高剪切混合器研究与应用进展
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摘要
高剪切混合器作为一种能量密集型的过程强化手段,具有剪切速率高、局部能量耗散率高的特点,可以实现均质、乳化、溶解、分散、悬浮、结晶、破碎、反应等过程的强化,但尚缺少理性设计方法的系统研究。本文简述了高剪切混合器分类、工作模式,总结了操作参数、结构参数、物性参数等对高剪切混合器的流动与返混特性、微观混合特性、乳化和液液传质特性、气泡分散与气液传质特性、固体破碎与分散特性等的影响规律,简介了高剪切混合设备的工业实用案例;进而提出了该领域有待深入拓展的研究方向,包括高剪切混合器能量效率的提升途径、多相体系下高剪切混合器模型的建立方法、高剪切混合器与其他单元操作耦合规律、高剪切作用与外场协同强化机理、基于高剪切混合器的过程强化工艺优化等。
High shear mixers(HSMs), as the energy intensive process intensification technique, have the feature of high shear rates and highly localized energy dissipation rates and will provide intensifications for homogenization, emulsification, dissolution, dispersion, suspension, crystallization, pulverization and reaction, etc. However, it lacks of systematic investigation on rational design method for HSMs. We briefly introduced the category and working mode of HSMs, summarized the effects of operation conditions,structural parameters and physical properties on the flow and backmixing characteristics, micromixing performance, emulsification and liquid-liquid mass transfer property, bubble dispersion and gas-liquid mass transfer property, solid pulverization and dispersion, etc. Several industrial application cases of HSMs were presented. Then we put forward the research aspects needed in future, involving how to improve the energy efficiency of HSMs and to establish the modeling method for HSMs in multiphase systems, to disclose the coupling principles with other unit operations and to understand the synergy effect of high shearing and external field, to explore optimal intensified technologies for HSMs, etc.
High shear mixers(HSMs), as the energy intensive process intensification technique, have the feature of high shear rates and highly localized energy dissipation rates and will provide intensifications for homogenization, emulsification, dissolution, dispersion, suspension, crystallization, pulverization and reaction, etc. However, it lacks of systematic investigation on rational design method for HSMs. We briefly introduced the category and working mode of HSMs, summarized the effects of operation conditions,structural parameters and physical properties on the flow and backmixing characteristics, micromixing performance, emulsification and liquid-liquid mass transfer property, bubble dispersion and gas-liquid mass transfer property, solid pulverization and dispersion, etc. Several industrial application cases of HSMs were presented. Then we put forward the research aspects needed in future, involving how to improve the energy efficiency of HSMs and to establish the modeling method for HSMs in multiphase systems, to disclose the coupling principles with other unit operations and to understand the synergy effect of high shearing and external field, to explore optimal intensified technologies for HSMs, etc.
引文
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[2]ZHANG J,XU S,LI W.High shear mixers:a review of typical applications and studies on power draw,flow pattern,energy dissipation and transfer properties[J].Chemical Engineering and Processing:Process Intensification,2012,57:25-41.
[3]GUICHARDON P,FALK L,ANDRIEU M.Experimental comparison of the iodide-iodate and the diazo coupling micromixing test reactions in stirred reactors[J].Chemical Engineering Research and Design,2001,79(8):906-914.
[4]ATIEMO-OBENG V,CALABRESE R V.Rotor-stator mixing devices[M]//Handbook of Industrial Mixing:Science and Practice.New York:John Wiley&Sons Inc.,2004:479-505.
[5]上海弗鲁克科技发展有限公司.http://www.fluko.net/.FLUKOEquipment Shanghai Co.Ltd.,http://www.fluko.net/.
[6]CHENG Q,XU S,SHI J,et al.Pump capacity and power consumption of two commercial in-line high shear mixers[J].Industrial&Engineering Chemistry Research,2012,52(1):525-537.
[7]DOUCET L,ASCANIO G,TANGUY P A.Hydrodynamics characterization of rotor-stator mixer with viscous fluids[J].Chemical Engineering Research and Design,2005,83(10):1186-1195.
[8]KHOPKAR A R,FRADETTE L,TANGUY P A.Hydrodynamics of a dual shaft mixer with newtonian and non-newtonian fluids[J].Chemical Engineering Research and Design,2007,85(6):863-871.
[9]UTOMO A T,BAKER M,PACEK A W.Flow pattern,periodicity and energy dissipation in a batch rotor-stator mixer[J].Chemical Engineering Research and Design,2008,86(12):1397-1409.
[10]UTOMO A,BAKER M,PACEK A W.The effect of stator geometry on the flow pattern and energy dissipation rate in a rotor-stator mixer[J].Chemical Engineering Research and Design,2009,87(4):533-542.
[11]MORTENSEN H H,CALABRESE R V,INNINGS F,et al.Characteristics of batch rotor-stator mixer performance elucidated by shaft torque and angle resolved PIV measurements[J].The Canadian Journal of Chemical Engineering,2011,89(5):1076-1095.
[12]MORTENSEN H H,INNINGS F,H?KANSSON A.The effect of stator design on flowrate and velocity fields in a rotor-stator mixer--an experimental investigation[J].Chemical Engineering Research and Design,2017,121:245-254.
[13]?ZCAN-TA?KIN G,KUBICKI D,PADRON G.Power and flow characteristics of three rotor-stator heads[J].The Canadian Journal of Chemical Engineering,2011,89(5):1005-1017.
[14]XU S,CHENG Q,LI W,et al.LDA measurements and CFDsimulations of an in-line high shear mixer with ultrafine teeth[J].AIChE Journal,2014,60(3):1143-1155.
[15]JASI?SKA M,BA?DYGA J,COOKE M,et al.Application of test reactions to study micromixing in the rotor-stator mixer(test reactions for rotor-stator mixer)[J].Applied Thermal Engineering,2013,57(1):172-179.
[16]COOKE M,RODGERS T L,KOWALSKI A J.Power consumption characteristics of an in-line Silverson high shear mixer[J].AIChEJournal,2012,58(6):1683-1692.
[17]ZHANG C,GU J,QIN H,et al.CFD analysis of flow pattern and power consumption for viscous fluids in in-line high shear mixers[J].Chemical Engineering Research and Design,2017,117:190-204.
[18]QIN H,XU Q,LI W,et al.Effect of stator geometry on the emulsification and extraction in the inline single-row blade-screen high shear mixer[J].Industrial&Engineering Chemistry Research,2017,56:9376-9388.
[19]XU S,SHI J,CHENG Q,et al.Residence time distributions of in-line high shear mixers with ultrafine teeth[J].Chemical Engineering Science,2013,87:111-121.
[20]张晨,秦宏云,徐钦,等.CFD优化管线式高剪切混合器停留时间分布[J].化工进展,2016,35(10):3110-3117.ZHANG C,QIN H Y,XU Q,et al.Optimization of residence time distribution of in-line high shear mixer by CFD[J].Chemical Industry and Engineering Progress,2016,35(10):3110-3117.
[21]BOURNE J,GARCIA-ROSAS J.Rotor-stator mixers for rapid micromixing[J].Chemical Engineering Research and Design,1986,64(1):11-17.
[22]BOURNE J R,STUDER M.Fast reactions in rotor-stator mixers of different size[J].Chemical Engineering and Processing:Process Intensification,1992,31(5):285-296.
[23]CHU G W,SONG Y H,YANG H J,et al.Micromixing efficiency of a novel rotor-stator reactor[J].Chemical Engineering Journal,2007,128(2):191-196.
[24]张占元,闵健,高正明.连续高速分散混合器内的微观混合性能[J].北京化工大学学报(自然科学版),2008,35(5):4-7.ZHANG Z Y,MIN J,GAO Z M.Micromixing characteristics of a continuous rotor-stator mixer[J].Journal of Beijing University of Chemical Technology(Natural Science Edition),2008,35(5):4-7.
[25]杨蕾,李志鹏,高正明.多级定转子连续分散混合器内的微观混合性能[J].北京化工大学学报(自然科学版),2010,37(1):1-4.YANG L,LI Z P,GAO Z M.Micromixing characteristics in a continuous rotor-stator mixer[J].Journal of Beijing University of Chemical Technology(Natural Science Edition),2010,37(1):1-4.
[26]QIN H,ZHANG C,XU Q,et al.Geometrical improvement of inline high shear mixers to intensify micromixing performance[J].Chemical Engineering Journal,2017,319:307-320.
[27]徐双庆.管线型高剪切混合器流体力学与返混特性[D].天津:天津大学,2012.XU S Q.Hydrodynamics and backmixing properties of in-line high shear mixers[D].Tianjin:Tianjin University,2012.
[28]CALABRESE R V,FRANCIS M K,KEVALA K R,et al.Fluid dynamics and emulsification in high shear mixers[C]//Proc.3rd World Congress on Emulsions,France,2002:24-27.
[29]CALABRESE R V,FRANCIS M K,MISHRA V P,et al.Measurement and analysis of drop size in a batch rotor-stator mixer[C]//Proc.10th European Conference on Mixing,Netherlands,2000:149-156.
[30]PADRON G A.Effect of surfactants on drop size distributions in a batch,rotor-stator mixer[D].Maryland:University of Maryland College Park,2005.
[31]THAPAR N.Liquid-liquid dispersions from in-line rotor-stator mixers[D].Cranfield Bedfordshire:Cranfield University,2004.
[32]GINGRAS J P,TANGUY P A,MARIOTTI S,et al.Effect of process parameters on bitumen emulsions[J].Chem.Eng.Process,2005,44(9):979-986.
[33]HALL S,COOKE M,El-HAMOUZ A,et al.Droplet break-up by inline Silverson rotor-stator mixer[J].Chem.Eng.Sci.,2011,66(10):2068-2079.
[34]HALL S,COOKE M,PACEK A W,et al.Scaling up of Silverson rotorstator mixers[J].The Canadian Journal of Chemical Engineering,2011,89(5):1040-1050.
[35]SHI J,XU S,QIN H,et al.Single-pass emulsification processes in two different inline high shear mixers[J].Industrial&Engineering Chemistry Research,2013,52:14463-14471.
[36]GU J,XU Q,ZHOU H,et al.Liquid-liquid mass transfer property of two inline high shear mixers[J].Chemical Engineering and Processing:Process Intensification,2016,101:16-24.
[37]JASI?SKA M,BA?DYGA J,COOKE M,et al.In investigations of mass transfer and micromixing effects in two-phase liquid-liquid systems with chemical reaction[C]//European Conference on Mixing,2012.
[38]林海霞.定-转子反应器气液传质及压降特性研究[D].北京:北京化工大学,2007.LIN H X.Studies on gas-liquid mass transfer and pressure drop characteristics of rotor-stator reactor[D].Beijing:Beijing University of Chemical Technology,2007.
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