for Flow Continuity, locate the Pair Selection section.
3 In the Pairs list, select Identity Boundary Pair 1 (ap1).

Convective Heat Flux 1

1 On the Physics toolbar, click Boundaries and choose Convective Heat Flux.
2 Select Boundaries 1, 2, 7, and 12 only.
3 In the Settings window for Convective Heat Flux, locate the Heat Flux section.

11 | NON-ISOTHERMAL FLOW IN A 2D MIXER

4 From the Heat transfer coefficient list, choose External natural convection.
5 In the L text field, type 0.2[m].

Temperature 1
1 On the Physics toolbar, click Boundaries and choose Temperature.
2 Select Boundaries 13–16 only.
3 In the Settings window for Temperature, locate the Temperature section.
4 In the T0 text field, type 60[degC].

Pressure Point Constraint 1

1 On the Physics toolbar, click Points and choose Pressure Point Constraint.
2 Select Point 5 only.

MESH 1
1 In the Model Builder window, under Component 1 (comp1) click Mesh 1.
2 In the Settings window for Mesh, locate the Mesh Settings section.
3 From the Element size list, choose Fine.
4 Right-click Component 1 (comp1)>Mesh 1 and choose Edit Physics-Induced Sequence.

Size
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size.
2 In the Settings window for Size, locate the Element Size section.
3 From the Predefined list, choose Coarse.

Free Triangular 1
To avoid unnecessarily small elements in the mixer vessel wall, add a separate size node
with reduced resolution in narrow regions.

Size 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 right-click
Free Triangular 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Domain.
4 Select Domain 1 only.
5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section. Select the Resolution of narrow regions check
box.

12 | NON-ISOTHERMAL FLOW IN A 2D MIXER

7 In the associated text field, type 0.1.

Free Triangular 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click
Free Triangular 1.
2 In the Settings window for Free Triangular, click Build Selected.

Boundary Layers 1
Use boundary layer mesh also in the solid domain to increase the resolution there.

1 Click in the Graphics window and then press Ctrl+A to select all domains.
2 In the Settings window for Boundary Layers, click Build Selected.

STUDY 1
On the Home toolbar, click Compute.

RESULTS

Velocity (rmnitf)
Re-create Figure 2 using the following steps.

Streamline 1
1 In the Model Builder window, under Results right-click Velocity (rmnitf) and choose
Streamline.
2 In the Settings window for Streamline, locate the Streamline Positioning section.
3 From the Positioning list, choose Uniform density.
4 In the Separating distance text field, type 0.02.
5 Locate the Coloring and Style section. From the Color list, choose White.
6 On the Velocity (rmnitf) toolbar, click Plot.
7 Click the Zoom Extents button on the Graphics toolbar.

Surface 1
Re-create Figure 3 using the following steps.

1 In the Model Builder window, expand the Results>Temperature (rmnitf) node, then click
Surface 1.
2 In the Settings window for Surface, locate the Coloring and Style section.
3 From the Color table list, choose Wave.

13 | NON-ISOTHERMAL FLOW IN A 2D MIXER

Streamline 1
1 In the Model Builder window, under Results right-click Temperature (rmnitf) and choose
Streamline.
2 In the Settings window for Streamline, locate the Streamline Positioning section.
3 From the Positioning list, choose Uniform density.
4 In the Separating distance text field, type 0.02.
5 Locate the Coloring and Style section. From the Color list, choose Gray.
6 On the Temperature (rmnitf) toolbar, click Plot.
Add a probe to follow the development of the flow during the time-dependent simulation.

DEFINITIONS

Domain Point Probe 1

1 On the Definitions toolbar, click Probes and choose Domain Point Probe.
2 In the Settings window for Domain Point Probe, locate the Point Selection section.
3 In row Coordinates, set x to -0.05[m].
4 In row Coordinates, set y to 0.065[m].
The probe is located at the outer edge of recirculation zone that is positioned along the
upper wall.
5 In the Model Builder window, expand the Domain Point Probe 1 node.
6 Right-click Point Probe Expression 1 (ppb1) and choose Duplicate.
7 In the Settings window for Point Probe Expression, locate the Expression section.
8 In the Expression text field, type T.
9 Click to expand the Table and window settings section. Locate the
Table and Window Settings section. From the Plot window list, choose New window.
Add a time dependent study.

ADD STUDY
1 On the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select Preset Studies>
Time Dependent.
4 Click Add Study in the window toolbar.
5 On the Home toolbar, click Add Study to close the Add Study window.

14 | NON-ISOTHERMAL FLOW IN A 2D MIXER

STUDY 2

Step 1: Time Dependent

1 In the Model Builder window, under Study 2 click Step 1: Time Dependent.
2 In the Settings window for Time Dependent, locate the Study Settings section.
3 In the Times text field, type range(0,0.5,40).
4 Click to expand the Values of dependent variables section. Locate the
Values of Dependent Variables section. Find the Initial values of variables solved for
subsection. From the Settings list, choose User controlled.
5 From the Method list, choose Solution.
6 From the Study list, choose Study 1, Frozen Rotor.
For the transient simulation, add a restriction on the time step. This will make sure that
the impeller rotation in each time step is bounded, and that a high accuracy is maintained
throughout the simulation. First generate the solver sequence.

Solution 2 (sol2)
1 On the Study toolbar, click Show Default Solver.
Apply a maximum time step of 0.05 s. This is equivalent to an impeller rotation of 6
degrees.
2 In the Model Builder window, expand the Solution 2 (sol2) node, then click Time-
Dependent Solver 1.
3 In the Settings window for Time-Dependent Solver, click to expand the Time stepping
section.
4 Locate the Time Stepping section. Select the Maximum step check box.
5 In the associated text field, type 0.05.
6 On the Study toolbar, click Compute.
Two probe-plots will automatically appear when you start the calculation.

The following steps creates an animation that contains the plots in Figure 5.

RESULTS

Temperature (rmnitf) 1
Plot the data set edges on the spatial frame to make them follow the rotation.

1 In the Model Builder window, under Results click Temperature (rmnitf) 1.

2 In the Settings window for 2D Plot Group, locate the Plot Settings section.

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3 From the Frame list, choose Spatial (x, y, z).

Surface 1
1 In the Model Builder window, expand the Temperature (rmnitf) 1 node, then click
Surface 1.
2 In the Settings window for Surface, locate the Coloring and Style section.
3 From the Color table list, choose Wave.

Streamline 1
1 In the Model Builder window, under Results right-click Temperature (rmnitf) 1 and
choose Streamline.
2 In the Settings window for Streamline, locate the Streamline Positioning section.
3 From the Positioning list, choose Uniform density.
4 In the Separating distance text field, type 0.02.
5 Locate the Coloring and Style section. From the Color list, choose Gray.

Animation 1
1 On the Results toolbar, click Animation and choose File.
2 In the Settings window for Animation, locate the Target section.
3 From the Target list, choose Player.
4 Locate the Scene section. From the Subject list, choose Temperature (rmnitf) 1.
5 Locate the Frames section. From the Frame selection list, choose All.
6 Locate the Playing section. In the Display each frame for text field, type 0.25.
7 Right-click Animation 1 and choose Play.

16 | NON-ISOTHERMAL FLOW IN A 2D MIXER

 Created in COMSOL Multiphysics 5.3

Mixing of Water in a Flat Bottom Mixer

This model is licensed under the COMSOL Software License Agreement 5.3.
All trademarks are the property of their respective owners. See www.comsol.com/trademarks.
Introduction
This model simulates the flow in a flat bottom mixer containing, agitated by a pitched four
blade impeller. The mixed fluid is water, and a the flow is assumed turbulent due to the
significant mixer Reynolds number (5.33·104). The flow in the mixer is modeled using the
k-ε turbulence model, and a time-dependent simulation corresponding to 30 revolutions
of the impeller is performed in order to reach the operating conditions of the mixer.

When postprocessing the results, the self-similarity of the axial flow along the baffles is
analyzed. In agreement with Ref. 1, the normalized velocity profiles at different axial
positions are found to be self-similar indicating that the flow in this region resemble a three
dimensional wall jet.

Model Definition
The mixer simulated consists of a baffled flat-bottom vessel including and a pitched four
blade. The mixer geometry and the simulation conditions used in this model corresponds
the one used in the experiments of Bittorf and Kresta (Ref. 1). The height (H) and
diameter (T) of the mixer vessel is 0.24 m. The diameter of the impeller, Da, is 0.33T, and
the clearance, C, between the impeller and the bottom is 0.40Da. The pitch of the impeller
blades is 45°. The geometry of the mixer simulated is shown in Figure 1. The fluid
contained in the mixer is water, which is mixed using an impeller rotational frequency of
N = 8.58 turns per second. The resulting impeller Reynolds number is:

ND a2 ρ 4
N Re = ---------------- = 5.33·10 (1)
μ

where μ and ρ are the dynamic viscosity (SI unit: kg/(m·s)) and density (SI unit: kg/m3) of
water, respectively. The impeller Reynolds number is significantly higher than one, and the
resulting fluid flow will be treated as turbulent. The turbulent flow is modeled using the
k-ε turbulence model, and the time-dependent fluid flow is solved for during 3.5 s. This
corresponds to 30 revolutions of the impeller.

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Figure 1: Mixer geometry showing the vessel, baffles and impeller.

WA LL JE T F LOW
Bittorf and Kresta (Ref. 1) compared the flow at the wall of a stirred tank to that of a
turbulent wall jet. They found the flow along the baffles of the stirred tank to compare
well to a three-dimensional wall jet. In order to asses whether the flow in this region of the
mixer has the characteristics of a wall jet, the self-similarity of the axial velocity profiles can
be examined. Self-similarity implies that the mean velocity profiles can be collapsed onto
a single profile when scaled with properly chosen length and velocity scales. The existence
of self-similarity indicates that the turbulent time scale is small enough for the turbulence
to adjust locally to the development of the jet.

For wall jets, the spreading is typically found to be characterized by the maximum jet
velocity, Um, and the distance from the wall to the position where the half the maximum
velocity value is attained. The latter is often referred to as the jet half width and denoted
by y1/2. Using the velocity data in Ref. 1, a similarity profile for a wall jet in a recirculating
flow was suggested by Bhattacharya and Kresta in Ref. 2:

U- 2
-------- = 1 – 1.5 tanh [ 0.78 ( η – 0.15 ) ] (2)
Um

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Here η denotes the distance from the wall normalized by the half width, η = y/y1/2. When
analyzing the results from the stirred tank in this model, the self-similarity will be assessed
by plotting the normalized axial velocity along the line shown in Figure 2. This
corresponds to position used in Ref. 1.

5 mm

Figure 2: Measurement position for analyzing the self-similarity of the axial velocity profiles.

Solution Procedure
The model is solved in two steps, using two different study types, in order to minimized
the solution time required to reach a fully developed, yet transient, flow state. First the
model is solved using a Frozen Rotor study step. In order to converge this step, the
parametric solver is used to first solve the model with a lower Reynolds number using a
too high dynamic viscosity. From this solution, the flow resulting from the physical
diffusion is computed.

The frozen rotor solution is then used as initial condition for the transient simulation.
During the transient simulation the model is run for 4.0 s corresponding to 34 full
revolutions of the impeller.

TIME AVERAGING
An Identity Mapping coupling operator is used when computing time averaged velocity
profiles. This is done to make sure that the average is computed along the measurement
positions shown Figure 2, regardless of the position of the rotating impeller domain. The
averages are computed using the time average operator in the manner of

timeavg(3.5,4,idmap1(w),'nointerp')

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where the axial velocity is averaged between t = 3.5 and 4 s. The nointerp flag is used to
compute the average without applying interpolation between the stored time steps.

Results and Discussion

The resulting flow field in the mixer after 4.0 s of transient simulation is shown in Figure 1.
It is clearly seen that the maximum velocity magnitude occurs at the tip of the impeller
blades. The streamlines show how the impeller pumps fluid downwards along the shaft and
ejects it towards the bottom of the vessel.

The velocity magnitude in a single cross section including the velocity vectors is shown in
Figure 3. From this figure the main flow structure of the mixer can be further examined.
The fluid flows with high speed along the bottom of the mixer. Upon reaching the wall,
vertical high speed streaks form along the outer walls. The fluid velocity decreases towards
the top of the vessel. Fluid at the top of the vessel travel towards the impeller shaft prior
to becoming pumped down toward the impeller.

Figure 3: Fluid flow at t = 4.0 s. The color of the slice plots and the width of the streamlines
indicate the velocity magnitude.

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Figure 4: Fluid flow magnitude and direction, at t = 4.0 s, in a cross section of the mixer.

To analyze the wall jet, characteristics of the upward flow along the outer walls is studied
in Figure 4. Here the averaged axial velocity, measured along the line shown in Figure 2,
is plotted at different heights from the vessel bottom. The lines correspond to z/T equal
to 0.458, 0.563, 0.667 and 0.771. The fluid velocity profiles are scaled by their individual
maximum velocity, and the distance from the wall is normalized by the jet half width as
defined in the section Wall Jet Flow. The similarity solution of Bhattacharya and Kresta
(Equation 2) is also shown.

The scaled velocity profiles are found to collapsed on top of the similarity solution, at least
for the first three positions from the bottom. The collapse occurs for η < 1.5; further out
from the wall, the velocity is directed in the opposite direction, corresponding to the
downward flow along the impeller shaft as seen in Figure 5. The collapse in the region with
upward flow indicates that the flow along the outer walls does indeed correspond to a wall

6 | M I XI N G O F WA T E R I N A F L AT B O T T O M M I XE R
jet flow. The results in Figure 5 compare well with the experimental results in Ref. 1.

Figure 5: Normalized axial velocity profiles measured at increasing heights of the mixer.

References
1. K.J. Bittorf and S.M. Kresta, “Three-dimensional wall jets: axial flow in a stirred tank,”
AIChE Journal, vol. 47, no. 6, pp. 1277–1284, 2001.

2. S. Bhattacharya and S.M. Kresta, “CFD Simulations of Three-dimensional Wall Jets in

a Stirred Tank,” Can. J. Chem. Eng., vol. 80, no. 4, pp. 1-15, 2002.

Application Library path: Mixer_Module/Benchmarks/wall_jet_4PB_mixer_flat

Modeling Instructions
From the File menu, choose New.

NEW
In the New window, click Model Wizard.

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MODEL WIZARD
1 In the Model Wizard window, click 3D.
2 In the Select Physics tree, select Fluid Flow>Single-Phase Flow>Rotating Machinery,
Fluid Flow>Rotating Machinery, Turbulent Flow, k-ε (rmspf).
3 Click Add.
4 Click Done.

GLOBAL DEFINITIONS

Parameters
1 On the Home toolbar, click Parameters.
2 In the Settings window for Parameters, locate the Parameters section.
3 Click Load from File.
4 Browse to the model’s Application Libraries folder and double-click the file
wall_jet_4PB_mixer_flat_parameters.txt.

DEFINITIONS
In the Model Builder window, expand the Component 1 (comp1)>Definitions node.

Variables 1
1 Right-click Definitions and choose Variables.
2 In the Settings window for Variables, locate the Variables section.
3 Click Load from File.
4 Browse to the model’s Application Libraries folder and double-click the file
wall_jet_4PB_mixer_flat_variables.txt.

Ramp 1 (rm1)
On the Home toolbar, click Functions and choose Global>Ramp.

GLOBAL DEFINITIONS

Ramp 1 (rm1)
1 In the Settings window for Ramp, locate the Parameters section.
2 Select the Cutoff check box.
3 In the Slope text field, type 1/tend*10.
4 Click to expand the Smoothing section. Select the Smooth at start check box.
5 Select the Smooth at cutoff check box.

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6 In the Size of transition zone text field, type tend/50.

GEOMETRY 1
Create the geometry. To simplify this step, insert a prepared geometry sequence.

1 On the Geometry toolbar, click Insert Sequence.

2 Browse to the Model Library folder and double-click the file
wall_jet_4PB_mixer.mph

3 Then click Build all on the Geometry toolbar.

MATERIALS
Now add water from the Material Library.

ADD MATERIAL
1 On the Home toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Built-In>Water, liquid.
4 Click Add to Component 1.

MATERIALS

Water, liquid (mat1)

1 On the Home toolbar, click Add Material to close the Add Material window.
2 In the Model Builder window, expand the Component 1 (comp1)>Geometry 1 node, then
click Water, liquid (mat1).
3 In the Settings window for Material, locate the Material Contents section.
4 In the table, enter the following settings:

Property Name Value Unit Property group

Dynamic viscosity mu eta(T[1/K])[Pa*s]* Pa·s Basic
visc_fact

R O T A T I N G M A C H I N E R Y, TU R B U L E N T F L O W, K - ε ( R M S P F )

Rotating Domain 1
1 On the Physics toolbar, click Domains and choose Rotating Domain.
2 Select Domain 2 only.
3 In the Settings window for Rotating Domain, locate the Rotating Domain section.

9 | M I XI N G O F WA T E R I N A F L AT B O T T O M M I XER
4 In the f text field, type N0.
5 From the Rotational direction list, choose Negative angular velocity.

Flow Continuity 1
1 On the Physics toolbar, in the Boundary section, click Pairs and choose Flow Continuity.
2 In the Settings window for Flow Continuity, locate the Pair Selection section.
3 In the Pairs list, select Identity Boundary Pair 1 (ap1).

Pressure Point Constraint 1

1 On the Physics toolbar, click Points and choose Pressure Point Constraint.
2 Select Point 3 only.

Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 Select Boundaries 5 and 16 only.

Interior Wall 1
1 On the Physics toolbar, click Boundaries and choose Interior Wall.
2 Select Boundaries 4, 9, 10, and 12 only.

Rotating Interior Wall 1

1 On the Physics toolbar, click Boundaries and choose Rotating Interior Wall.
2 Select Boundaries 17, 18, 23, and 39 only.

MESH 1
1 In the Model Builder window, under Component 1 (comp1) click Mesh 1.
2 In the Settings window for Mesh, locate the Mesh Settings section.
3 From the Element size list, choose Coarser.
4 From the Sequence type list, choose User-controlled mesh.

Size 1
1 In the Model Builder window, under Component 1 (comp1)>Mesh 1 click Size 1.
2 In the Settings window for Size, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check box.
5 Select the Minimum element size check box.
6 Select the Maximum element growth rate check box.

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7 Select the Curvature factor check box.
8 Select the Resolution of narrow regions check box.
9 In the Maximum element size text field, type 0.01.

Free Tetrahedral 1
1 In the Model Builder window, expand the Component 1 (comp1)>Mesh 1>
Free Tetrahedral 1 node, then click Free Tetrahedral 1.
2 In the Settings window for Free Tetrahedral, locate the Domain Selection section.
3 From the Geometric entity level list, choose Domain.
4 Select Domain 2 only.
5 Click Build Selected.

Copy Face 1
1 In the Model Builder window, right-click Mesh 1 and choose More Operations>Copy Face.
2 In the Settings window for Copy Face, locate the Source Boundaries section.
3 Click Paste Selection.
4 In the Paste Selection dialog box, type 15 in the Selection text field.
5 Click OK.
6 In the Settings window for Copy Face, locate the Destination Boundaries section.
7 Click Paste Selection.
8 In the Paste Selection dialog box, type 7 in the Selection text field.
9 Click OK.

Copy Face 2
1 Right-click Mesh 1 and choose More Operations>Copy Face.
2 In the Settings window for Copy Face, locate the Source Boundaries section.
3 Click Paste Selection.
4 In the Paste Selection dialog box, type 13 14 34 45 in the Selection text field.
5 Click OK.
6 In the Settings window for Copy Face, locate the Destination Boundaries section.
7 Click Paste Selection.
8 In the Paste Selection dialog box, type 6 in the Selection text field.
9 Click OK.
10 In the Settings window for Copy Face, click Build Selected.

11 | M I XI N G O F WA T E R I N A F L AT B O T T O M M I XER
11 In the Settings window for Mesh, click Build All.

ADD STUDY
1 On the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select Preset Studies>Frozen Rotor.
4 Click Add Study in the window toolbar.

STUDY 1

Step 1: Frozen Rotor

Set up an auxiliary continuation sweep for the visc_fact parameter.

1 In the Settings window for Frozen Rotor, click to expand the Study extensions section.
2 Locate the Study Extensions section. Select the Auxiliary sweep check box.
3 Click Add.
4 In the table, enter the following settings:

Parameter name Parameter value list Parameter unit

visc_fact 10 1

5 From the Run continuation for list, choose No parameter.

6 From the Reuse solution from previous step list, choose Yes.
7 On the Home toolbar, click Compute.
Now run a time-dependent simulation using the results from the frozen rotor study as
initial values.

ADD STUDY
1 Go to the Add Study window.
2 Find the Studies subsection. In the Select Study tree, select Preset Studies>
Time Dependent.
3 Click Add Study in the window toolbar.
4 On the Home toolbar, click Add Study to close the Add Study window.

STUDY 2

Step 1: Time Dependent

1 In the Model Builder window, under Study 2 click Step 1: Time Dependent.

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2 In the Settings window for Time Dependent, locate the Study Settings section.
3 In the Times text field, type range(0,0.2,3), range(3, 0.05, 4).
4 Click to expand the Values of dependent variables section. Locate the
Values of Dependent Variables section. Find the Initial values of variables solved for
subsection. From the Settings list, choose User controlled.
5 From the Method list, choose Solution.
6 From the Study list, choose Study 1, Frozen Rotor.
7 From the Parameter value (visc_fact) list, choose Last.
8 On the Home toolbar, click Compute.
When working with large 3D models it is often convenient to disable automatic update of
plots.

RESULTS
1 In the Model Builder window, click Results.
2 In the Settings window for Results, locate the Result Settings section.
3 Clear the Automatic update of plots check box.

Cut Line 3D 1
1 On the Results toolbar, click Cut Line 3D.
2 In the Settings window for Cut Line 3D, locate the Line Data section.
3 In row Point 1, set x to -0.005, y to T/2-0.12, and z to 0.458*H-C.
4 In row Point 2, set x to -0.005, y to T/2, and z to 0.458*H-C.
5 Locate the Data section. From the Data set list, choose Study 2/Solution 2 (sol2).
6 Click Plot.

Cut Line 3D 2
1 Right-click Cut Line 3D 1 and choose Duplicate.
2 In the Settings window for Cut Line 3D, locate the Line Data section.
3 In row Point 1, set z to 0.563*H-C.
4 In row Point 2, set z to 0.563*H-C.

Cut Line 3D 3
1 Right-click Results>Data Sets>Cut Line 3D 2 and choose Duplicate.
2 In the Settings window for Cut Line 3D, locate the Line Data section.
3 In row Point 1, set z to 0.667*H-C.

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4 In row Point 2, set z to 0.667*H-C.

Cut Line 3D 4
1 Right-click Results>Data Sets>Cut Line 3D 3 and choose Duplicate.
2 In the Settings window for Cut Line 3D, locate the Line Data section.
3 In row Point 1, set z to 0.771*H-C.
4 In row Point 2, set z to 0.771*H-C.
To evaluate the self-similarity of the axial velocities, the axial velocity needs to be
normalized by the maximum axial velocity along the 3D cut lines. The following lines
compute the maximum axial velocities.

Line Maximum 1
1 On the Results toolbar, click More Derived Values and choose Maximum>Line Maximum.
2 In the Settings window for Line Maximum, locate the Data section.
3 From the Data set list, choose Cut Line 3D 1.
4 From the Time selection list, choose Last.
5 Locate the Expressions section. In the table, enter the following settings:

Expression Unit Description

w m/s Velocity field, z component

6 Click Evaluate.
7 In the Settings window for Line Maximum, locate the Data section.
8 From the Data set list, choose Cut Line 3D 2.
9 Click Evaluate.
10 In the Settings window for Line Maximum, locate the Data section.
11 From the Data set list, choose Cut Line 3D 3.
12 Click Evaluate.
13 In the Settings window for Line Maximum, locate the Data section.
14 From the Data set list, choose Cut Line 3D 4.
15 Click Evaluate.
Note that the maximum values of the axial velocity along these cut-lines are shown in
the table.
Now proceed to plot the axial velocity profiles in a 1D plot in the manner of Figure 5.

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1D Plot Group 7
On the Results toolbar, click 1D Plot Group.

DEFINITIONS

Identity Mapping 1 (idmap1)

1 On the Definitions toolbar, click Component Couplings and choose Identity Mapping.
2 In the Settings window for Identity Mapping, locate the Source Selection section.
3 From the Selection list, choose All domains.
4 Locate the Frames section. From the Destination frame list, choose Material (X, Y, Z).

STUDY 2

Velocity (rmspf) 1
On the Study toolbar, click Update Solution.

RESULTS

Line Graph 1
1 In the Model Builder window, under Results right-click 1D Plot Group 7 and choose
Line Graph.
2 In the Settings window for Line Graph, locate the Data section.
3 From the Data set list, choose Cut Line 3D 1.
4 From the Time selection list, choose Last.
5 Locate the y-Axis Data section. In the Expression text field, type timeavg(3.5,4,
idmap1(w),’nointerp’)/0.498[m].

6 Locate the x-Axis Data section. From the Parameter list, choose Expression.
7 In the Expression text field, type (0.12[m]-y)/0.0238[m].
8 Click to expand the Coloring and style section. Locate the Coloring and Style section.
Find the Line style subsection. From the Line list, choose None.
9 Find the Line markers subsection. From the Marker list, choose Diamond.
10 From the Positioning list, choose In data points.
11 Click to expand the Legends section. From the Legends list, choose Manual.
12 Select the Show legends check box.

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13 In the table, enter the following settings:

Legends
z/T = 0.483

Line Graph 2
1 Right-click Results>1D Plot Group 7>Line Graph 1 and choose Duplicate.
2 In the Settings window for Line Graph, locate the Data section.
3 From the Data set list, choose Cut Line 3D 2.
4 Locate the y-Axis Data section. In the Expression text field, type timeavg(3.5,4,
idmap1(w),’nointerp’)/0.404[m].
5 Locate the x-Axis Data section. In the Expression text field, type (0.12[m]-y)/
0.0259[m].

6 Click to expand the Coloring and style section. Locate the Coloring and Style section.
Find the Line markers subsection. From the Marker list, choose Square.
7 Click to expand the Legends section. In the table, enter the following settings:

Legends
z/T=0.563

Line Graph 3
1 Right-click Results>1D Plot Group 7>Line Graph 2 and choose Duplicate.
2 In the Settings window for Line Graph, locate the Data section.
3 From the Data set list, choose Cut Line 3D 3.
4 Locate the y-Axis Data section. In the Expression text field, type timeavg(3.5,4,
idmap1(w),’nointerp’)/0.339[m].

5 Locate the x-Axis Data section. In the Expression text field, type (0.12[m]-y)/
0.0279[m].

6 Locate the Legends section. In the table, enter the following settings:

Legends
z/T=0.667

7 Locate the Coloring and Style section. Find the Line markers subsection. From the Marker
list, choose Plus sign.

Line Graph 4
1 Right-click Results>1D Plot Group 7>Line Graph 3 and choose Duplicate.

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2 In the Settings window for Line Graph, locate the Data section.
3 From the Data set list, choose Cut Line 3D 4.
4 Locate the y-Axis Data section. In the Expression text field, type timeavg(3.5,4,
idmap1(w),’nointerp’)/0.292[m].
5 Locate the x-Axis Data section. In the Expression text field, type (0.12[m]-y)/
0.0336[m].

6 Locate the Coloring and Style section. Find the Line markers subsection. From the Marker
list, choose Triangle.
7 Locate the Legends section. In the table, enter the following settings:

Legends
z/T=0.771

Line Graph 5
1 In the Model Builder window, under Results right-click 1D Plot Group 7 and choose
Line Graph.
2 In the Settings window for Line Graph, locate the Data section.
3 From the Data set list, choose Cut Line 3D 1.
4 From the Time selection list, choose Last.
5 Locate the y-Axis Data section. In the Expression text field, type 1-1.5*tanh(0.78*(y*
50-0.15))^2.

6 Locate the x-Axis Data section. From the Parameter list, choose Expression.
7 In the Expression text field, type y*50.
8 Locate the Coloring and Style section. From the Color list, choose Black.
9 Locate the Legends section. From the Legends list, choose Manual.
10 Select the Show legends check box.
11 In the table, enter the following settings:

Legends
Bhattacharya and Kresta

1D Plot Group 7
1 In the Model Builder window, under Results click 1D Plot Group 7.
2 In the Settings window for 1D Plot Group, click to expand the Title section.
3 From the Title type list, choose None.

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4 Locate the Plot Settings section. Select the x-axis label check box.
5 In the associated text field, type \eta.
6 Select the y-axis label check box.
7 In the associated text field, type U/Um.
8 Locate the Axis section. Select the Manual axis limits check box.
9 In the x minimum text field, type 0.
10 In the x maximum text field, type 5.
11 In the y minimum text field, type -1.
12 In the y maximum text field, type 1.
13 On the 1D Plot Group 7 toolbar, click Plot.
The following instructions re-create Figure 3.

Streamline 1
1 In the Model Builder window, under Results right-click Velocity (rmspf) 1 and choose
Streamline.
2 In the Settings window for Streamline, locate the Streamline Positioning section.
3 From the Positioning list, choose Uniform density.
4 Locate the Coloring and Style section. From the Line type list, choose Ribbon.
5 In the Width expression text field, type rmspf.U.
6 Select the Width scale factor check box.
7 In the associated text field, type 5e-3.

Slice 1
1 In the Model Builder window, under Results>Velocity (rmspf) 1 click Slice 1.
2 In the Settings window for Slice, locate the Plane Data section.
3 In the Planes text field, type 1.
4 On the Velocity (rmspf) 1 toolbar, click Plot.
The following instructions re-create Figure 4.

Cut Plane 1
1 On the Results toolbar, click Cut Plane.
2 In the Settings window for Cut Plane, locate the Data section.
3 From the Data set list, choose Study 2/Solution 2 (sol2).
4 Locate the Plane Data section. From the Plane type list, choose General.

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5 In row Point 2, set y to -1.
6 In row Point 3, set y to 0 and z to 1.
7 Click Plot.

3D Plot Group 8
1 On the Results toolbar, click 3D Plot Group.
2 In the Model Builder window, expand the Results>Data Sets node.

Arrow Surface 1
1 Right-click Results>3D Plot Group 8 and choose Arrow Surface.
2 In the Settings window for Arrow Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 1.
4 From the Time list, choose 4.
5 Locate the Coloring and Style section. In the Number of arrows text field, type 500.
6 Select the Scale factor check box.
7 In the associated text field, type 0.03.

Surface 1
1 Right-click 3D Plot Group 8 and choose Surface.
2 In the Settings window for Surface, locate the Data section.
3 From the Data set list, choose Cut Plane 1.
4 From the Time list, choose 4.
5 On the 3D Plot Group 8 toolbar, click Plot.
6 Click the Zoom Extents button on the Graphics toolbar.

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