The numerical simulation of a new double swirl static mixer for gas reactants mixing

doi:10.1016/j.cjche.2020.05.008

Chinese Journal of Chemical Engineering ›› 2020, Vol. 28 ›› Issue (9): 2438-2446.DOI: 10.1016/j.cjche.2020.05.008

• Energy, Resources and Environmental Technology • Previous Articles Next Articles

The numerical simulation of a new double swirl static mixer for gas reactants mixing

Zhuokai Zhuang^1,2, Jingtian Yan³, Chenglang Sun^1,2, Haiqiang Wang^1,2, Yuejun Wang^2,4, Zhongbiao Wu^1,2

1 Key Laboratory of Environment Remediation and Ecological Health, Ministry of Education, College of Environmental & Resources Science, Zhejiang University, Hangzhou 310058, China;
2 Zhejiang Provincial Engineering Research Centre of Industrial Boiler & Furnace Flue Gas Pollution Control, Hangzhou 310058, China;
3 College of Control Science and Engineering, Zhejiang University, Hangzhou 310027, China;
4 Zhejiang Tianlan Environmental Protection Technology Co. Ltd, Hangzhou 311202, China

Received:2019-07-02 Revised:2020-05-09 Online:2020-10-21 Published:2020-09-28
Contact: Haiqiang Wang, Yuejun Wang
Supported by:
This research was financially supported by National Key Research and Development Plan of China (2016YFC0204700), Key Project of Zhejiang Provincial Science and Technology Program, Zhejiang Provincial "151" Talents Program, and Program for Zhejiang Leading Team of S&T Innovation (Grant No. 2013TD07).

The numerical simulation of a new double swirl static mixer for gas reactants mixing

Zhuokai Zhuang^1,2, Jingtian Yan³, Chenglang Sun^1,2, Haiqiang Wang^1,2, Yuejun Wang^2,4, Zhongbiao Wu^1,2

1 Key Laboratory of Environment Remediation and Ecological Health, Ministry of Education, College of Environmental & Resources Science, Zhejiang University, Hangzhou 310058, China;
2 Zhejiang Provincial Engineering Research Centre of Industrial Boiler & Furnace Flue Gas Pollution Control, Hangzhou 310058, China;
3 College of Control Science and Engineering, Zhejiang University, Hangzhou 310027, China;
4 Zhejiang Tianlan Environmental Protection Technology Co. Ltd, Hangzhou 311202, China

通讯作者: Haiqiang Wang, Yuejun Wang
基金资助:
This research was financially supported by National Key Research and Development Plan of China (2016YFC0204700), Key Project of Zhejiang Provincial Science and Technology Program, Zhejiang Provincial "151" Talents Program, and Program for Zhejiang Leading Team of S&T Innovation (Grant No. 2013TD07).

Abstract

Abstract: For the nitrogen oxide removal processes, high performance gas mixer is deeply needed for the injection of NH₃ or O₃. In this study, a new type of double swirl static mixer in gas mixing was investigated using computational fluid dynamics (CFD). The results obtained using Particle Image Velocimetry (PIV) correlated well with the results obtained from simulation. The comparisons in pressure loss between the experimental results and the simulation results showed that the model was suitable and accurate for the simulation of the static mixer. Optimal process conditions and design were investigated. When L/D equaled 4, coefficient of variation (COV) was <5%. The inlet velocity did not affect the distributions of turbulent kinetic energy. In terms of both COV and pressure loss, the inner connector is important in the design of the static mixer. The nozzle length should be set at 4 cm. Taking both COV and pressure loss into consideration, the optimal oblique degree is 45°. The averaged kinetic energy changed according to process conditions and design. The new static mixer resulted in improved mixing performance in a more compact design. The new static mixer is more energy efficient compared with other SV static mixers. Therefore, the double swirl static mixer is promising in gas mixing.

Key words: CFD, PIV, Gas mixing, Double swirl static mixer, Pressure loss

摘要： For the nitrogen oxide removal processes, high performance gas mixer is deeply needed for the injection of NH₃ or O₃. In this study, a new type of double swirl static mixer in gas mixing was investigated using computational fluid dynamics (CFD). The results obtained using Particle Image Velocimetry (PIV) correlated well with the results obtained from simulation. The comparisons in pressure loss between the experimental results and the simulation results showed that the model was suitable and accurate for the simulation of the static mixer. Optimal process conditions and design were investigated. When L/D equaled 4, coefficient of variation (COV) was <5%. The inlet velocity did not affect the distributions of turbulent kinetic energy. In terms of both COV and pressure loss, the inner connector is important in the design of the static mixer. The nozzle length should be set at 4 cm. Taking both COV and pressure loss into consideration, the optimal oblique degree is 45°. The averaged kinetic energy changed according to process conditions and design. The new static mixer resulted in improved mixing performance in a more compact design. The new static mixer is more energy efficient compared with other SV static mixers. Therefore, the double swirl static mixer is promising in gas mixing.

关键词: CFD, PIV, Gas mixing, Double swirl static mixer, Pressure loss

Zhuokai Zhuang, Jingtian Yan, Chenglang Sun, Haiqiang Wang, Yuejun Wang, Zhongbiao Wu. The numerical simulation of a new double swirl static mixer for gas reactants mixing[J]. Chinese Journal of Chemical Engineering, 2020, 28(9): 2438-2446.

References

[1] N.Y. Topsøe, Mechanism of the selective catalytic reduction of nitric oxide by ammonia elucidated by in situ on-line Fourier transform infrared spectroscopy, Science 265(1994) 1217-1219.
[2] C. Sun, N. Zhao, Z. Zhuang, H. Wang, Y. Liu, X. Weng, Z. Wu, Mechanisms and reaction pathways for simultaneous oxidation of NOx and SO₂ by ozone determined by in situ IR measurements, J. Hazard. Mater. 274(2014) 376-383.
[3] Y.S. Mok, H.J. Lee, Removal of sulfur dioxide and nitrogen oxides by using ozone injection and absorption-reduction technique, Fuel Process. Technol. 87(2006) 591-597.
[4] R.K. Thakur, C. Vial, K.D.P. Nigam, E.B. Nauman, G. Djelveh, Static mixers in the process industries-A review, Chem. Eng. Res. Des. 81(2003) 787-826.
[5] C. G. Clayton, A. Ball, R. Spackman, Dispersion and mixing during turbulent flow of water in a circular pipe, Report of Isotope Research Division, Wantage Research Laboratory, Wantage, Berks, UK, 1968, (No. AERE-R5569).
[6] A. Ghanem, T. Lemenand, D. Della Valle, H. Peerhossaini, Static mixers:Mechanisms, applications, and characterization methods-A review, Chem. Eng. Res. Des. 92(2014) 205-228.
[7] E. Talansier, D. Dellavalle, C. Loisel, A. Desrumaux, J. Legrand, Elaboration of controlled structure foams with the SMX static mixer, AIChE J. 59(2013) 132-145.
[8] P. Sungwornpatansakul, J. Hiroi, Y. Nigahara, T.K. Jayasinghe, K. Yoshikawa, Enhancement of biodiesel production reaction employing the static mixing, Fuel Process. Technol. 116(2013) 1-8.
[9] M. Rafiee, M.J.H. Simmons, A. Ingram, E.H. Stitt, Development of positron emission particle tracking for studying laminar mixing in Kenics static mixer, Chem. Eng. Res. Des. 91(2013) 2106-2113.
[10] E. Santacesaria, R. Turco, M. Tortorelli, V. Russo, M. Di Serio, R. Tesser, Biodiesel process intensification by using static mixers tubular reactors, Ind. Eng. Chem. Res. 51(2012) 8777-8787.
[11] M. Hammoudi, E.K. Si-Ahmed, J. Legrand, Dispersed two-phase flow analysis by pulsed ultrasonic velocimetry in SMX static mixer, Chem. Eng. J. 191(2012) 463-474.
[12] H. Tajima, Y. Yoshida, S. Abiko, K. Yamagiwa, Size adjustment of spherical temperature-sensitive hydrogel beads by liquid-liquid dispersion using a Kenics static mixer, Chem. Eng. J. 156(2010) 479-486.
[13] D. Li, K. Xiong, Z. Yang, C. Liu, X. Feng, X. Lu, Process intensification of heterogeneous photocatalysis with static mixer:Enhanced mass transfer of reactive species, Catal. Today 175(2011) 322-327.
[14] E. Lang, P. Drtina, Numeirical simulation of the fluid flow and the mixing process in a static mixer, Inf. J. Heat Mass Transfer. 38(1995) 2239-2250.
[15] W. Tasucher, F. Streiff, Static mixing of gases, Chem. Eng. Prog. 75(1979) 61-65.
[16] A. Bakker, R. D. Laroche, Modelling of the turbulent flow in HEV static mixers, The Online CFM Book, 1998, accessed on January 1998 http://www.bakker.org/cfm.
[17] H. Barrué, A. Karoui, N. Le Sauze, J. Costes, F. Illy, Comparison of aerodynamics and mixing mechanisms of three mixers:Oxynator^TM gas-gas mixer, KMA and SMI static mixers, Chem. Eng. J. 84(2001) 343-354.
[18] C. Harris, D. Roekaerts, F. Rosendal, F. Buitendijk, P. Daskopoulos, A. Vreenegoor, H. Wang, Computational fluid dynamics for chemical reactor engineering, Chem. Eng. Sci. 51(1996) 1569-1594.
[19] H. Meng, F. Wang, Y. Yu, M. Song, J. Wu, A numerical study of mixing performance of high-viscosity fluid in novel static mixers with multitwisted leaves, Ind. Eng. Chem. Res. 53(2014) 4084-4095.
[20] C.M. Fonte, M.E. Leblebici, M.M. Dias, J.C.B. Lopes, The NETmix reactor:Pressure drop measurements and 3D CFD modeling, Chem. Eng. Res. Des. 91(2013) 2250-2258.
[21] E. Saatdjian, A.J.S. Rodrigo, J.P.B. Mota, On chaotic advection in a static mixer, Chem. Eng. J. 187(2012) 289-298.
[22] E. Fourcade, R. Wadley, H.C. Hoefsloot, A. Green, P.D. Iedema, CFD calculation of laminar striation thinning in static mixer reactors, Chem. Eng. Sci. 56(2001) 6729-6741.
[23] M.S. Gandhi, M.J. Sathe, J.B. Joshi, P.K. Vijayan, Two phase natural convection:CFD simulations and PIV measurement, Chem. Eng. Sci. 66(2011) 3152-3171.
[24] A. Amokrane, S. Charton, F. Lamadie, J. Paisant, F. Puel, Single-phase flow in a pulsed column:Particle image velocimetry validation of a CFD based model, Chem. Eng. Sci. 114(2014) 40-50.
[25] M.S. Gandhi, J.B. Joshi, A.K. Nayak, P.K. Vijayan, Reduction in thermal stratification in two phase natural convection in rectangular tanks:CFD simulations and PIV measurements, Chem. Eng. Sci. 100(2013) 300-325.
[26] A. Lehwald, G. Janiga, D. Thévenin, K. Zähringer, Simultaneous investigation of macro- and micro-mixing in a static mixer, Chem. Eng. Sci. 79(2012) 8-18.
[27] C. Drumm, M.W. Hlawitschka, H.J. Bart, CFD simulations and particle image velocimetry measurements in an industrial scale rotating disc contactor, AIChE J. 57(2011) 10-26.
[28] V.V. Ranade, M. Perrard, C. Xuereb, N. Le Sauze, J. Bertrand, Influence of gas flow rate on the structure of trailing vortices of a rushton turbine:PIV measurements and CFD simulations, Chem. Eng. Res. Des. 79(2001) 957-964.
[29] F. Grosz-Roll, Assessing homogeneity in motionless mixers, Int. Chem. Eng. 20(1980) 542-549.
[30] C. Habchi, T. Lemenand, D.D. Valle, H. Peerhossaini, Alternating mixing tabs in multifunctional heat exchanger-reactor, Chem. Eng. Process. 49(2010) 653-661.
[31] J. Bałdyga, M. Kotowicz, Application of new chemical test reactions to study mass transfer from shrinking droplets and micromixing in the Rotor-Stator mixer, Chem. Process. Eng. 38(2017) 477-489.
[32] X.F. Shao, Z.B. Wu, Simulation and analysis on the two-phase flow fields in a rotating-stream-tray absorber by using computational fluid dynamics, Chin. J. Chem. Eng. 12(2004) 169-173.
[33] B.E. Launder, D. Spalding, The numerical computation of turbulent flows, Comput. Method. Appl. M. 3(1974) 269-289.
[34] Z.M. Lu, B. Xu, The design of static mixers, Chem. Eng. (China). 22(5) (1994) 59-69(in Chinese).

The numerical simulation of a new double swirl static mixer for gas reactants mixing

The numerical simulation of a new double swirl static mixer for gas reactants mixing

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Chaojie Li, Xianxin Fang, Meiling Sun, Jihai Duan, Weiwen Wang. Study on two-phase cloud dispersion from liquefied CO₂ release [J]. Chinese Journal of Chemical Engineering, 2023, 60(8): 37-45.
[2]	Lijuan Zhao, Zhe Tan, Xiaoguang Zhang, Qijun Zhang, Wei Wang, Qiang Deng, Jie Ma, De'an Pan. Research on process modeling and simulation of spent lead paste desulfurization enhanced reactor [J]. Chinese Journal of Chemical Engineering, 2023, 60(8): 293-303.
[3]	Hongwei Liang, Wenling Li, Zisheng Feng, Jianming Chen, Guangwen Chu, Yang Xiang. Numerical simulation of gas-liquid flow in the bubble column using Wray-Agarwal turbulence model coupled with population balance model [J]. Chinese Journal of Chemical Engineering, 2023, 58(6): 205-223.
[4]	Chengang Yang, Huaizhi Han, Quan Zhu, Xiangyuan Li. Cracking and buoyancy effect on hydrocarbon endothermic and heat transfer characteristics in rectangular mini-channel [J]. Chinese Journal of Chemical Engineering, 2023, 56(4): 242-254.
[5]	Shuangfei Zhao, Yingying Nie, Wenyan Zhang, Runze Hu, Lianzhu Sheng, Wei He, Ning Zhu, Yuguang Li, Dong Ji, Kai Guo. Microfluidic field strategy for enhancement and scale up of liquid–liquid homogeneous chemical processes by optimization of 3D spiral baffle structure [J]. Chinese Journal of Chemical Engineering, 2023, 56(4): 255-265.
[6]	Qi Han, Xin-Yuan Zhang, Hai-Bo Wu, Xian-Tai Zhou, Hong-Bing Ji. Different efficiency toward the biomimetic aerobic oxidation of benzyl alcohol in microchannel and bubble column reactors: Hydrodynamic characteristics and gas–liquid mass transfer [J]. Chinese Journal of Chemical Engineering, 2023, 55(3): 84-92.
[7]	Songsong Wang, Hong Li, Changyuan Tao, Renlong Liu, Yundong Wang, Zuohua Liu. Study on cavern evolution and performance of three mixers in agitation of yield-pseudoplastic fluids [J]. Chinese Journal of Chemical Engineering, 2023, 55(3): 111-122.
[8]	Tianpeng LiZhou, Jiajia Luo, Tiefeng Wang. Enhancement of acetylene and ethylene yields in partially decoupled oxidation of ethane by changing the composition of heat carrier [J]. Chinese Journal of Chemical Engineering, 2022, 47(7): 71-78.
[9]	Shidong Xue, Jingkun Han, Xi Xi, Junyi Zhao, Zhong Lan, Rongfu Wen, Xuehu Ma. Rapid velocity reduction and drift potential assessment of off-nozzle pesticide droplets [J]. Chinese Journal of Chemical Engineering, 2022, 46(6): 243-254.
[10]	Yongjun Wu, Pan You, Peicheng Luo. Effect of pitched short blades on the flow characteristics in a stirred tank with long-short blades impeller [J]. Chinese Journal of Chemical Engineering, 2022, 45(5): 143-152.
[11]	Mohsen Rezaeimanesh, Ali Asghar Ghoreyshi, S.M. Peyghambarzadeh, Seyed Hassan Hashemabadi. A coupled CFD simulation approach for investigating the pyrolysis process in industrial naphtha thermal cracking furnaces [J]. Chinese Journal of Chemical Engineering, 2022, 44(4): 528-542.
[12]	Anshi Hong, Zisheng Zhang, Xingang Li, Xin Gao. A generalized CFD model for evaluating catalytic separation process in structured porous materials [J]. Chinese Journal of Chemical Engineering, 2022, 51(11): 168-177.
[13]	Chunhui Li, Bin Wu, Junjie Zhang, Peicheng Luo. Effect of swirling addition on the liquid mixing performance in a T-jets mixer [J]. Chinese Journal of Chemical Engineering, 2022, 50(10): 108-116.
[14]	Yang Lü, Kai Lu, Youxiang Bai, Yulong Ma, Yongsheng Ren. Fouling characteristics of 90° elbow in high salinity wastewater from coal chemical industry [J]. Chinese Journal of Chemical Engineering, 2021, 35(7): 143-151.
[15]	Qiang Zheng, Jingxuan Yang, Wenhao Lian, Baoping Zhang, Xueer Pan, Zhonglin Zhang, Xiaogang Hao, Guoqing Guan. Multi-fluid Eulerian simulation of binary particles mixing and gas-solids contacting in high solids-flux downer reactor equipped with a lateral particle feeding nozzle [J]. Chinese Journal of Chemical Engineering, 2021, 35(7): 152-162.