Advances in Industrial Mixing
A Companion to the Handbook of Industrial Mixing
1. Auflage Dezember 2015
1040 Seiten, Hardcover
Wiley & Sons Ltd
ISBN:
978-0-470-52382-7
John Wiley & Sons
Kurzbeschreibung
A companion and update to the first edition, this book explains the difference and uses of a variety of mixers including gear mixers, top entry mixers, side entry mixers, bottom entry mixers, on-line mixers, and submerged mixers, to name some of the more important ones. It also explains the difference between shear and flow in the mixture process and the connection of shear and flow to impeller design. It also discusses the trade-offs among various mixers, which might be considered for a particular process.
Advances in Industrial Mixing is a companion volume and update to the Handbook of Industrial Mixing. The second volume fills in gaps for a number of industries that were not covered in the first edition. Significant changes in five of the fundamental areas are covered in entirely updated or new chapters. The original text is provided as a searchable pdf file on the accompanying USB.
* This book explains industrial mixers and mixing problems clearly and concisely.
* Gives practical insights by the top professionals in the field, combining industrial design standards with fundamental insight.
* Details applications in 14 key industries. Six of these are new since the first edition.
* Provides the professional with information he/she did not receive in school.
* Five completely rewritten chapters on mixing fundamentals where significant advances have happened since the first edition and seven concise update chapters which summarize critical technical information.
Contributors List xxxix
Editors' Introduction xliii
Contents of the DVD, Including Instructional Videos lvii
A Technical Definition of Mixing 1
Jo¨elle Aubin and Suzanne M. Kresta
Range of Industrial Mixing Applications 2
Three Dimensions of Segregation: A Technical Definition of Mixing 3
Identifying Mixing Problems: Defining the Critical Scales and Process Objectives 5
Notation 9
References 9
1a Residence Time Distributions 11
E. Bruce Nauman
1a-1 Introduction 12
1b Mean Age Theory for Quantitative Mixing Analysis 15
Minye Liu
1b-1 Introduction 15
1b-2 Age and Time in a Flow System 16
1b-3 Governing Equations of Mean Age and Higher Moments 17
1b-4 Computation of Mean Age 20
1b-4.1 Validations of Numerical Solutions 20
1b-4.2 Spatial Distribution of Mean Age in Mixing Devices 21
1b-5 Relations of Mean Age and Residence Time Distribution 25
1b-6 Variances and the Degree of Mixing 27
1b-6.1 Variance of Residence Time Distribution 27
1b-6.2 Variances of Age 28
1b-6.3 Degree of Mixing 28
1b-6.4 Spatial Nonuniformity in CFSTRs 30
1b-7 Mean Age and Concentration in a CFSTR 31
1b-7.1 Time History of Tracer Concentration 31
1b-7.2 Mixing Time in CFSTRs 33
1b-8 Probability Distribution Function of Mean Age 34
1b-8.1 Definition 34
1b-8.2 Scaling and Blend Time Estimation 35
1b-9 Future Development of Mean Age Theory 39
Nomenclature 39
Greek Letters 40
References 41
2a Turbulence in Mixing Applications 43
Suzanne M. Kresta and Robert S. Brodkey
2a-1 Introduction 44
2b Update to Turbulence in Mixing Applications 47
M´arcio B. Machado and Suzanne M. Kresta
2b-1 Introduction 47
2b-2 The Velocity Field and Turbulence 48
2b-2.1 Circulation and Macromixing 51
2b-2.2 Fully Turbulent Limits and the Scaling of Turbulence 53
2b-3 Spectrum of Turbulent Length Scales: Injection of Scalar (Either Reagent or Additive) and the Macro-, Meso-, and Microscales of Mixing 56
2b-3.1 Mesoscale Mixing 59
2b-3.2 New Experimental Results 61
2b-3.3 Summary 65
2b-4 Turbulence and Mixing of Solids, Liquids, and Gases 65
2b-5 Specifying Mixing Requirements for a Process 66
2b-5.1 Mixing Test Cells 69
2b-6 Conclusions 78
Notation 78
Roman Characters 78
Greek Characters 79
References 80
3a Laminar Mixing: A Dynamical Systems Approach 85
Edit S. Szalai, Mario M. Alvarez, and Fernando J. Muzzio
3a-1 Introduction 86
3b Microstructure, Rheology, and Processing of Complex Fluids 87
Patrick T. Spicer and James F. Gilchrist
3b-1 Introduction 87
3b-2 Literature Analysis--Mixing of Complex Fluids 90
3b-3 Common Complex Fluid Rheology Classes and Their Effects 92
3b-3.1 Shear-Thinning Fluids 93
3b-3.2 Yield Stress Fluids 95
3b-3.3 Shear-Thickening Fluids 101
3b-3.4 Time-Dependent Fluids 103
3b-4 Conclusions 110
Nomenclature 110
Greek Symbols 111
References 111
Part A: Measuring Tools and Techniques for Mixing and Flow Visualization Studies 115
David A. R. Brown, Pip N. Jones, and John C. Middleton
5a Computational Fluid Mixing 119
Elizabeth Marden Marshall and Andr´e Bakker
5a-1 Introduction 120
5b CFD Modeling of Stirred Tank Reactors 123
Minye Liu
5b-1 Numerical Issues 123
5b-1.1 Mesh Types 123
5b-1.2 Effect of Mesh Size on Mean Flow and Turbulent Diffusion 124
5b-1.3 Discretization Schemes 125
5b-1.4 Time Integration 126
5b-1.5 Convergence 127
5b-1.6 Treatment of Impellers 129
5b-1.7 Numerical Diffusion 130
5b-2 Turbulence Models 131
5b-2.1 The RANS Models 132
5b-2.2 The LES Method 133
5b-2.3 The DES Method 135
5b-2.4 The DNS Method 135
5b-2.5 Laminar and Transitional Flows 136
5b-3 Quantitative Predictions 137
5b-3.1 Power Number 137
5b-3.2 Flow Number Calculation 137
5b-3.3 Blend Time Calculation 139
5b-4 Modeling Other Physics 142
5b-4.1 Solid-Liquid Flows 142
5b-4.2 Gas-Liquid and Liquid-Liquid Flows 143
5b-4.3 Flows with Other Physics and Chemistry 143
Nomenclature 144
Greek Letters 144
References 145
6a Mechanically Stirred Vessels 149
Ramesh R. Hemrajani and Gary B. Tatterson
6a-1 Introduction 150
6b Flow Patterns and Mixing 153
Suzanne M. Kresta and David S. Dickey
6b-1 Introduction 153
6b-2 Circulation Patterns 154
6b-2.1 Base Case: Down-Pumping Pitched-Blade Turbine--(PBTD, D = T/3 and C = T/3) 157
6b-2.2 Baffles 157
6b-2.3 Changing the Impeller Type 158
6b-2.4 Impeller Diameter 160
6b-2.5 Off-Bottom Clearance 162
6b-2.6 Bottom Shape 166
6b-2.7 Liquid Level 168
6b-2.8 Baffle Options 170
6b-2.9 Viscosity 173
6b-2.10 Off-Set and Angled Shafts 175
6b-2.11 Continuous Flow 178
6b-3 Coupling the Velocity Field with Applications 178
6b-3.1 Solids Suspension 179
6b-3.2 Gas Dispersion 181
6b-3.3 Air Entrainment, Liquid Drawdown, and Drawdown of Floating Solids 182
6b-3.4 Reactor Design 184
6b-3.5 Summary 185
Nomenclature 185
Greek Symbols 185
References 186
6c Vessel Heads: Depths, Volumes, and Areas 189
David S. Dickey, Daniel R. Crookston, and Reid B. Crookston
6c-1 Head Depth 190
6c-2 Head Volume 193
6c-3 Head Area 194
6c-4 Dimensionless Coefficients for Torispherical Heads 195
6c-5 Calculations for Conical Bottoms 197
6c-6 Other Types of Bottoms 199
Nomenclature 199
Dimensional Variables and Parameters 199
Dimensionless Variables and Parameters 199
Dimensionless Greek Symbols 200
References 200
7a Mixing in Pipelines 201
Arthur W. Etchells III and Chris F. Meyer
7a-1 Introduction 202
7b Update to Mixing in Pipelines 205
Thomas A. Simpson, Michael K. Dawson, and Arthur W. Etchells III
7b-1 Introduction 205
7b-2 Use of CFD with Static Mixers 206
7b-3 Recent Developments in Single-Phase Blending 207
7b-3.1 Laminar Blending Updates 207
7b-3.2 Transitional Blending Updates 209
7b-3.3 Turbulent Blending Updates 210
7b-3.4 Reactive Mixing with Static Mixers 218
7b-3.5 Low-Pressure-Drop Turbulent Blending 219
7b-4 Recent Developments in Multiphase Dispersions 222
7b-4.1 Liquid-Liquid and Gas-Liquid Dispersions in Viscous Bulk 222
7b-4.2 Liquid-Liquid Dispersions in Turbulent and Transitional Flow 223
7b-4.3 New Methods for Calculation of Pressure Drop and Drop Size 225
7b-4.4 Emulsification 225
7b-4.5 Vortex Mixer Emulsification 226
7b-4.6 Dispersion with Screens 227
7b-4.7 Supercritical Mass Transfer 228
7b-4.8 Gas-Phase Continuous Systems 228
7b-5 Mixing with Static Mixers When Solids are Present 229
7b-5.1 Disposable Static Mixers 231
Notation 232
Roman Characters 232
Greek Characters 233
Subscripts 233
References 235
7c Introduction to Micromixers 239
Jo¨elle Aubin and Abraham D. Stroock
7c-1 Introduction 239
7c-2 Mixing and Transport Phenomena 240
7c-3 Micromixer Geometries and Fluid Contacting Mechanisms 241
7c-4 Characterization of Flow and Mixing 244
7c-5 Multiphase Mixing 245
7c-5.1 Liquid-Liquid Mixing 246
7c-5.2 Gas-Liquid Mixing 247
7c-6 Commercial Equipment and Industrial Examples 247
7c-7 Evaluation of the Current and Future Applicability of Microreactors in Industry 250
Notation 251
Suggested Reading 251
References 251
8 Rotor-Stator Mixing Devices 255
Victor Atiemo-Obeng and Richard V. Calabrese
9a Blending of Miscible Liquids 259
Richard K. Grenville and Alvin W. Nienow
9a-1 Introduction 260
9b Laminar Mixing Processes in Stirred Vessels 261
Philippe A. Tanguy, Louis Fradette, Gabriel Ascanio, and Ryuichi Yatomi
9b-1 Introduction 261
9b-2 Laminar Mixing Background 263
9b-3 Rheologically Complex Fluids 266
9b-4 Heat Effects 268
9b-5 Laminar Mixing Equipment 269
9b-6 Key Design Parameters 274
9b-6.1 Determination of the Power Number by Dimensional Analysis 275
9b-7 Power Number and Power Constant 276
9b-7.1 Newtonian Power Analysis 276
9b-7.2 Non-Newtonian Power Analysis 278
9b-8 Experimental Techniques to Determine Blend Time 282
9b-9 Mixing Efficiency 285
9b-10 Characterization of the Mixing Flow Field 288
9b-10.1 Experimental Characterization 288
9b-10.2 Computational Fluid Dynamics Characterization 299
9b-11 Hydrodynamic Characterization of Laminar Blending 301
9b-11.1 Identifying the Operating Regime for Laminar Blending 302
9b-11.2 Open Turbines and Close-Clearance Impellers 303
9b-11.3 Coaxial Systems 312
9b-11.4 Mixers with Multiple Off-Centered Shafts 314
9b-11.5 Planetary Mixers 315
9b-11.6 When to Use Baffles 315
9b-11.7 Design Example 316
9b-12 Application of Chaos in Mixing 317
9b-12.1 Impeller Design 317
9b-12.2 Operating Modes 319
9b-12.3 Impeller Position 325
9b-12.4 Impeller Speed 327
9b-13 Selecting an Appropriate Geometry for Generic Applications 328
9b-13.1 Blending 328
9b-13.2 Liquid-Liquid Dispersion and Emulsification 329
9b-13.3 Solid-Liquid Dispersion 330
9b-13.4 Gas-Liquid Dispersion 331
9b-13.5 Aeration Technologies 333
9b-13.6 Fluid Level Changes 334
9b-13.7 Caverns 335
9b-14 Heat and Mass Transfer in the Laminar Mixing 336
9b-15 Industrial Mixing Process Requirements 338
9b-16 Scale-up Rules in the Laminar Regime 340
9b-16.1 Scale-up Based on Constant Speed 340
9b-16.2 Scale-up Based on Constant Heat Balance 341
9b-16.3 Scale-up Based on Constant Mass Balance 341
9b-17 Mixer Troubleshooting and Engineering Calculations 342
9b-17.1 Adhesion 342
9b-17.2 Change of Re upon Change of Scale 342
9b-17.3 Shear Heating Issue 343
9b-17.4 Significant Viscosity Change 344
9b-17.5 Miscible Liquid-Liquid Mixing with Excessive Different Viscosity 344
9b-17.6 Example of Industrial Calculation 346
9b-18 Concluding Remarks 347
Acknowledgments 348
References 348
10 Solid-Liquid Mixing 357
David A. R. Brown, Arthur W. Etchells III, with sections by Richard K. Grenville, Kevin J. Myers, N. Gul O¨ zcan-Tas¸kin incorporating sections by Victor A. Atiemo-Obeng, Piero H. Armenante, and W. Roy Penney
Nomenclature 441
Dimensional Variables and Parameters 441
Dimensionless Parameters 442
Greek Symbols 443
References 443
11 Gas--Liquid Mixing in Turbulent Systems 451
John C. Middleton and John M. Smith
12 Immiscible Liquid-Liquid Systems 457
Douglas E. Leng and Richard V. Calabrese
13a Mixing and Chemical Reactions 465
Gary K. Patterson, Edward L. Paul, Suzanne M. Kresta, and Arthur W. Etchells III
13a-1 Introduction 466
13a-1.1 How Mixing Can Cause Problems 468
13a-1.2 Reaction Schemes of Interest 469
13a-1.3 Relating Mixing and Reaction Time Scales: The Mixing Damkoehler Number 472
13b Scale-up Using the Bourne Protocol: Reactive Crystallization and Mixing Example 479
Aaron Sarafinas and Cheryl I. Teich
13b-1 Example: Redesigning an Uncontrolled Precipitation to a Reactive Crystallization 479
Goal 479
Issue 479
References 489
14a Heat Transfer 491
W. Roy Penney and Victor A. Atiemo-Obeng
14a-1 Introduction 492
14b Heat Transfer In Stirred Tanks--Update 493
Jose Roberto Nunhez
14b-1 Introduction 493
14b-1.1 Overall Heat Transfer Coefficient 493
14b-2 Consideration of Heat Transfer Surfaces used in Mixing Systems 496
14b-2.1 Correlations for Conventional and Spiral-Baffle Annular Jackets 502
14b-2.2 Correlations for Half-Pipe and Dimple Jackets 504
14b-3 Heating and Cooling of Liquids 506
14b-3.1 Heating: Inner Coils or Jacketed Vessel with an Isothermal Medium 507
14b-3.2 Cooling: Inner Coils or Jacketed Vessel with an Isothermal Medium 508
14b-3.3 Heating: Inner Coils or Jacketed Vessel with Nonisothermal Medium 508
14b-3.4 Cooling: Inner Coils or Jacketed Vessel with Nonisothermal Medium 509
14b-3.5 External Heat Exchanger, Isothermal Heating Medium 510
14b-3.6 External Heat Exchanger, Isothermal Cooling Medium 511
14b-4 Summary of Proposed Equations Used in Heat Transfer for Stirred Tanks 512
14b-4.1 Correcting for the Viscosity 512
14b-4.2 Use of Compact Heat Exchangers 517
14b-4.3 Cooling, a Real Problem 517
14b-5 Methodology for Design of Heating Mixing System 518
14b-6 Example 518
14b-6.1 Resolution 519
Acknowledgments 529
Nomenclature 529
Greek Symbols 531
References 531
15 Solids Mixing
Part A: Fundamentals of Solids Mixing 533
Fernando J. Muzzio, Albert Alexander, Chris Goodridge, Elizabeth Shen, and Troy Shinbrot
Part B: Mixing of Particulate Solids in the Process Industries 533
Konanur Manjunath, Shrikant Dhodapkar, and Karl Jacob
16 Mixing of Highly Viscous Fluids, Polymers, and Pastes 539
the late David B. Todd
17 Mixing in the Fine Chemicals and Pharmaceutical Industries 541
Edward L. Paul (retired), Michael Midler, and Yongkui Sun
18 Mixing in the Fermentation and Cell Culture Industries 543
Ashraf Amanullah and Barry C. Buckland, and Alvin W. Nienow
19 Fluid Mixing Technology in the Petroleum Industry 547
Ramesh R. Hemrajani
20 Mixing in the Pulp and Paper Industry 551
the late Chad P.J. Bennington
21a Mechanical Design of Mixing Equipment 555
David S. Dickey and Julian B. Fasano
21b Magnetic Drives for Mixers 559
David S. Dickey
21b-1 Introduction 559
21b-2 Laboratory Magnetic Stirrers 559
21b-3 Top-Entering Magnetic Mixer Drives 561
21b-4 Bottom-Entering Magnetic Mixer Drives 563
22 Role of the Mixing Equipment Supplier 567
Ron Weetman
23 Commissioning Mixing Equipment 569
David S. Dickey, Eric Janz, Todd Hutchinson, Thomas Dziekonski, Richard O. Kehn, and Kayla Preston and Jay Dinnison
Nomenclature 639
Greek Symbols 640
References 640
24 Mixing Safety 641
Gord Winkel and David S. Dickey
References 663
25 Mixing Issues in Crystallization and Precipitation Operations 665
Alvin W. Nienow and Edward L. Paul
Nomenclature 716
Greek Symbols 717
Subscripts 718
References 718
Appendices 722
Problem Example 1: Slow Approach to Equilibrium 722
Problem Example 2 723
Problem Example 3 725
26 Mixing in theWater and Wastewater Industry 729
Michael K. Dawson
Nomenclature 775
Greek Symbols 776
References 777
27 Mixing in the Food Industry 783
P. J. Cullen, Wesley Twombly, Robin Kay Connelly, and David S. Dickey
Nomenclature 823
Greek Symbols 823
References 823
28 Mixing and Processes Validation in the Pharmaceutical Industry 827
Otute Akiti and Piero M. Armenante
Acknowledgment 885
References 885
Index 891
Editors' Introduction xliii
Contents of the DVD, Including Instructional Videos lvii
A Technical Definition of Mixing 1
Jo¨elle Aubin and Suzanne M. Kresta
Range of Industrial Mixing Applications 2
Three Dimensions of Segregation: A Technical Definition of Mixing 3
Identifying Mixing Problems: Defining the Critical Scales and Process Objectives 5
Notation 9
References 9
1a Residence Time Distributions 11
E. Bruce Nauman
1a-1 Introduction 12
1b Mean Age Theory for Quantitative Mixing Analysis 15
Minye Liu
1b-1 Introduction 15
1b-2 Age and Time in a Flow System 16
1b-3 Governing Equations of Mean Age and Higher Moments 17
1b-4 Computation of Mean Age 20
1b-4.1 Validations of Numerical Solutions 20
1b-4.2 Spatial Distribution of Mean Age in Mixing Devices 21
1b-5 Relations of Mean Age and Residence Time Distribution 25
1b-6 Variances and the Degree of Mixing 27
1b-6.1 Variance of Residence Time Distribution 27
1b-6.2 Variances of Age 28
1b-6.3 Degree of Mixing 28
1b-6.4 Spatial Nonuniformity in CFSTRs 30
1b-7 Mean Age and Concentration in a CFSTR 31
1b-7.1 Time History of Tracer Concentration 31
1b-7.2 Mixing Time in CFSTRs 33
1b-8 Probability Distribution Function of Mean Age 34
1b-8.1 Definition 34
1b-8.2 Scaling and Blend Time Estimation 35
1b-9 Future Development of Mean Age Theory 39
Nomenclature 39
Greek Letters 40
References 41
2a Turbulence in Mixing Applications 43
Suzanne M. Kresta and Robert S. Brodkey
2a-1 Introduction 44
2b Update to Turbulence in Mixing Applications 47
M´arcio B. Machado and Suzanne M. Kresta
2b-1 Introduction 47
2b-2 The Velocity Field and Turbulence 48
2b-2.1 Circulation and Macromixing 51
2b-2.2 Fully Turbulent Limits and the Scaling of Turbulence 53
2b-3 Spectrum of Turbulent Length Scales: Injection of Scalar (Either Reagent or Additive) and the Macro-, Meso-, and Microscales of Mixing 56
2b-3.1 Mesoscale Mixing 59
2b-3.2 New Experimental Results 61
2b-3.3 Summary 65
2b-4 Turbulence and Mixing of Solids, Liquids, and Gases 65
2b-5 Specifying Mixing Requirements for a Process 66
2b-5.1 Mixing Test Cells 69
2b-6 Conclusions 78
Notation 78
Roman Characters 78
Greek Characters 79
References 80
3a Laminar Mixing: A Dynamical Systems Approach 85
Edit S. Szalai, Mario M. Alvarez, and Fernando J. Muzzio
3a-1 Introduction 86
3b Microstructure, Rheology, and Processing of Complex Fluids 87
Patrick T. Spicer and James F. Gilchrist
3b-1 Introduction 87
3b-2 Literature Analysis--Mixing of Complex Fluids 90
3b-3 Common Complex Fluid Rheology Classes and Their Effects 92
3b-3.1 Shear-Thinning Fluids 93
3b-3.2 Yield Stress Fluids 95
3b-3.3 Shear-Thickening Fluids 101
3b-3.4 Time-Dependent Fluids 103
3b-4 Conclusions 110
Nomenclature 110
Greek Symbols 111
References 111
Part A: Measuring Tools and Techniques for Mixing and Flow Visualization Studies 115
David A. R. Brown, Pip N. Jones, and John C. Middleton
5a Computational Fluid Mixing 119
Elizabeth Marden Marshall and Andr´e Bakker
5a-1 Introduction 120
5b CFD Modeling of Stirred Tank Reactors 123
Minye Liu
5b-1 Numerical Issues 123
5b-1.1 Mesh Types 123
5b-1.2 Effect of Mesh Size on Mean Flow and Turbulent Diffusion 124
5b-1.3 Discretization Schemes 125
5b-1.4 Time Integration 126
5b-1.5 Convergence 127
5b-1.6 Treatment of Impellers 129
5b-1.7 Numerical Diffusion 130
5b-2 Turbulence Models 131
5b-2.1 The RANS Models 132
5b-2.2 The LES Method 133
5b-2.3 The DES Method 135
5b-2.4 The DNS Method 135
5b-2.5 Laminar and Transitional Flows 136
5b-3 Quantitative Predictions 137
5b-3.1 Power Number 137
5b-3.2 Flow Number Calculation 137
5b-3.3 Blend Time Calculation 139
5b-4 Modeling Other Physics 142
5b-4.1 Solid-Liquid Flows 142
5b-4.2 Gas-Liquid and Liquid-Liquid Flows 143
5b-4.3 Flows with Other Physics and Chemistry 143
Nomenclature 144
Greek Letters 144
References 145
6a Mechanically Stirred Vessels 149
Ramesh R. Hemrajani and Gary B. Tatterson
6a-1 Introduction 150
6b Flow Patterns and Mixing 153
Suzanne M. Kresta and David S. Dickey
6b-1 Introduction 153
6b-2 Circulation Patterns 154
6b-2.1 Base Case: Down-Pumping Pitched-Blade Turbine--(PBTD, D = T/3 and C = T/3) 157
6b-2.2 Baffles 157
6b-2.3 Changing the Impeller Type 158
6b-2.4 Impeller Diameter 160
6b-2.5 Off-Bottom Clearance 162
6b-2.6 Bottom Shape 166
6b-2.7 Liquid Level 168
6b-2.8 Baffle Options 170
6b-2.9 Viscosity 173
6b-2.10 Off-Set and Angled Shafts 175
6b-2.11 Continuous Flow 178
6b-3 Coupling the Velocity Field with Applications 178
6b-3.1 Solids Suspension 179
6b-3.2 Gas Dispersion 181
6b-3.3 Air Entrainment, Liquid Drawdown, and Drawdown of Floating Solids 182
6b-3.4 Reactor Design 184
6b-3.5 Summary 185
Nomenclature 185
Greek Symbols 185
References 186
6c Vessel Heads: Depths, Volumes, and Areas 189
David S. Dickey, Daniel R. Crookston, and Reid B. Crookston
6c-1 Head Depth 190
6c-2 Head Volume 193
6c-3 Head Area 194
6c-4 Dimensionless Coefficients for Torispherical Heads 195
6c-5 Calculations for Conical Bottoms 197
6c-6 Other Types of Bottoms 199
Nomenclature 199
Dimensional Variables and Parameters 199
Dimensionless Variables and Parameters 199
Dimensionless Greek Symbols 200
References 200
7a Mixing in Pipelines 201
Arthur W. Etchells III and Chris F. Meyer
7a-1 Introduction 202
7b Update to Mixing in Pipelines 205
Thomas A. Simpson, Michael K. Dawson, and Arthur W. Etchells III
7b-1 Introduction 205
7b-2 Use of CFD with Static Mixers 206
7b-3 Recent Developments in Single-Phase Blending 207
7b-3.1 Laminar Blending Updates 207
7b-3.2 Transitional Blending Updates 209
7b-3.3 Turbulent Blending Updates 210
7b-3.4 Reactive Mixing with Static Mixers 218
7b-3.5 Low-Pressure-Drop Turbulent Blending 219
7b-4 Recent Developments in Multiphase Dispersions 222
7b-4.1 Liquid-Liquid and Gas-Liquid Dispersions in Viscous Bulk 222
7b-4.2 Liquid-Liquid Dispersions in Turbulent and Transitional Flow 223
7b-4.3 New Methods for Calculation of Pressure Drop and Drop Size 225
7b-4.4 Emulsification 225
7b-4.5 Vortex Mixer Emulsification 226
7b-4.6 Dispersion with Screens 227
7b-4.7 Supercritical Mass Transfer 228
7b-4.8 Gas-Phase Continuous Systems 228
7b-5 Mixing with Static Mixers When Solids are Present 229
7b-5.1 Disposable Static Mixers 231
Notation 232
Roman Characters 232
Greek Characters 233
Subscripts 233
References 235
7c Introduction to Micromixers 239
Jo¨elle Aubin and Abraham D. Stroock
7c-1 Introduction 239
7c-2 Mixing and Transport Phenomena 240
7c-3 Micromixer Geometries and Fluid Contacting Mechanisms 241
7c-4 Characterization of Flow and Mixing 244
7c-5 Multiphase Mixing 245
7c-5.1 Liquid-Liquid Mixing 246
7c-5.2 Gas-Liquid Mixing 247
7c-6 Commercial Equipment and Industrial Examples 247
7c-7 Evaluation of the Current and Future Applicability of Microreactors in Industry 250
Notation 251
Suggested Reading 251
References 251
8 Rotor-Stator Mixing Devices 255
Victor Atiemo-Obeng and Richard V. Calabrese
9a Blending of Miscible Liquids 259
Richard K. Grenville and Alvin W. Nienow
9a-1 Introduction 260
9b Laminar Mixing Processes in Stirred Vessels 261
Philippe A. Tanguy, Louis Fradette, Gabriel Ascanio, and Ryuichi Yatomi
9b-1 Introduction 261
9b-2 Laminar Mixing Background 263
9b-3 Rheologically Complex Fluids 266
9b-4 Heat Effects 268
9b-5 Laminar Mixing Equipment 269
9b-6 Key Design Parameters 274
9b-6.1 Determination of the Power Number by Dimensional Analysis 275
9b-7 Power Number and Power Constant 276
9b-7.1 Newtonian Power Analysis 276
9b-7.2 Non-Newtonian Power Analysis 278
9b-8 Experimental Techniques to Determine Blend Time 282
9b-9 Mixing Efficiency 285
9b-10 Characterization of the Mixing Flow Field 288
9b-10.1 Experimental Characterization 288
9b-10.2 Computational Fluid Dynamics Characterization 299
9b-11 Hydrodynamic Characterization of Laminar Blending 301
9b-11.1 Identifying the Operating Regime for Laminar Blending 302
9b-11.2 Open Turbines and Close-Clearance Impellers 303
9b-11.3 Coaxial Systems 312
9b-11.4 Mixers with Multiple Off-Centered Shafts 314
9b-11.5 Planetary Mixers 315
9b-11.6 When to Use Baffles 315
9b-11.7 Design Example 316
9b-12 Application of Chaos in Mixing 317
9b-12.1 Impeller Design 317
9b-12.2 Operating Modes 319
9b-12.3 Impeller Position 325
9b-12.4 Impeller Speed 327
9b-13 Selecting an Appropriate Geometry for Generic Applications 328
9b-13.1 Blending 328
9b-13.2 Liquid-Liquid Dispersion and Emulsification 329
9b-13.3 Solid-Liquid Dispersion 330
9b-13.4 Gas-Liquid Dispersion 331
9b-13.5 Aeration Technologies 333
9b-13.6 Fluid Level Changes 334
9b-13.7 Caverns 335
9b-14 Heat and Mass Transfer in the Laminar Mixing 336
9b-15 Industrial Mixing Process Requirements 338
9b-16 Scale-up Rules in the Laminar Regime 340
9b-16.1 Scale-up Based on Constant Speed 340
9b-16.2 Scale-up Based on Constant Heat Balance 341
9b-16.3 Scale-up Based on Constant Mass Balance 341
9b-17 Mixer Troubleshooting and Engineering Calculations 342
9b-17.1 Adhesion 342
9b-17.2 Change of Re upon Change of Scale 342
9b-17.3 Shear Heating Issue 343
9b-17.4 Significant Viscosity Change 344
9b-17.5 Miscible Liquid-Liquid Mixing with Excessive Different Viscosity 344
9b-17.6 Example of Industrial Calculation 346
9b-18 Concluding Remarks 347
Acknowledgments 348
References 348
10 Solid-Liquid Mixing 357
David A. R. Brown, Arthur W. Etchells III, with sections by Richard K. Grenville, Kevin J. Myers, N. Gul O¨ zcan-Tas¸kin incorporating sections by Victor A. Atiemo-Obeng, Piero H. Armenante, and W. Roy Penney
Nomenclature 441
Dimensional Variables and Parameters 441
Dimensionless Parameters 442
Greek Symbols 443
References 443
11 Gas--Liquid Mixing in Turbulent Systems 451
John C. Middleton and John M. Smith
12 Immiscible Liquid-Liquid Systems 457
Douglas E. Leng and Richard V. Calabrese
13a Mixing and Chemical Reactions 465
Gary K. Patterson, Edward L. Paul, Suzanne M. Kresta, and Arthur W. Etchells III
13a-1 Introduction 466
13a-1.1 How Mixing Can Cause Problems 468
13a-1.2 Reaction Schemes of Interest 469
13a-1.3 Relating Mixing and Reaction Time Scales: The Mixing Damkoehler Number 472
13b Scale-up Using the Bourne Protocol: Reactive Crystallization and Mixing Example 479
Aaron Sarafinas and Cheryl I. Teich
13b-1 Example: Redesigning an Uncontrolled Precipitation to a Reactive Crystallization 479
Goal 479
Issue 479
References 489
14a Heat Transfer 491
W. Roy Penney and Victor A. Atiemo-Obeng
14a-1 Introduction 492
14b Heat Transfer In Stirred Tanks--Update 493
Jose Roberto Nunhez
14b-1 Introduction 493
14b-1.1 Overall Heat Transfer Coefficient 493
14b-2 Consideration of Heat Transfer Surfaces used in Mixing Systems 496
14b-2.1 Correlations for Conventional and Spiral-Baffle Annular Jackets 502
14b-2.2 Correlations for Half-Pipe and Dimple Jackets 504
14b-3 Heating and Cooling of Liquids 506
14b-3.1 Heating: Inner Coils or Jacketed Vessel with an Isothermal Medium 507
14b-3.2 Cooling: Inner Coils or Jacketed Vessel with an Isothermal Medium 508
14b-3.3 Heating: Inner Coils or Jacketed Vessel with Nonisothermal Medium 508
14b-3.4 Cooling: Inner Coils or Jacketed Vessel with Nonisothermal Medium 509
14b-3.5 External Heat Exchanger, Isothermal Heating Medium 510
14b-3.6 External Heat Exchanger, Isothermal Cooling Medium 511
14b-4 Summary of Proposed Equations Used in Heat Transfer for Stirred Tanks 512
14b-4.1 Correcting for the Viscosity 512
14b-4.2 Use of Compact Heat Exchangers 517
14b-4.3 Cooling, a Real Problem 517
14b-5 Methodology for Design of Heating Mixing System 518
14b-6 Example 518
14b-6.1 Resolution 519
Acknowledgments 529
Nomenclature 529
Greek Symbols 531
References 531
15 Solids Mixing
Part A: Fundamentals of Solids Mixing 533
Fernando J. Muzzio, Albert Alexander, Chris Goodridge, Elizabeth Shen, and Troy Shinbrot
Part B: Mixing of Particulate Solids in the Process Industries 533
Konanur Manjunath, Shrikant Dhodapkar, and Karl Jacob
16 Mixing of Highly Viscous Fluids, Polymers, and Pastes 539
the late David B. Todd
17 Mixing in the Fine Chemicals and Pharmaceutical Industries 541
Edward L. Paul (retired), Michael Midler, and Yongkui Sun
18 Mixing in the Fermentation and Cell Culture Industries 543
Ashraf Amanullah and Barry C. Buckland, and Alvin W. Nienow
19 Fluid Mixing Technology in the Petroleum Industry 547
Ramesh R. Hemrajani
20 Mixing in the Pulp and Paper Industry 551
the late Chad P.J. Bennington
21a Mechanical Design of Mixing Equipment 555
David S. Dickey and Julian B. Fasano
21b Magnetic Drives for Mixers 559
David S. Dickey
21b-1 Introduction 559
21b-2 Laboratory Magnetic Stirrers 559
21b-3 Top-Entering Magnetic Mixer Drives 561
21b-4 Bottom-Entering Magnetic Mixer Drives 563
22 Role of the Mixing Equipment Supplier 567
Ron Weetman
23 Commissioning Mixing Equipment 569
David S. Dickey, Eric Janz, Todd Hutchinson, Thomas Dziekonski, Richard O. Kehn, and Kayla Preston and Jay Dinnison
Nomenclature 639
Greek Symbols 640
References 640
24 Mixing Safety 641
Gord Winkel and David S. Dickey
References 663
25 Mixing Issues in Crystallization and Precipitation Operations 665
Alvin W. Nienow and Edward L. Paul
Nomenclature 716
Greek Symbols 717
Subscripts 718
References 718
Appendices 722
Problem Example 1: Slow Approach to Equilibrium 722
Problem Example 2 723
Problem Example 3 725
26 Mixing in theWater and Wastewater Industry 729
Michael K. Dawson
Nomenclature 775
Greek Symbols 776
References 777
27 Mixing in the Food Industry 783
P. J. Cullen, Wesley Twombly, Robin Kay Connelly, and David S. Dickey
Nomenclature 823
Greek Symbols 823
References 823
28 Mixing and Processes Validation in the Pharmaceutical Industry 827
Otute Akiti and Piero M. Armenante
Acknowledgment 885
References 885
Index 891
Suzanne M. Kresta is a professor in the Department of Chemical and Materials Engineering at the University of Alberta.
Arthur W. Etchells III is a retired DuPont Fellow with over forty years consulting in industrial mixing.
David S. Dickey is a consultant specializing in mixing processes and equipment with MixTech, Inc. He has more than forty years experience with mixing processes and equipment.
Victor Atiemo-Obeng is retired from The Dow Chemical Company where he worked as a scientist in the Engineering Science and Market Development department.
The North American Mixing Forum provides an opportunity for dialogue about mixing problems in a wide range of industrial applications.
Arthur W. Etchells III is a retired DuPont Fellow with over forty years consulting in industrial mixing.
David S. Dickey is a consultant specializing in mixing processes and equipment with MixTech, Inc. He has more than forty years experience with mixing processes and equipment.
Victor Atiemo-Obeng is retired from The Dow Chemical Company where he worked as a scientist in the Engineering Science and Market Development department.
The North American Mixing Forum provides an opportunity for dialogue about mixing problems in a wide range of industrial applications.
