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Separations 09 00122 v2

This study utilizes computational fluid dynamics (CFDs) to analyze solid-liquid mixing in a stirred vessel with two types of impellers: a traditional dual triple blade impeller (DTBI) and a modified dual rigid-flexible triple blade impeller (DRFTBI). The findings indicate that the DRFTBI significantly enhances solid suspension and reduces solid accumulation at the tank's bottom compared to the DTBI. Optimal parameters for the DRFTBI were identified, including connection strap length, width, and off-bottom clearance, which improve the mixing efficiency in high solid loading systems.

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0% found this document useful (0 votes)
1 views16 pages

Separations 09 00122 v2

This study utilizes computational fluid dynamics (CFDs) to analyze solid-liquid mixing in a stirred vessel with two types of impellers: a traditional dual triple blade impeller (DTBI) and a modified dual rigid-flexible triple blade impeller (DRFTBI). The findings indicate that the DRFTBI significantly enhances solid suspension and reduces solid accumulation at the tank's bottom compared to the DTBI. Optimal parameters for the DRFTBI were identified, including connection strap length, width, and off-bottom clearance, which improve the mixing efficiency in high solid loading systems.

Uploaded by

Hamza Zabet
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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separations

Article
Numerical Simulation of Dense Solid-Liquid Mixing in Stirred
Vessel with Improved Dual Axial Impeller
Xia Xiong 1,2 , Zuohua Liu 1,2, *, Changyuan Tao 1,2 , Yundong Wang 3 and Fangqin Cheng 4

1 School of Chemistry and Chemical Engineering, Chongqing University, Chongqing 400044, China;
[email protected] (X.X.); [email protected] (C.T.)
2 State Key Laboratory of Coal Mine Disaster Dynamics and Control, Chongqing 400044, China
3 Department of Chemical Engineering, Tsinghua University, Beijing 100084, China; [email protected]
4 Institute of Resources and Environment Engineering, Shanxi University, Taiyuan 030006, China;
[email protected]
* Correspondence: [email protected]

Abstract: Computational fluid dynamics (CFDs) were adopted in order to investigate the solid
suspending process in a dense solid–liquid system (with a solid volume fraction of 30%), agitated
by a traditional dual axial impeller and a modified dual axial impeller, otherwise known as a dual
triple blade impeller (DTBI) and a dual rigid-flexible triple blade impeller (DRFTBI), respectively.
The effects of rotational speed, connection strap length/width, and off-bottom clearance on the solid
distribution were investigated. The results show that the proportion of solid concentration larger
than 0.4 in the DTBI system was 26.56 times of that in the DRFTBI system. This indicates that the
DRFTBI system can strengthen the solid suspension and decrease the solid accumulation in the
bottom of the tank. Furthermore, the velocity and turbulent kinetic energy in the DRFTBI system
were promoted. In addition, for an optimal selection, the optimum length of connection strap was
1.2 H1 , the optimum range of connection strap width was D/7–D/8, and the off-bottom clearance
Citation: Xiong, X.; Liu, Z.; Tao, C.; selected as T/4 was better.
Wang, Y.; Cheng, F. Numerical
Simulation of Dense Solid-Liquid Keywords: solid–liquid suspension; numerical simulation; high solid concentration; modified impeller
Mixing in Stirred Vessel with
Improved Dual Axial Impeller.
Separations 2022, 9, 122. https://
doi.org/10.3390/separations9050122 1. Introduction
Academic Editor: Sohrab Solid suspension in a stirred tank is a common operation in the process industry. It is
Zendehboudi common in the processes of hydrogenation, crystallization, leaching, precipitation, etc. [1].
In general, when the equipment requires a major upgrade, the production capacity of a
Received: 9 April 2022
plant is limited. Therefore, solid loading increasing could maximize the throughput or yield
Accepted: 10 May 2022
Published: 16 May 2022
within the current production capacity. Moreover, it could improve the volume utilization
rate of current tanks besides promoting the throughput. Thus, it has application value in
Publisher’s Note: MDPI stays neutral the study of solid suspension in a stirred tank with high solid loading.
with regard to jurisdictional claims in The accumulation of solid in the bottom of the tank is a common phenomenon in a
published maps and institutional affil-
high solid loading stirred tank, making it difficult to achieve good mixing effect. Drewer
iations.
et al. [2] found that with increasing solid concentrations, a point was reached where
suspension is unattainable. Tamburini et al. [3] found that with a solid concentration of
25% wsolid/wliquid, the sufficient suspension speed reaches up to 1100 rpm. This not only
Copyright: © 2022 by the authors.
consumes high energy, but also places higher demands on the safety and stability of the
Licensee MDPI, Basel, Switzerland.
equipment. Thus, studying the actions required to improve solid suspension in the high
This article is an open access article solid loading stirred tanks by process intensification is necessary.
distributed under the terms and Generally speaking, large stirring speed is a common way to improve solid suspension
conditions of the Creative Commons in stirred tanks. However, power consumption will increase sharply following an increase
Attribution (CC BY) license (https:// in rotation speed. There are some other methods available to strengthen mixing, such
creativecommons.org/licenses/by/ as eccentric stirring [4,5] and unsteady speed stirring [6]. These two methods are not
4.0/). conducive to the safe and stable operation of the equipment. There are some researchers

Separations 2022, 9, 122. https://doi.org/10.3390/separations9050122 https://www.mdpi.com/journal/separations


Separations 2022, 9, 122 2 of 16

who intensified the mixing process by improving the structure of the impeller. Xu et al. [7]
found that the logarithmic helicoidal impeller could promote the solid suspension com-
pared with rushton disc turbine impeller at the same power consumption. Zhao et al. [8]
applied an improved Intermig impeller in the solid suspension process, and found that
the improved Intermig impeller could promote the fluid circulation compared with the
standard Intermig impeller. Gu et al. [9,10] designed a kind of rigid-flexible impeller and
found that a longer and wider flexible connection piece is conducive to solid particles in
suspension. Nevertheless, all of these methods were simply employed in concentration
systems with low solidity. So far, only few efforts have been devoted to improving the solid
suspension with a high solid loading. Thus, studies relevant to enhancing the high solid
mixing system need to be carried out.
In order to observe the internal flow field, both experimental methods and numerical
simulation methods could be adopted. Particle image velocimetry (PIV), laser doppler
velocimetry (LDV), radioactive particle tracking (RPT), positron emission particle tracking
(PEPT), and new invasive image velocimetry (NIIV) are some examples of experimental
methods. Furthermore, the upper limit values of solid concentration that the fluid field can
accurately measure are 8% [11], 15% [12], 7% [13], 10.4% [14], and 8.8% [15], respectively.
Thus, the maximum value of the solid volume fraction which can be accurately measured
by the fluid field is 15%. To sum up, there is still no suitable technique to measure the
flow pattern of dense solid–liquid systems. One possible approach to predict suspension
curves has been proposed by Tamburini et al. [16]. This model has reliable predictions
starting from low impeller speed to complete suspension agitation speed. In addition,
Tamburini et al. [17] predicted the minimum impeller speed for complete suspension in
a dense solid–liquid suspension system using CFD simulation. Moreover, the concept
of sufficient suspension was proposed to take the place of complete suspension. This
suggests that the CFD method could effectively reveal the flow field of the dense solid–
liquid suspension system. In summary, CFD simulation is more suitable than experimental
studies for analyzing the flow field structure of the high solid loading system.
In this work, the CFD simulation was used to investigate the solid suspension in the
dense solid concentration mixing system. Both the dual triple blade impeller (DTBI) and
dual rigid-flexible triple blade impeller (DRFTBI) were used in this study. The effects of the
impeller type, impeller speed, length and width of a connect piece, and off-bottom clearance
on the solid–liquid mixing process were studied. The solid dispersion, the velocity profile,
and the degree of uniformity were also analysed. The purpose was to explore an efficient
impeller to strengthen solid suspension in a high solid loading mixing system.

2. System Studied
The mixing tank used in this study was a transparent flat-bottomed vessel with an
inner diameter T = 0.18 m and a height H = 0.3 m. The height of liquid level HL = 0.2 m. A
sketch of the stirred tank is shown in Figure 1. The impellers used in this work include a
dual triple blade impeller (DTBI) and a dual rigid-flexible triple blade impeller (DRFTBI),
shown in Figure 2. The DRFTBI is the improvement of DTBI by connecting strap between
two triple blade impellers. The slant angle of the blade is 45 degrees, the diameter of the
impeller D = 0.07 m, and th e spacing of two impellers HS = 0.1 m. The off-bottom clearance
C is one of the investigated variables which can affect the suspension of solid. A dense
solid–liquid suspension was studied: water and coal ash (dp ≤ 75 µm; ρ = 2400 kg/m3 )
with the solid volume fraction equal to 30%. In order to comprehensively evaluate the
mixing effect, different locations in the mixing tank were selected to analyse the result,
as presented in Figure 3. The coordinate of vertical plane is X = 0; the coordinates of all
horizontal planes are Z1 = 0 HL , Z2 = 0.2 HL , Z3 = 0.4 HL , Z4 = 0.6 HL , and Z5 = 0.8 HL ; and
the coordinates of all the y lines are y1 = 2T/9, y2 = 4T/9, y3 = 6T/9, and y4 = 8T/9.
the solid
the solid volume
the solid volume
fraction
volume equal fraction
to 30%.
fraction equal
equal to 30%.
In order
to 30%.
to InIn order
order to
comprehensively to comprehensively
comprehensively evaluate
evaluate theevaluatemixing the the mixing
mixing
effect,
effect, different
effect, different
locations locations
differentinlocations
the mixing in
in thethe mixing
tankmixing tank
were selected
tank were were selected
to selected
analyse the to analyse
result, as
to analyse the result,
thepre-
result, as as pre-
pre
sented
sented in Figure
sented in
3. in
TheFigure 3. The
coordinate
Figure 3. Theof coordinate
vertical plane
coordinate ofof vertical
vertical
is X =planeplane
0; the isis XX == 0;
0; the
coordinates the coordinates
coordinates
of all horizon- of all
of all horizon-
horizon
Separations 2022, 9, 122
tal planes aretal
tal Zplanes
1 = 0 H
planes are
L, Z
are Z = 0
Z21 == 0.2
1 H
0 HH , Z
L,L,ZZ
L = 0.2
2 3= =0.2
2 0.4HH H , Z
L,L,ZZ
L = 0.4
3 4= =0.4
3 H
0.6HH , Z
L,L,Zand
L 4 = 0.6
4 = 0.6Z5 H H ,
= L0.8
L and
, and Z
HL;Zand5 = 0.8
5 = 0.8
3 H
of 16;
theHL; and
L and the
the
coordinates
coordinatescoordinates of all
of all the y lines
of allaretheyyy1 lines
the =lines
2T/9, are
arey2yy=11 =4T/9,
= 2T/9,
2T/9, y3yy=22 =6T/9,
= 4T/9,
4T/9,andyy33 =y
=46T/9,
6T/9,
= 8T/9. and yy44 == 8T/9.
and 8T/9.

Figure
Figure 1. Sketch
Figure
Figure 1.Sketch
of the
1.1. Sketch
stirred
Sketch of
ofof
thethe
tank. stirred
stirred
the tank.
tank.
stirred tank.

(a) (a)
(a) (b) (b)
(b)
Figureof
Figure 2. Structure
Figure
Figure 2.the
2.
2. Structure
impeller
Structure
Structure ofthe
ofof the
and
the impeller
the tank
impeller
impeller and
used
and the
in
thethe
and tanktank
this used
work.
used
tank in
in this
used in this
(a)this
Dualwork.
work. triple
work. (a)
(a) Dual
blade
(a) Dual Dual triple
impeller;
triple
triple blade impeller; (b)
(b) impeller;
bladeblade
impeller; (b
dual
dual rigid-flexible rigid-flexible
triple
(b) dual
dual rigid-flexible
rigid-flexible triple
blade impeller. blade
tripleblade
triple impeller.
blade impeller.
impeller.

Figure3.3.
Figure 3.Distribution
Figure 3. Distribution
Figure Distribution
of of
ofof
the monitoring
Distribution the
thethe monitoring
monitoring
position in
monitoring position
position
the invessel.
in thein
vessel.
position the vessel.
the vessel.

3. Computational Model and Details


3. Computational
Computational
3. Computational
3. Model
Model and Model and Details
Detailsand Details
The numerical solution of this 3D mixing system was implemented in the commercial
The numerical
CFD The
Thesolution
numerical
numerical
solver ANSYS
solution
ofFluent
this 3D15.0.
solution ofThe
of thissystem
mixing
this 3Dmixing
3D mixing system
wassystem wasimplemented
implemented
Eulerian–Eulerian was implemented
in the
multi-fluid
inadopted
commercial
model in
was
thecommercial
the commercia
CFD
CFD solver CFD
ANSYS
for solver
solver
the ANSYS
Fluent 15.0.
ANSYS
simulation Fluent
The
of aFluent 15.0. The
15.0.system.
two-phase Eulerian–Eulerian
Eulerian–Eulerian multi-fluid
The Eulerian–Eulerian
The continuity multi-fluid
model model
was adopted
andmulti-fluid
momentum model was
was
equations adopted for
forwere
adopted fo
the simulation
the simulation
solved
the simulation
of separately of
a two-phase
and
of aa simultaneously.
two-phase
system.
two-phase system.
Thesystem. The and
continuity
The coupling
The continuity and
momentum
between
continuity the
andtwomomentum
equations
phases waswere
momentum equations were
obtained
equations were
solved
via
solved separately separately
inter-phase and
exchange
and simultaneously.
solved separately simultaneously.
terms. All the
The coupling
and simultaneously. The
details of coupling
the model
The between between
equations
couplingthe the
have
two phases
between two
been
the two phases
listed
wasphases waswas
as following:
Separations 2022, 9, 122 4 of 16

3.1. Equations of Motion


The continuity equations [16]:
→ →
 

(α ρ ) + ∇ αl ρl U l = 0 (1)
∂t l l
→ →
 

(αs ρs ) + ∇ αs ρs U s = 0 (2)
∂t
where the subscripts l and s refer to the continuous and dispersed phases, respectively; α is
the volumetric fraction; ρ is the density; and U is the mean velocity.
Clearly,
αl + αs = 1 (3)
The momentum balance equations:
( "  →  T !#)
→ → → → →→ →
 

∂(t)
αl ρl U l + ∇· αl ρl U l U l − (µl + µtl ) ∇U l + ∇U l
(4)
→ →
 

= αl ρl g − ∇ P + F l,s

( "  T !#)
→ → → → →→ →→
  

∂(t)
αs ρs U s + ∇· αs ρs U s U s − (µs + µts ) ∇U s + ∇U s
(5)
→ →
 

= αs ρs g − ∇ P + F s,l

where g is the gravitational acceleration, µ is the viscosity, µt is the turbulent viscosity, P is


the pressure (the continuous and dispersed phases are assumed to share the same pressure
field), and F is the interphase momentum transfer term.

3.2. Turbulence Model


The standard k-ε turbulence model was used to simulate the dense solid–liquid
suspensions system in light of the research of Tamburini et al. [16,17]. In addition, the
results were verified to be reliable. Thus, the standard k-ε turbulence model was applied in
this work. Then, the continuous and dispersed phases were assumed to share the same
turbulent kinetic energy k and the same turbulent energy dissipation rate ε. The equations
are given as follows [16,17]:
→ → → 
 
µtl

( α
∂t l lρ k ) + ∇ α ρ U
l l l k − α l µ l + σ ∇k
!k
(6)
!
→→ →→ →→ T
 
= αl µtl ∇U l ∇U l + ∇U l − ρl ε

→ → → 
 
µtl

∂t ( α l ρ l ε ) + ∇
αl ρl U l ε − αl µl + ∇ε
σε
(7)
! !
→→ →→
 →→
 T
ε2
= αl C1 k µtl ∇U l ∇U l + ∇U l
ε
− C2 ρl k

where
k2
µtl = ρl Cµ (8)
ε
Separations 2022, 9, 122 5 of 16

3.3. Interphase Drag Force and Drag Coefficient


Interactions between the two phases were simulated by inter-phase drag force terms
within the momentum equations [16]:
→ → → → → →
  
3 CD
F D,s = − F D,l = α ρs U l − U s Ul − Us (9)
4 dp l

where CD is the inter-phase drag coefficient and was estimated using the Gidaspow drag
model for densely distributed solid particles [14,18]:
( h i
24 0.687
αl Res 1 + 0.15 ( α l Re s ) , Res < 1000
CD = (10)
0.44, Res > 1000

3.4. Numerical Details


In this study, the multiple reference frame (MRF) approach was employed to simulate
impeller rotation [19–21]. The stirred tank was divided into two parts: the inner part was
the rotating zone while the outer part was the non-rotating domain. The optimum grid size
was obtained when the change in velocity and solid concentration profiles was less than
5%. The number of cells used for DTBI and DRFTBI was 754,916 and 895,634, respectively.
In this work, the SIMPLEC algorithm was used for pressure velocity coupling along
with the standard pressure interpolation scheme. The hybrid-upwind discretization scheme
was employed for the convective terms. In the initial simulation condition, a solid uniform
average concentration of 30% was taken in the computational domain. The time step used
in the simulation was 0.01 s, and the relative residual was set as 10−5 , which is considered
as the index of convergence.

4. Results and Discussions


4.1. Verification of Modelling
Simulated results of the specific power consumption Pv were compared with ex-
perimental data in Figure 4a to validate the CFD model. The specific power consump-
tion is defined as the impeller power draw divided by the total volume of solid and
liquid. The power consumption in the agitated system could be calculated according to the
formula [22–26]:
Psum = 2πNMa (11)
Thus, the specific power consumption is:

Psum 2πNMa
Pv = = (12)
V V

where Psum is the impeller power draw (W); V is the total volume of solid and liquid (m3 );
N is the impeller rotational speed in revolutions per second (rps); and Ma is the absolute
torque that could be obtained by using the torque transducer, determined according to the
following equation [27]:
Ma = Mm − Mr (13)
where Mm is the torque measured by the experiments, and Mr represents the residual
torque cause of the mechanical friction in the bearing, determined by operating the impeller
without any liquid or solid in the tank. Figure 4a shows that when the rotational speed was
equal to 2 rps and the solid volume fraction was equal to 30%, the power consumption
per unit volume of the experiment and simulation was 22.21 W/m3 and 20.68 W/m3 ,
respectively. The variation of experimental data and the simulation result was 6.9%.
Figure 4b shows the solid distribution between the simulation and the experiment. The
stratification of solid distribution on the DTBI system can be seen as obvious, both in the
simulation and experimental results, while the DRFTBI system significantly improved.
torque cause of the mechanical friction in the bearing, determined by operating the impel-
ler without any liquid or solid in the tank. Figure 4a shows that when the rotational speed
was equal to 2 rps and the solid volume fraction was equal to 30%, the power consumption
per unit volume of the experiment and simulation was 22.21 W/m3 and 20.68 W/m3, re-
spectively. The variation of experimental data and the simulation result was 6.9%. Figure
Separations 2022, 9, 122 4b shows the solid distribution between the simulation and the experiment. The stratifi- 6 of 16

cation of solid distribution on the DTBI system can be seen as obvious, both in the simu-
lation and experimental results, while the DRFTBI system significantly improved. To sum
up,Tothe
sumsimulated results show
up, the simulated a good
results showagreement with thosewith
a good agreement of corresponding experi-
those of corresponding
experiments;
ments; therefore,therefore, the simulated
the simulated results
results were were reliable.
reliable.

(a) (b)
Figure 4. (a)
Figure 4. Comparation of Pv in
(a) Comparation ofthe
PvDRFTBI system between
in the DRFTBI system simulation and experiment;
between simulation (b) com-
and experiment;
paration of solid distribution between the simulation and the experiment. (Rotational speed: 120
(b) comparation of solid distribution between the simulation and the experiment. (Rotational speed:
rpm; solid loading: 30%.)
120 rpm; solid loading: 30%).

4.2.4.2. Strengthening
Strengthening Effects
Effects of the
of the Improved
Improved Impeller
Impeller
4.2.1. Comparison of Solid Particle Distribution
4.2.1. Comparison of Solid Particle Distribution
Figures
Figures 5 and
5 and 6 show
6 show thethe solid
solid distribution
distribution of of
twotwo kinds
kinds of of stirred
stirred systems.
systems. It can
It can be be
observed that the solid sedimentation on the bottom of a tank equipped
observed that the solid sedimentation on the bottom of a tank equipped with DRFTBI was with DRFTBI was
less than a tank equipped with DTBI. Figure 7 shows the histogram of
less than a tank equipped with DTBI. Figure 7 shows the histogram of solid distribution solid distribution
forfor
twotwo mixing
mixing systems.
systems. TheThe maximum
maximum value
value of of
thethe local
local solid
solid concentration
concentration in in
thethe DTBI
DTBI
system
system waswas 0.58
0.58 andthe
and themaximum
maximumvaluevalueofoflocal
localsolid
solid concentration
concentration inin the
the DRFTBI
DRFTBI system
sys-
was 0.49. The solid concentration proportions larger than 0.4 in the DRFTBI system and
tem was 0.49. The solid concentration proportions larger than 0.4 in the DRFTBI system
the DTBI system were 0.64% and 17%, respectively, which indicates that the DRFTBI could
and the DTBI system were 0.64% and 17%, respectively, which indicates that the DRFTBI
promote the solid suspension from the bottom. The solid concentration distribution of
could promote the solid suspension from the bottom. The solid concentration distribution
the DRFTBI system mainly aggregated in the range of 0.2–0.4 was close to the average
of the DRFTBI system mainly aggregated in the range of 0.2–0.4 was close to the average
concentration of 0.3, accounting for 94%. For the DTBI system, the proportion of solid
concentration of 0.3, accounting for 94%. For the DTBI system, the proportion of solid
concentration distribution below 0.2 and over 0.4 accounted for 39.8%, which was much
concentration distribution below 0.2 and over 0.4 accounted for 39.8%, which was much
larger than that in the DRFTBI system. This indicates that the DRFTBI could improve the
ions 2022, 9, x FOR PEER REVIEW larger than that in the DRFTBI system. This indicates that the DRFTBI could improve the
uniform distribution. According to Figure 8, the dimensionless axial solid concentrations 7 of 17
uniform distribution. According to Figure 8, the dimensionless axial solid concentrations
of the DRFTBI system at all Y lines were nearer to 1 compared to the DTBI system. This
of the DRFTBI system at all Y lines were nearer to 1 compared to the DTBI system. This
proves that the axial solid distribution was much more homogeneous in the DRFTBI tank.
proves that the axial solid distribution was much more homogeneous in the DRFTBI tank.

(a) (b)
Figure 5.Figure 5. Contour
Contour plots
plots of of solid
solid distribution
distribution for for differentimpeller
different impeller types.
types. (a)
(a)DTBI;
DTBI;(b)(b)
DRFTBI.
DRFTBI.
(Rotational speed: 120 rpm; solid loading: 30%; connection strap
(Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 length: 1.2 H ; plane: X
S HS; plane:= 0). X = 0.)
(a) (b)
Separations 2022, 9, 122 7 of 16
Figure 5. Contour plots of solid distribution for different (a)
impeller types. (a) DTBI; (b) DRFTBI. (b)
(Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 H S; plane: X = 0.)
Figure 5. Contour plots of solid distribution for different impeller types. (a) DTBI; (b) DR
(Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 HS; plane: X

(a) (b)
(a) (b)
Figure 6. Contour
Figure 6.plots of solid
Contour distribution
plots for different for
of solid distribution impeller types.
different (a) DTBI;
impeller (b) DRFTBI.
types. (a) DTBI;(Ro-
(b) DRFTBI.
tational speed: 120 rpm; solid120 Figure
loading: 6. Contour
30%; plotsstrap
connection of solid distribution
length: 1.2strapfor different
H; plane: 0 impeller
Z =1.2 H, types. (a) DTBI; (b) DR
(Rotational speed: rpm; solid
tational loading:
speed: 30%;solid
120 rpm; connection
loading: 30%; length:
connection H;Zplane:
strap
= 0.2
length:Z1.2= H;
0 H,
plane: Z = 0
H, Z = 0.4 ZH,=Z0.2
= 0.6 H, and Z = 0.8
H, Z = 0.4 H, Z = H, H.)
0.6ZH,= 0.4
andH,Z Z= =0.8
0.6H).
H, and Z = 0.8 H.)

Figure Figure
Separations 2022, 9, 7.
7. Histogram Histogram
x FORof solid
PEER Figure
of solid
distribution
REVIEW 7.for
Histogram
distribution forof
different solid distribution
different
impeller impeller
types. for different
types.
(Rotational impeller
(Rotational
speed: types.
120speed:
rpm; 120(Rotational
8 ofrpm;
17 speed
solid loading: 30%; solid
connection loading:
strap
solid loading: 30%; connection strap length: 1.2 HS.) 30%;
length:connection
1.2 Hs). strap length: 1.2 H S.)

(a) (b)

Figure 8. Axial solidFigure


concentration
8. Axial solidprofile at different
concentration profile at axial locations.
different (a) DTBI;
axial locations. (b)
(a) DTBI; (b)DRFTBI. (Rota-
DRFTBI. (Rota-
tional speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 HS.)
tional speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs).
4.2.2. Comparison of Velocity
4.2.2. Comparison of Velocity
Figure 9 shows the contour plots of velocity distribution for different impeller types.
Figure 9 shows
Thethe
value contour plots
of velocity in theof velocity
DRFTBI distribution
system was larger and for
thedifferent
distributionimpeller
of velocitytypes.
was
more uniform.
The value of velocity The velocity
in the DRFTBI profile atwas
system different axialand
larger locations
the was also demonstrated.
distribution Ac-
of velocity
cording to Figure 10, the max dimensionless velocities of the DTBI system and the DRFTBI
was more uniform. The velocity profile at different axial locations was also demonstrated.
system were 0.26 and 0.36, respectively. The presence of the connecting belt increased the
According to Figure 10,area
contact theof max dimensionless
the fluid and the impeller,velocities of the
which can then driveDTBI system
more fluid and the
and promote
DRFTBI system were 0.26fluid
the whole and 0.36, respectively.
movement. The presence
Thus, the fluid velocity of the DRFTBIof system
the connecting
was larger thanbelt
that ofarea
increased the contact the DTBI
of thesystem.
fluidMoreover,
and theinimpeller,
both two systems,
whichthe canvelocity
then in the regions
drive moreclose
fluid
to the shaft or the wall was significantly lower than in the mid region; this is because the
and promote the whole fluid movement. Thus, the fluid velocity of the DRFTBI system
fluid flow was mainly influenced by the rotational motion of the impellers. Naturally, the
was larger than that ofinthe
fluid theDTBI system.
area close Moreover,
to the impeller couldinbeboth
more two systems,
significantly the velocity
influenced. Thus, ininthe
the
regions close to the shaft or
near-shaft the
area, thewall was significantly
flow velocity was smaller thanlower than
the other in the mid region; this
areas.
Figure 9 shows the contour plots of velocity distribution for different impeller types.
The value of velocity in the DRFTBI system was larger and the distribution of velocity was
more uniform. The velocity profile at different axial locations was also demonstrated. Ac-
cording to Figure 10, the max dimensionless velocities of the DTBI system and the DRFTBI
system were 0.26 and 0.36, respectively. The presence of the connecting belt increased the
Separations 2022, 9, 122 contact area of the fluid and the impeller, which can then drive more fluid and promote 8 of 16
the whole fluid movement. Thus, the fluid velocity of the DRFTBI system was larger than
that of the DTBI system. Moreover, in both two systems, the velocity in the regions close
to the shaft or the wall was significantly lower than in the mid region; this is because the
is because the fluid flow was mainly influenced by the rotational motion of the impellers.
fluid flow was mainly influenced by the rotational motion of the impellers. Naturally, the
fluid inNaturally, the to
the area close fluid
the in the area
impeller close
could be to thesignificantly
more impeller could be more
influenced. significantly
Thus, in the influenced.
Thus, in the near-shaft area, the flow velocity was smaller
near-shaft area, the flow velocity was smaller than the other areas. than the other areas.

(a) (b)
Figure Figure
9. Contour plots of velocity
9. Contour plots ofdistribution for different for
velocity distribution impeller types.impeller
different (a) DTBI;types.
(b) DRFTBI.
(a) DTBI; (b)9 ofDRFTBI.
Separations 2022, 9, x FOR PEER REVIEW 17
(Rotational speed: 120 rpm, Solid loading: 30%, Connection strap length: 1.2 HS, Plane: X = 0).
(Rotational speed: 120 rpm, Solid loading: 30%, Connection strap length: 1.2 HS , Plane: X = 0).

Separations 2022, 9, x FOR PEER REVIEW 9 of 17

(a) (b)

Figure 10. VelocityFigure 10. Velocity


profile profile ataxial
at different different axial location.
location. (a)(a)DTBI;
DTBI; (b)
(b)DRFTBI.
DRFTBI.(Rotational speed: 120speed:
(Rotational
rpm; solid loading: 30%; connection strap length: 1.2 Hs.)
120 rpm; solid loading: 30%; connection strap length: 1.2 Hs).
(a) (b)
4.2.3. Comparison of Turbulent Kinetic Energy
4.2.3. Comparison ofFigure
Figure Turbulent
10. Velocity
11 shows
Kinetic
profile
that
Energy
at different axial location.
the variation tendency (a)ofDTBI; (b) DRFTBI.
turbulent kinetic(Rotational
energy inspeed: 120
the stirred
rpm;
tanksolid loading:
Figure 11 shows was
that the 30%;
similar to theconnection
variation velocity. strap length: kinetic
Turbulent
tendency 1.2 Hs.) energy in the regions close to the shaft
of turbulent kinetic energy in the stirred
or the wall was lower in the mid region. A comparation of turbulent kinetic energies at
tank was similar4.2.3.
to the velocity.
eachComparison
axial location of isTurbulent
Turbulent
shown inKinetic
kinetic
FigureEnergy
energy in the regions close to the shaft
12. At the location of y1 and y2, the difference of
or the wall was lower Figure
turbulent inkinetic
the
11 mid
shows that
energy region.
profile A comparation
the variation
betweentendency of turbulent
of turbulent
two systems was kinetic
not kinetic
energy
so significant. energies
inHowever,
the stirredat at
tank
each axial location was
the is similar
shown of yto
3inthe yvelocity.
Figure Turbulent
12. At thekinetic energy
location in
for theof the regions
y y2close
thetolarger
the shaft
location and 4, turbulent kinetic energy 1 and
DRFTBI system , was difference
than of
orthat
thefor
wallthewas
DTBIlower in theThis
system. midisregion.
becauseAthe comparation
connectingofbelt
turbulent
expandingkinetic
theenergies
zone of at
the
turbulent kineticeach
energy
axialcan
profile
location
between two systems was not so significant. However, at
impeller affect is
theshown in Figure 12.
tank, promoting Atturbulence.
fluid the locationTheof results
y1 and show
y2, the difference
that of
the DRFTBI
the location of y3turbulent
and y 4 , turbulent
kinetic energy kinetic
profile energy
between two for the
systems DRFTBI
was
could strengthen the turbulent kinetic energy in the region close to wall. not so system
significant. was larger
However, at than
that for the DTBI thesystem.
location ofThisy3 andisy4because
, turbulent kinetic energy for thebelt
the connecting DRFTBI system wasthe
expanding larger than of the
zone
that for the DTBI system. This is because the connecting belt expanding the zone of the
impeller can affect the tank, promoting fluid turbulence. The results show
impeller can affect the tank, promoting fluid turbulence. The results show that the DRFTBI
that the DRFTBI
could strengthencouldthe strengthen
turbulent kinetic energy in the region close
the turbulent kinetic energy in the region close to wall. to wall.

(a) (b)

Figure 11. Turbulent kinetic energy profile at different axial location. (a) DTBI; (b) DRFTBI. (Rota-
tional speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs.)
(a) (b)

Figure
Figure 11. Turbulent 11. Turbulent
kinetic energy kinetic energy
profile atprofile at different
different axialaxial location. (a)
location. (a) DTBI;
DTBI; (b) (b)
DRFTBI. (Rota- (Rota-
DRFTBI.
tional speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs.)
tional speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs).
Separations 2022, 9, 122 9 of 16
Separations 2022, 9, x FOR PEER REVIEW 10 of 17

(a) (b)

(c) (d)

Figure 12. Comparation Figure of12.


turbulent kinetic
Comparation energykinetic
of turbulent profiles between
energy two systems.
profiles between (a) y(a)
two systems. 1 ; (b) y2y; 2; (c)
y1; (b)
y 3; (d) y4. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs.)
(c) y3 ; (d) y4 . (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs).
4.2.4.
4.2.4. Comparison of Comparison of Homogeneity
Homogeneity
The homogeneity ξ is a parameter which is often used to evaluate the solid suspen-
The homogeneity ξ is a parameter which is often used to evaluate the solid suspension
sion quality in the stirred tank. It can be calculated as [17]:
quality in the stirred tank. It can be calculated as [17]:
2
1 n  Ch 
Ch n 
v
u1 n
u 
 =1-  2  1  (14)
n 1  C avg
n n∑
ξ = 1− t −1  (14)
=1 Cavg
Figure 13 illustrates the axial ξ as a function of the radial position for DTBI and
DRFTBI. As displayed in Figure 13, in both the DTBI system and the DRFTBI system, the
Figure 13 illustrates
axial ξ the
willaxial ξ as
increase a function
following of the radial
an increase position
in the distance forfrom
away DTBI and
the DRFTBI.
shaft. In addition,
As displayed in Figure 13, of
the value inaxial
both the
ξ in theDTBI
DRFTBI system
systemand the DRFTBI
was always system,
larger than that in the axialsystem;
the DTBI ξ
thus, the
will increase following DRFTBI system
an increase in thecould strongly
distance promote
away fromthe thesolid suspension
shaft. quality.the
In addition, Mean-
value of axial ξ in while, accordingsystem
the DRFTBI to Figure 14, always
was the deviation of axial
larger thanξ that
between the two
in the DTBI systems
system;was not
very large. This indicates that the strengthening effect of the DRFTBI system was in the
thus, the DRFTBI system could strongly promote the solid suspension quality. Meanwhile,
global range of the stirred tank, not just a local region.
according to Figure 14, the The deviation
mechanismof of axial ξ between the
the strengthening two
effect systemsiswas
of DRFTBI shownnotinvery large.
Figure 15. The
This indicates that the strengthening
strengthening process effect of the
is carried outDRFTBI system
in two main steps.was
Thein thestep
first global
is therange of
solid suspen-
the stirred tank, notsion.
justThe
a local
cavityregion.
formation, broken in the first stage of stirring, can induce many vortexes.
The mechanism These
of vortexes can promote solid
the strengthening effectsuspension
of DRFTBI by enhancing
is shown theinfluctuation
Figure 15. of fluid
Theflow-
strengthening process ing.isThe secondout
carried stepinistwo
the solid
mainparticle
steps.distribution.
The first stepAfter
is solid particles
the solid are in suspen-
suspension.
sion, they can crash with the connection strap or flow with the fluid driven by the
The cavity formation, broken in the first stage of stirring, can induce many vortexes. These
vortexes can promote solid suspension by enhancing the fluctuation of fluid flowing. The
second step is the solid particle distribution. After solid particles are in suspension, they
can crash with the connection strap or flow with the fluid driven by the connection strap.
Furthermore, the solid particle could be distributed in bulk of the stirred tank during
this process.
Separations 2022,
Separations 9, 9,
2022, x FOR PEER
x FOR REVIEW
PEER REVIEW

Separations 2022, 9, 122 10 of 16


connection strap.
connection Furthermore,
strap. the
Furthermore, solid
the particle
solid could
particle bebe
could distributed inin
distributed bulk o
bulk
tank during
tank this
during process.
this process.
Separations 2022, 9, x FOR PEER REVIEW 11 of 17

connection strap. Furthermore, the solid particle could be distributed in bulk of the stirred
tank during this process.

Figure 13. Comparation ofFigure


homogeneity
Figure13.13. in the two
Comparation
Comparation systems.
ofof (Solid
homogeneity
homogeneity loading:
inin
the two
the 30%; connection
systems.
two (Solid
systems. strap 30%;
loading:
(Solid loading: con
30%; co
length: 1.2 Hs). length: 1.21.2
length: Hs.)
Hs.)
Figure 13. Comparation of homogeneity in the two systems. (Solid loading: 30%; connection strap
length: 1.2 Hs.)

Figure 14.
Figure 14.Deviation of axial
Deviation ξ Figure
at Figure
of axial different
ξ at14. axial
14. locations.
Deviation
Deviation
different of(Solid
axial axial
of loading:
axialξξ
locations. 30%; connection
at atdifferent axial
different
(Solid loading: strap
axiallocations. (Solid
locations. (Solidloading:
30%; connection strap 30%;
loading: 30%;conn
co
length: 1.2 Hs.) length: 1.21.2
Hs.)
length: 1.2 Hs). length: Hs.)

Figure 15. The schematic diagram of DRFTBI strengthens the solid suspension.

4.3. Effect of Rotation Speed


Solid distribution under different rotational speed has been studied and the results
are shown in Figure 16. As expected, the solid aggregation at the bottom of tank decreased
following an increase in rotational speed. The solid distribution was quantified, as shown
in Figure 17. When the rotational speed increased from 90 rpm to 120 rpm, the proportion
of solid concentration larger than 0.4 decreased from 3.9% to 0.6%, and the proportion of
solid concentration in the range of 0.25–0.35 increased from 49.5% to 52.9%. The results
Figure 15. The schematic diagram of DRFTBI strengthens the solid suspension.

4.3. Effect of Rotation Speed


Figure 15. The schematic diagram of DRFTBI strengthens the solid suspension.
Solid distribution under different rotational speed has been studied and the results
4.3. Effect of Rotation Speed
are shown in Figure 16. As expected, the solid aggregation at the bottom of tank decreased
Solid distribution
following an increase in rotational speed. Theunder
solid different rotational
distribution speed has as
was quantified, been studied and the results
shown
Separations 2022, 9, 122 11 of 16
in Figure 17. When the rotational speed increased from 90 rpm to 120 rpm, the proportion of tank decreased
are shown in Figure 16. As expected, the solid aggregation at the bottom
following an increase in rotational speed. The solid distribution was quantified, as shown
of solid concentration larger than 0.4 decreased from 3.9% to 0.6%, and the proportion of
in Figure 17. When the rotational speed increased from 90 rpm to 120 rpm, the proportion
solid concentration in the range of 0.25–0.35 increased from 49.5% to 52.9%. The results
indicate of solid concentration
that increasing largerspeed
the rotational than 0.4 decreased
could fromimprove
slightly 3.9% to 0.6%, and
theand the proportion
suspension and of
indicate that increasing the rotational speed could slightly improve the suspension
solid concentration in the range of 0.25–0.35 increased from 49.5% to 52.9%. The results
distribution
distribution of solid.of solid.
indicate that increasing the rotational speed could slightly improve the suspension and
distribution of solid.

(a) (b)
(a) (b)
FigureFigure
16. Contour plots of solid
16. Contour plotsdistribution for DRFTBIfor
of solid distribution at different
DRFTBIrotational speeds.
at different (a) 90 rpm;
rotational speeds. (a) 90 rpm;
(b) 120 rpm. (Rotational Figure120
speed: 16. Contour
rpm; plots
solid of solid30%;
loading: distribution for DRFTBI
connection strap at different
length: 1.2 Hs;rotational speeds. (a) 90 rpm;
plane:12 of
(b) 120 rpm. (Rotational
Separations 2022, 9, x FOR PEER REVIEW speed: 120 rpm; solid loading: 30%; connection strap length:
(b) 120 rpm. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length:1.2
18Hs; plane:
1.2 Hs; plane:
X = 0.)
X = 0). X = 0.)

(a) (a) (b) (b)


(a) (b)
FigureFigure 17. Histogram
17. Histogram Figure
of solid of
17.solid
distribution distribution
Histogram for DRFTBI
of solid distribution
for DRFTBI at different for at different
DRFTBI
rotational rotational
at different
speeds. speeds.
rotational
(a) 90 rpm; (b)speeds.(a)
(a)90
90 rpm;
rpm; (b)
(b) 12017.
Figure
120 rpm. rpm.
Histogram
(Rotational 120120
speed: ofrpm.
(Rotational (Rotational
speed:
solid
rpm; solid120
distributionspeed:
rpm;
loading: 120
for solidrpm;
DRFTBI
30%; solid
loading:
at loading:
30%;
different
connection 30%; connection
connection
straprotational
length: strap
speeds.
1.2 Hs.) strap 90length:
(a)length: 1.2Hs).
rpm;1.2
(b) Hs.)
120 rpm. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs.)
4.4. EffectStrap
4.4. Effect of Connection of Connection
Length Strap Length
4.4. Effect of Connection Strap Length
4.4. Effect The results of the solid distribution for DRFTBI with different connection strap
The The of
results Connection
results
of Strap
theofsolid
the Length
solid distribution
distribution for DRFTBI
for DRFTBI with different
with different connection
connection strap strap lengths
lengths are shown in Figure 18. Furthermore, the histograms of solid distribution are
areare
lengths The
shown results
shown of the 18.
ininFigure
Figure solid distribution the
Furthermore,
18. Furthermore, fortheDRFTBI with
histograms
histograms different
of solid
of solid connection are strap
distribution
distribution are shown
shown in Figure 19. To discover the effect of connection strap length on solid distribution,
shownlengths
ininFigureare19.
Figure shown
To
Tothe in Figure
discover
discover the 18.
effect
the Furthermore,
of
effect connection
of the histograms
strap
connection length
strap on ofsolid
length solid distribution
distribution,
proportion of solid concentration in the range of 0.25–0.35 and larger than 0.35 the
on solid are
distribution, is dis-
shown
the proportion in Figure
of solid 19. To discover in
concentration thethe
effect
inrange ofrange
connection
of range
0.25–0.35 strap
and length
larger on solid distribution,
proportion of solid cussed.concentration
The proportions the
in the of of
0.25–0.35
0.25–0.35 for than
and alarger 0.35 is dis-
than
connection 0.35 is
strap discussed.
length of 1.1 Hs,
theThe
proportion of 1.2
solid concentration in the range of 0.25–0.35 and larger than 0.35
cussed.
The proportions
proportions inHs,
in the
the andrange
range ofof0.25–0.35
1.3 Hs 0.25–0.35
were 45.6%,forfor
a connection
a connection
52.9%, strap
and 52.6%, lengthlength
strap
respectively. of 1.1 of is
Hs, 1.1dis-
Furthermore, Hs,the
1.2propor-
Hs,
cussed.
1.2 Hs, and The
1.3 Hs proportions
were 45.6%,
tions in in the
52.9%,
the range
range and of 0.25–0.35
52.6%,
larger than for aconnection
respectively.
0.35 for connection
Furthermore,strap
strap length
the
lengths of
propor-
of 1.11.1 Hs,
Hs, 1.2 Hs, and
and 1.3 Hs were 45.6%, 52.9%, and 52.6%, respectively. Furthermore, the proportions in1.3
1.2the
tions in Hs,range
and 1.3 HsHswere
larger than
were 45.6%,
0.35 for52.9%,
26.7%, 22.6%, and 22.6%,
connection
and 52.6%, respectively.
straprespectively.
lengths of 1.1 TheFurthermore,
Hs, 1.2 Hs,
results show the
and
that propor-
1.3
the better connection
the range
tions in the
larger
rangeand
than 0.35
larger
for connection strap lengths of of
1.11.1 Hs, 1.2 Hs, and 1.3 Hs were
Hs were 26.7%, 22.6%, strap, asthan
22.6%, 0.35 for
respectively.
opposed connection
to the The
longer strap
results
one, waslengths
show that the
intensified byHs,
better 1.2 Hs, and
connection
increasing 1.3
the connection strap
26.7%, 22.6%, and 22.6%, respectively. The results show that the better connection strap,
strap,Hs
as were 26.7%,
opposed to 22.6%,
the and
longer
within 22.6%,
one, was
a certain respectively.
range of length.The
intensified by results showthe
increasing that the better connection
connection strap
asa opposed
withinstrap, to the
as opposed
certain range ofto longer
the longer
length. one,one,waswas intensified
intensifiedby byincreasing
increasingthe theconnection
connection strapstrap within a
certain range of length.
within a certain range of length.

(a) (b) (c)

Figure
Figure18.
18.Contour
Contour plots of solid
plots distribution
of solid for DRFTBI
distribution with different
for DRFTBI connection
with different strap lengths.
connection strap lengths.
(a) 1.1
(a) 1.1Hs;
Hs;(b)
(b)1.2
1.2Hs;
Hs;(c)(c)
1.31.3
Hs.Hs.
(Rotational speed:
(Rotational 120 rpm;
speed: 120solid
rpm;loading: 30%; plane:
solid loading: 30%;X =plane:
0). X = 0).
Separations 2022, 9, x FOR PEER REVIEW 13 of 18

Separations 2022, 9, 122 12 of 16

Separations 2022, 9, x FOR PEER REVIEW 13 of 17

(a) (b) (c)


Figure 19.
19. Histogram
Histogram of solid distribution for DRFTBI with different connection strap length. (a) 1.1
Figure
Figure 19. Histogramofofsolid distribution
solid distribution for
for DRFTBI
DRFTBI with
with different
different connection
connection strap length.
strap length. (a) 1.1 C
Hs; (b) 1.2 Hs; (c) 1.3 Hs. (Rotational speed: 120 rpm; solid loading: 30%.)
(a) 1.1
Hs;Hs;
(b)(b)
1.21.2
Hs;Hs;
(c) (c)
1.3 1.3
Hs.Hs. (Rotational
(Rotational speed:
speed: 120 rpm;
120 rpm; solid solid loading:
loading: 30%.) 30%). e
4.5. Effect of Connection Strap Width
4.5. Effect of Connection Strap Width C
TheTheresults of solid
results distribution
distribution
of solid distribution forfor
DRFTBI
DRFTBI
DRFTBI with
withdifferent
with differentconnection
different connectionstrap
connection strap widths
strap widths
widths
are shown
shown in
in Figure
Figure 20.
20. Furthermore,
Furthermore, thethehistograms
histograms of solid
of distribution
solid
are shown in Figure 20. Furthermore, the histograms of solid distribution are shown distribution are shown
are shown in
in
Figure
in Figure21. According
21. According to Figure
to 20,
Figure the
20, proportions
the proportions in thein range
the larger
range
Figure 21. According to Figure 20, the proportions in the range larger than 0.35 for con- than
larger 0.35
than for
0.35 con-
for
nection
connectionstrap
nection widths
strap
strap widths
widthsof D/5,
of D/5,
of D/5,D/6, D/7,
D/6,
D/6, D/8,
D/7,
D/7, D/8,and
D/8,
andD/9
and
D/9 were
were16.5%,
D/9 were 25.3%,
16.5%,
16.5%, 25.3%, 22.6%,
25.3%,
22.6%, 24.1%,
22.6%,
24.1%, and
24.1%,
and
25.5%, respectively.
and 25.5%,
25.5%, respectively. Except
respectively. forfor
Except
Except D/5
for and
D/5D/5 D/9,
and and the
D/9,D/9,accumulation
the the accumulation
accumulation ofofsolid ofinin
solid the
thebottom
solid in of
of the
the bottom
bottom the
tank
of the had
tank
tank nohad
had significant
no no difference
significant
significant between
difference
difference the
between
between theother
the
other strap
other width
strapstrap
width investigated
width investigated
investigated in
in this in
this study,
study,study, asasthe
as the themaximum
maximummaximum difference
difference
difference among
amongamong
them
them them
is lower
is is than
lower lower
than3%. than
3%. The
The 3%.
widerThe
wider thewider
the connec-
connec-the
connection
tion strap,
tion strap,
the
strap, the the
greater greater
thethe
greater the resistance.
resistance.
resistance.ForFor Forthe
D/5,
D/5, D/5,
the strapthewas
strap strap was than
waswider
wider wider
thanthe than
the the others;
others;
others; thus,
thus,
thus,
the the
the
power power
power consumption
consumption
consumption must must must
be be be higher
higher
higher than
than than
others.
others. others. Thus,
Thus,from
Thus, fromthe from
the the perspective
perspective
perspective of power
of power of
powerconsumption,
consumption, D/5D/5
consumption, was
wasD/5 notnot
thethe
was notbest
best the choice
choice of strap
bestofchoice
strap ofwidth.
width. However,
strapHowever,
width. foraanarrow
However,
for narrow connec-
for aconnec-
narrow
tion tion
connection strap,
strap, although
strap,
although thethe
although resistance was
the resistance
resistance was lower,
lower,was the
lower,
the solidthe
solid accumulation ratewas
solid accumulation
accumulation rate was relatively
relatively
rate was
high.high.
relatively So,
high.
So, D/9 D/9
was was
So,alsoalso
D/9not not
was the
thealso best
bestnot choice
the best
choice of strap
choice
of strap width.
of strap
width. To maintain
width. Tothe
To maintain the balance
maintain
balancethe of power
ofbalance
power C
consumption
of power consumption
consumption and the
and the mixing mixing
and the effect,
mixing
effect, a better
effect,
a better option
a better
option for a
for optionconnection strap
for a connection
a connection width
strap widthstrap should
should widthbe
be
the
should range
be of of D/8–D/7.
theD/8–D/7.
range of D/8–D/7. m
the range
C

C
m

(a) (b) (c)


(a) (b) (c)

(d) (e)
(d) (e)
Figure 20. Contour plots of solid distribution for DRFTBI with different connection strap width.
(a) D/5; (b) D/6; (c) D/7; (d) D/8; and (e) D/9. (Rotational speed: 120 rpm; solid loading: 30%;
connection strap length: 1.2 Hs).

Figure 20. Contour plots of solid distribution for DRFTBI with different connection strap width. (a)
C
D/5; (b) D/6; (c) D/7; (d) D/8; and (e) D/9. (Rotational speed: 120 rpm; solid loading: 30%; connection
strap length: 1.2 Hs.) e
Separations 2022, 9, x FOR PEER REVIEW 14 of 17

Separations 2022, 9, 122 13 of 16


Separations 2022, 9, x FOR PEER REVIEW 14 of 17

(a) (b) (c)


(a) (b) (c)

(d)(d) (e)(e)
Figure 21. Histogram of solid distribution for DRFTBI with different connection strap widths. (a)
Figure
Figure 21. Histogram of ofD/5;
solid
solid distributionfor
distribution forDRFTBI
DRFTBIwith with different
different connection
connection strap
strap widths.
widths. (a)
(a) D/5;
(b) D/6; (c) D/7; (d) D/8; and (e) D/9. (Rotational speed: 120 rpm; solid loading: 30%; connection Co
D/5; (b) D/6; (c) D/7; (d)
(b) D/6; (c) D/7; (d) D/8; D/8; and
strapand (e)
(e)1.2
length: D/9.
D/9. (Rotational
Hs.) (Rotational speed: 120 rpm; solid loading: 30%; connection
120 rpm; solid loading: 30%; connection
strap
strap length:
length: 1.2
1.2Hs.)
Hs). ex
4.6. Effect of Off-Bottom Clearance
4.6. Effect
4.6. EffectofofOff-Bottom The results of solid distribution for DRFTBI with different off-bottom clearances are
Off-BottomClearance
Clearance Co
shown in Figure 22. Furthermore, the histograms of solid distribution are shown in Figure
The results
The resultsofofsolid
solid
23. Withdistribution
distribution
the increasefor infor DRFTBI
DRFTBI
off-bottom with with different
different
clearance, the off-bottom
off-bottom
accumulation inclearances
clearances
of solid are of
the bottom
are shown
shown in Figure
in Figure 22. decreased,
tank Furthermore,
22. Furthermore, the the
histograms
and the histograms
distribution of solid of
of solid solid
indistribution
the upper distribution
partare tankare
shown
of the inshown
Figure
improved. in
When
Figure
23. With23.
theWith thethe
increase off-bottom
increase
in off-bottom inclearance
off-bottomincreased
clearance, thefrom
clearance, T/5 to
accumulation theT/3,accumulation
the of
proportions
solid inofthe solid
of concentration
solid
bottom in of
the
larger than 0.4 were 23.1%, 0.65%, and 0.96%, respectively, while the proportions of solid
bottom
tank of tankand
decreased, decreased,
the and theofdistribution
distribution solid of solid partinof the upper part of the tank
concentration lower than 0.2in
werethe22.9%,
upper 16.38%, and the tankrespectively.
14.03%, improved. When
For the low
improved. When
the off-bottom clearancethe off-bottom
solidincreased
loading system,clearance
fromwhen T/5 theincreased
to T/3, thewas
impeller from
proportions T/5 to
close to the of T/3, the
solidthe
bottom, proportions
concentration
mixing effect and
of solid
larger concentration
than larger
driving
0.4 were 23.1%, than
force
0.65%, 0.4 0.96%,
for and
solid were 23.1%,
suspension in the0.65%,
lower part
respectively, andof 0.96%,
while the
thetank respectively,
was while
relativelyofbetter
proportions solid than
in the upper part. Unlike the low solid loading system, a mass of solid weight
the proportions
concentration of solid
lower than concentration
0.2 were 22.9%, lower
16.38%, thanand 0.214.03%,
were 22.9%, 16.38%,For
respectively. andthe lowthe
on
14.03%,
Co
blades of the impeller in the high loading system weakened the solid suspension effect
respectively.
solid loading For the low
system, when
and
solidtheloading
resulted inimpeller
system,
was close
an accumulation
when the
of solidtointhe
impeller
bottom,
the bottom
was close
thetank.
of the mixing to effect
the bottom,
and
the mixing effect and driving forceinfor m
driving force for solid suspension thesolid
lower suspension
part of theintank the was
lower part of the
relatively tank
better was
than
relatively
in the upper better than
part. in the
Unlike theupper
low solidpart. loading
Unlike the low solid
system, a mass loading
of solid system,
weighta on masstheof Co
solid weight
blades of the on the blades
impeller in the ofhigh
the impeller
loading in the high
system loadingthe
weakened system
solidweakened
suspensionthe solid
effect
suspension effect and resulted in an accumulation
and resulted in an accumulation of solid in the bottom of the tank. of solid in the bottom of the tank. Co
m

Co

Co
(a) (b) (c)
m
Figure 22. Contour plots of solid distribution for DRFTBI with different off-bottom clearance. (a)
T/3; (b) T/4; and (c) T/5. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2
Hs). Co

(a) (b) (c)


Figure 22. Contour plots
Figure plots of
of solid
soliddistribution
distributionfor
forDRFTBI
DRFTBIwith different
with off-bottom
different clearance.
off-bottom (a) (a)
clearance. T/3;
Co
T/3; (b) T/4; and (c) T/5. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length:
(b) T/4; and (c) T/5. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs). 1.2
Hs). ex

Co
Separations 2022, 9, 122 14 of 16

Figure 23. Histogram of solid distribution for DRFTBI with different off-bottom clearance. (a) T/3;
(b) T/4; and (c) T/5. (Rotational speed: 120 rpm; solid loading: 30%; connection strap length: 1.2 Hs).

5. Conclusions
This paper studies the intensification of solid suspension and homogeneous distribu-
tion in a high solid loading mixing system using the CFD method. The DTBI and DRFTBI
systems were investigated. The simulated results showed that DRFTBI had better mixing
performance compared to DTBI. Meanwhile, the effects of impeller speed, connection
strap length/width, and off-bottom clearance were investigated. The main conclusions are
listed below.
(1) The local solid concentration of the DRFTBI system was lower than that of the
DTBI system. Meanwhile, the proportion of solid concentration in the range of 0.25–0.3
was increased, meaning that more region with a solid concentration closer to the average
concentration. In conclusion, the DRFTBI system could promote the suspension of solid in
the stirred tank and enhance the homogeneity. This is because the DRFTBI could induce
many vortexes in order to enhance the solid suspension. On the other hand, solid particle
crash with a connection strap could their distribution in bulk of the stirred tank.
(2) Longer strap lengths were not the best. The strengthening effect of increasing the
strap length only worked in a definite range. For the strap width, the promotion of particle
suspension was limited when the strap was too thin. Thus, the strap width was most
effective in the range of D/7–D/8, whereby variation was only small between each width.
(3) For the off-bottom clearance, when the initial solid concentration was the same, a
lower impeller location could accumulate more solid in the impeller blades, thus inhibiting
the rotation of the impeller. Thus, the lower off-bottom clearance did not improve the
mixing in the lower part of the tank, as expected.

Author Contributions: Conceptualization, Z.L., Y.W. and F.C.; methodology, X.X., Z.L., Y.W. and
C.T.; investigation, X.X.; resources, Z.L. and C.T.; Supervision, Z.L., Y.W. and C.T.; writing—original
draft preparation, X.X. and Z.L.; writing—review and editing, X.X. and Z.L.; supervision, Z.L.;
funding acquisition, Z.L. and Y.W. All authors have read and agreed to the published version of
the manuscript.
Funding: The study was supported by the National Natural Science Foundation of China (22078030,
Z20200804), National Key Research and Development Project (2019YFC1905802), Key Project of Inde-
pendent Research Project of State Key Laboratory of Coal Mine Disaster Dynamics and Control (2011D-
A105287-zd201902), Hubei Three Gorges Laboratory Open/Innovation Fund (SK211009, SK215001).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available on request from the
1corresponding author.
Conflicts of Interest: The authors declare no conflict of interest.
Acknowledgments: The study was supported by the National Natural Science Foundation of China
(22078030 and Z20200804), the National Key Research and Development Project (2019YFC1905802),
the Key Project of Independent Research Project of State Key Laboratory of Coal Mine Disaster Dy-
namics and Control (2011DA105287-zd201902), and the Hubei Three Gorges Laboratory Open/In-
Separations 2022, 9, 122
novation Fund (SK211009 and SK215001). 15 of 16

Conflicts of Interest: The authors declare no conflict of interest

Nomenclature Nomenclature
C off-bottom clearance (m)
C off-bottom clearance (m)
Ch Ch local solid volume fraction at height of of hh
Cavg Cavg average solid volume fraction
Cε1, Cε2, Cε3, Cμ Cε1 , Cε2 , Cε3 , Cµ ὺparameters
parameters in the standard k-ε model
CD CD coefficient
drag coefficient
D D impeller diameter (m)
dp dp particle diameter (m)
F F interphase momentum transfer term term (N)
(N)
Fdrag Fdrag drag force (N)
g gravitational acceleration (m/s 2
g (m/s2))
H H stirred
stirred vessel
vessel height
height (m)
(m)
HL HL liquid height (m)
liquid height (m)
HS HS interlayer
interlayer spacing
spacing of
of two
two impeller
impeller (m)
(m)
k turbulent kinetic energy (m 2 /s2 )
k turbulent kinetic energy (m2/s 2)

Ma Ma absolute
absolute torque
torque (N.m)
(N.m)
Mm Mm torque
torque measured experimentally
measured experimentally (N.m)
(N.m)
Mr residual torque (N.m)
Mr residual torque (N.m)
N impeller speed (rpm)
N impeller speed (rpm)
n number of sampling points
n number of sampling points
P pressure (Pa)
P pressure (Pa)
Psum power consumption (W)
Psum power consumption (W)
Pv specific power consumption (W/m33 )
Pv specific power consumption (W/m )
r radial coordinate (m)
r radial coordinate (m)
T inner diameter of stirred vessel (m)
T t inner(s)
time diameter of stirred vessel (m)
t Ui time (s)
velocity (m/s)
Ui V velocity
total (m/s)of solid and liquid (m3 )
volume
V Greek Letters total volume of solid and liquid (m3)
Greek Letters ρl liquid density (kg/m3 )
ρl ρs liquiddensity
solid density(kg/m
(kg/m33))
ρs ρ density (kg/m ) 3)
solid density (kg/m
3
ρ α density (kg/m
volume fraction3)

α αl volume fraction
liquid phase volume fraction
αl αs liquidphase
solid phasevolume
volumefraction
fraction
αs ε solid phase
turbulent volume
energy fraction rate
dissipation
ε µ viscosity
turbulent(Pa · s) dissipation rate
energy
μ µl liquid phase
viscosity viscosity (Pa · s)
(Pa⸱s)
μl µt turbulent
liquid phaseviscosity
viscosity · s)
(Pa(Pa⸱s)
μt µtl liquid phase turbulent
turbulent viscosity (Pa⸱s) viscosity (Pa · s)
μtl σk , σ ε k and ε turbulent Prandtl number
liquid phase turbulent viscosity (Pa⸱s)
σk, σε ξ homogeneity
k and ε turbulent Prandtl number
ξ homogeneity
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