Advances in Industrial Mixing

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.

“Advances in Industrial Mixing” is an updated version of the “Handbook of Industrial Mixing”(1). The unchanged text of the “Handbook of Industrial Mixing” is provided electronically (on the accompanying DVD), and only the new or substantially revised contents are provided in the hard copy.....In summary, “Advances in Industrial Mixing” provides an expansion to the “Handbook of Industrial Mixing” (1), including new developmentsin both experimental and numerical approaches and new methods developed based on more extensive data for assessing mixing quality. With regards to the issues raised in industry, a wide range of new materials are added in this volume, such as health and safety, and mixing in water, food and the pharmaceutical industry. (Johnson Matthey Technol. Rev., 2017, 61:4)

• Contributors List xxxixEditors’ Introduction xliiiContents of the DVD, Including Instructional Videos lviiA Technical Definition of Mixing 1Joelle Aubin and Suzanne M. KrestaRange of Industrial Mixing Applications 2Three Dimensions of Segregation: A Technical Definition of Mixing 3Identifying Mixing Problems: Defining the Critical Scales and Process Objectives 5Notation 9References 91a Residence Time Distributions 11E. Bruce Nauman1a-1 Introduction 121a-2 Measurements and Distribution Functions1a-3 Residence Time Models of Flow Systems1a-4 Uses of Residence Time Distributions1a-5 Extensions of Residence Time TheoryNomenclatureReferences1b Mean Age Theory for Quantitative Mixing Analysis 15Minye Liu1b-1 Introduction 151b-2 Age and Time in a Flow System 161b-3 Governing Equations of Mean Age and Higher Moments 171b-4 Computation of Mean Age 201b-5 Relations of Mean Age and Residence Time Distribution 251b-6 Variances and the Degree of Mixing 271b-7 Mean Age and Concentration in a CFSTR 311b-8 Probability Distribution Function of Mean Age 341b-9 Future Development of Mean Age Theory 39Nomenclature 39Greek Letters 40References 412a Turbulence in Mixing Applications 43Suzanne M. Kresta and Robert S. Brodkey2a-1 Introduction 442a-2 Background2a-3 Classical Measures of Turbulence2a-4 Dynamics and Averages: Reducing the Dimensionality of the Problem2a-5 Modeling the Turbulent Transport2a-6 What Have We Learned?NomenclatureReferences2b Update to Turbulence in Mixing Applications 47Marcio B. Machado and Suzanne M. Kresta2b-1 Introduction 472b-2 The Velocity Field and Turbulence 482b-3 Spectrum of Turbulent Length Scales: Injection of Scalar (Either Reagent or Additive) and the Macro-, Meso-, and Microscales of Mixing 562b-4 Turbulence and Mixing of Solids, Liquids, and Gases 652b-5 Specifying Mixing Requirements for a Process 662b-6 Conclusions 78Notation 78Roman Characters 78Greek Characters 79References 803a Laminar Mixing: A Dynamical Systems Approach 85Edit S. Szalai, Mario M. Alvarez, and Fernando J. Muzzio3a-1 Introduction 863a-2 Background3a-3 How to Evaluate Mixing Performance3a-4 Physics of Chaotic Flows Applied to Laminar Mixing3a-5 Applications to Physically Realizable Chaotic Flows3a-6 Reactive Chaotic Flows3a-7 Summary3a-8 ConclusionsNomenclatureReferences3b Microstructure, Rheology, and Processing of Complex Fluids 87Patrick T. Spicer and James F. Gilchrist3b-1 Introduction 873b-2 Literature Analysis—Mixing of Complex Fluids 903b-3 Common Complex Fluid Rheology Classes and Their Effects 923b-4 Conclusions 110Nomenclature 110Greek Symbols 111References 1114 Experimental MethodsPart A: Measuring Tools and Techniques for Mixing and Flow Visualization Studies 115David A. R. Brown, Pip N. Jones, and John C. Middleton4-1 Introduction 1174-2 Mixing Laboratory4-3 Power Draw or Torque Measurement4-4 Single-Phase Blending4-5 Solid–Liquid Mixing4-6 Liquid–Liquid Dispersion4-7 Gas–Liquid Mixing4-8 Other TechniquesPart B: Fundamental Flow Measurement4-9 Scope of Fundamental Flow Measurement Techniques4-10 Laser Doppler Anemometry4-11 Phase Doppler Anemometry4-12 Particle Image VelocimetryNomenclatureReferences5a Computational Fluid Mixing 119Elizabeth Marden Marshall and Andre Bakker5a-1 Introduction 1205a-2 Computational Fluid Dynamics5a-3 Numerical Methods5a-4 Stirred Tank Modeling Using Experimental Data5a-5 Stirred Tank Modeling Using the Actual Impeller Geometry5a-6 Evaluating Mixing from Flow Field Results5a-7 Applications5a-8 Closing RemarksAcknowledgmentsNomenclatureReferences5b CFD Modeling of Stirred Tank Reactors 123Minye Liu5b-1 Numerical Issues 1235b-2 Turbulence Models 1315b-3 Quantitative Predictions 1375b-4 Modeling Other Physics 142Nomenclature 144Greek Letters 144References 1456a Mechanically Stirred Vessels 149Ramesh R. Hemrajani and Gary B. Tatterson6a-1 Introduction 1506a-2 Key Design Parameters6a-3 Flow Characteristics6a-4 Scale-up6a-5 Performance Characteristics and Ranges of Application6a-6 Laminar Mixing in Mechanically Stirred VesselsNomenclatureReferences6b Flow Patterns and Mixing 153Suzanne M. Kresta and David S. Dickey6b-1 Introduction 1536b-2 Circulation Patterns 1546b-3 Coupling the Velocity Field with Applications 178Nomenclature 185Greek Symbols 185References 1866c Vessel Heads: Depths, Volumes, and Areas 189David S. Dickey, Daniel R. Crookston, and Reid B. Crookston6c-1 Head Depth 1906c-2 Head Volume 1936c-3 Head Area 1946c-4 Dimensionless Coefficients for Torispherical Heads 1956c-5 Calculations for Conical Bottoms 1976c-6 Other Types of Bottoms 199Nomenclature 199Dimensional Variables and Parameters 199Dimensionless Variables and Parameters 199Dimensionless Greek Symbols 200References 2007a Mixing in Pipelines 201Arthur W. Etchells III and Chris F. Meyer7a-1 Introduction 2027a-2 Fluid Dynamic Modes: Flow Regimes7a-3 Overview of Pipeline Device Options by Flow Regime7a-4 Applications7a-5 Blending and Radial Mixing in Pipeline Flow7a-6 Tee Mixers7a-7 Static or Motionless Mixing Equipment7a-8 Static Mixer Design Fundamentals7a-9 Multiphase Flow in Motionless Mixers and Pipes7a-10 Transitional Flow7a-11 Motionless Mixers: Other Considerations7a-12 In-line Mechanical Mixers7a-13 Other Process Results7a-14 Summary and Future DevelopmentsAcknowledgmentsNomenclatureReferences7b Update to Mixing in Pipelines 205Thomas A. Simpson, Michael K. Dawson, and Arthur W. Etchells III7b-1 Introduction 2057b-2 Use of CFD with Static Mixers 2067b-3 Recent Developments in Single-Phase Blending 2077b-4 Recent Developments in Multiphase Dispersions 2227b-5 Mixing with Static Mixers When Solids are Present 229Notation 232Roman Characters 232Greek Characters 233Subscripts 233References 2357c Introduction to Micromixers 239Joelle Aubin and Abraham D. Stroock7c-1 Introduction 2397c-2 Mixing and Transport Phenomena 2407c-3 Micromixer Geometries and Fluid Contacting Mechanisms 2417c-4 Characterization of Flow and Mixing 2447c-5 Multiphase Mixing 2457c-6 Commercial Equipment and Industrial Examples 2477c-7 Evaluation of the Current and Future Applicability of Microreactors in Industry 250Notation 251Suggested Reading 251References 2518 Rotor–Stator Mixing Devices 255Victor Atiemo-Obeng and Richard V. Calabrese8-1 Introduction 2568-2 Geometry and Design Configurations8-3 Hydrodynamics of Rotor–Stator Mixers8-5 Mechanical Design Considerations8-6 Rotor–Stator Mixing Equipment SuppliersNomenclatureReferences9a Blending of Miscible Liquids 259Richard K. Grenville and Alvin W. Nienow9a-1 Introduction 2609a-2 Blending of Newtonian Fluids in the Turbulent and Transitional Regimes9a-3 Blending of Non-Newtonian, Shear-Thinning Fluids in the Turbulent and Transitional Regimes9a-4 Blending in the Laminar Regime9a-5 Jet Mixing in TanksNomenclatureReferences9b Laminar Mixing Processes in Stirred Vessels 261Philippe A. Tanguy, Louis Fradette, Gabriel Ascanio, and Ryuichi Yatomi9b-1 Introduction 2619b-2 Laminar Mixing Background 2639b-3 Rheologically Complex Fluids 2669b-4 Heat Effects 2689b-5 Laminar Mixing Equipment 2699b-6 Key Design Parameters 2749b-7 Power Number and Power Constant 2769b-8 Experimental Techniques to Determine Blend Time 2829b-9 Mixing Efficiency 2859b-10 Characterization of the Mixing Flow Field 2889b-11 Hydrodynamic Characterization of Laminar Blending 3019b-12 Application of Chaos in Mixing 3179b-13 Selecting an Appropriate Geometry for Generic Applications 3289b-14 Heat and Mass Transfer in the Laminar Mixing 3369b-15 Industrial Mixing Process Requirements 3389b-16 Scale-up Rules in the Laminar Regime 3409b-17 Mixer Troubleshooting and Engineering Calculations 3429b-18 Concluding Remarks 347Acknowledgments 348References 34810 Solid–Liquid Mixing 357David A. R. Brown, Arthur W. Etchells III, with sections by Richard K. Grenville, Kevin J. Myers, N. Gul Ozcan-Taskin incorporating sections by Victor A. Atiemo-Obeng, Piero H. Armenante, and W. Roy Penney10-1 Introduction and Scope 35810-2 Solid and Liquid Physical Characteristics 36410-3 Agitation of Sinking or Settling Solids 37110-4 Incorporation and Dispersion of Floating Solids 41610-5 Attrition and Particle Damage 42510-6 Solids Suspension and Distribution Using Liquid Jets 43010-7 Mass Transfer 43110-8 Lab and Pilot-Scale Testing 440Nomenclature 441Dimensional Variables and Parameters 441Dimensionless Parameters 442Greek Symbols 443References 44311 Gas—Liquid Mixing in Turbulent Systems 451John C. Middleton and John M. Smith11-1 Introduction 45211-2 Selection and Configuration of Gas–Liquid Equipment11-3 Flow Patterns and Operating Regimes11-4 Power11-5 Gas Hold-up or Retained Gas Fraction11-6 Gas–Liquid Mass Transfer11-7 Bubble Size11-8 Consequences of Scale-upNomenclatureReferences12 Immiscible Liquid–Liquid Systems 457Douglas E. Leng and Richard V. Calabrese12-1 Introduction 45912-2 Liquid–Liquid Dispersion12-3 Drop Coalescence12-4 Population Balances12-5 More Concentrated Systems12-6 Other Considerations12-7 Equipment Selection for Liquid–Liquid Operations12-8 Scale-up of Liquid–Liquid Systems12-9 Industrial ApplicationsNomenclatureReferences13a Mixing and Chemical Reactions 465Gary K. Patterson, Edward L. Paul, Suzanne M. Kresta, and Arthur W. Etchells III13a-1 Introduction 46613a-2 Principles of Reactor Design for Mixing-Sensitive Systems13a-3 Mixing and Transport Effects in Heterogeneous Chemical Reactors13a-4 Scale-up and Scale-down of Mixing-Sensitive Systems13a-5 Simulation of Mixing and Chemical Reaction13a-6 ConclusionsNomenclatureReferences13b Scale-up Using the Bourne Protocol: Reactive Crystallization and Mixing Example 479Aaron Sarafinas and Cheryl I. Teich13b-1 Example: Redesigning an Uncontrolled Precipitation to a Reactive Crystallization 479Goal 479Issue 479References 48914a Heat Transfer 491W. Roy Penney and Victor A. Atiemo-Obeng14a-1 Introduction 49214a-2 Fundamentals14a-3 Most Cost-Effective Heat Transfer Geometry14a-4 Heat Transfer Coefficient Correlations14a-5 ExamplesNomenclatureReferences14b Heat Transfer in Stirred Tanks—Update 493Jose Roberto Nunhez14b-1 Introduction 49314b-2 Consideration of Heat Transfer Surfaces used in Mixing Systems 49614b-3 Heating and Cooling of Liquids 50614b-4 Summary of Proposed Equations Used in Heat Transfer for Stirred Tanks 51214b-5 Methodology for Design of Heating Mixing System 51814b-6 Example 518Acknowledgments 529Nomenclature 529Greek Symbols 531References 53115 Solids MixingPart A: Fundamentals of Solids Mixing 533Fernando J. Muzzio, Albert Alexander, Chris Goodridge, Elizabeth Shen, and Troy Shinbrot15-1 Introduction15-2 Characterization of Powder Mixtures15-3 Theoretical Treatment of Granular Mixing15-4 Batch Mixers and Mechanisms15-6 ConclusionsPart B: Mixing of Particulate Solids in the Process Industries 533Konanur Manjunath, Shrikant Dhodapkar, and Karl Jacob15-7 Introduction15-8 Mixture Characterization and Sampling15-9 Selection of Batch and Continuous Mixers15-10 Fundamentals and Mechanics of Mixer Operation15-11 Continuous Mixing of Solids15-12 Scale-up and Testing of MixersNomenclatureReferences16 Mixing of Highly Viscous Fluids, Polymers, and Pastes 539the late David B. Todd16-1 Introduction 53916-2 Viscous Mixing Fundamentals16-3 Equipment for Viscous Mixing16-4 Equipment Selection16-5 SummaryNomenclatureReferences17 Mixing in the Fine Chemicals and Pharmaceutical Industries 541Edward L. Paul (retired), Michael Midler, and Yongkui Sun17-1 Introduction 54217-2 General Considerations17-3 Homogeneous Reactions17-4 Heterogeneous Reactions17-5 Mixing and CrystallizationReferences18 Mixing in the Fermentation and Cell Culture Industries 543Ashraf Amanullah and Barry C. Buckland, and Alvin W. Nienow18-1 Introduction 54418-2 Scale-up/Scale-down of Fermentation Processes18-3 Polysaccharide Fermentations18-4 Mycelial Fermentations18-5 Escherichia coli Fermentations18-6 Cell Culture18-7 Plant Cell CulturesNomenclatureReferences19 Fluid Mixing Technology in the Petroleum Industry 547Ramesh R. Hemrajani19-1 Introduction 54819-2 Shear-Thickening Fluid for Oil Drilling Wells19-3 Gas Treating for CO2 Reduction19-4 Homogenization of Water in Crude Oil Transfer Lines19-5 Sludge Control in Crude Oil Storage Tanks19-6 Desalting19-7 Alkylation19-8 Other ApplicationsNomenclatureReferences20 Mixing in the Pulp and Paper Industry 551the late Chad P.J. Bennington20-1 Introduction 55220-2 Selected Mixing Applications in Pulp and Paper Processes: Non fibrous Systems20-3 Pulp Fiber Suspensions20-4 Scales of Mixing in Pulp Suspensions20-5 Macroscale Mixing/Pulp Blending Operations20-6 Mixing in Pulp Bleaching Operations20-7 ConclusionsNomenclatureReferences21a Mechanical Design of Mixing Equipment 555David S. Dickey and Julian B. Fasano21-1 Introduction 55621-2 Mechanical Features and Components of Mixers21.3 Motors21.4 Speed Reducers21.5 Shaft Seals21.6 Shaft Design21.7 Impeller Features and Design21.8 Tanks and Mixer Supports21.9 Wetted Materials of ConstructionNomenclatureReferences21b Magnetic Drives for Mixers 559David S. Dickey22 Role of the Mixing Equipment Supplier 567Ron Weetman22-1 Introduction 56822-2 Vendor Experience22-3 Options22-4 Testing22-5 Mechanical Reliability22-6 Service22-7 Key PointsReferences23 Commissioning Mixing Equipment 569David S. Dickey, Eric Janz, Todd Hutchinson, Thomas Dziekonski, Richard O. Kehn, and Kayla Preston and Jay Dinnison23-1 Introduction 56923-2 Commissioning Concepts 57023-3 Instructions for Commissioning 57223-4 Safety Instructions 57323-5 Receiving the Equipment 57523-6 Kinds of Storage 57823-7 Installation 58223-8 Lubrication 59023-9 Wiring 59423-10 Initial Operation 59523-11 Troubleshooting 59723-12 Maintenance 59723-13 Commissioning Shaft Seals 59723-14 Mechanical Checkout, Startup, and Troubleshooting of Agitator Equipment 60923-15 Summary 639Nomenclature 639Greek Symbols 640References 64024 Mixing Safety 641Gord Winkel and David S. Dickey24-1 Introduction 64124-2 The Practice of Risk Management 64224-3 Summary Comments on Mixing Safety 661References 66325 Mixing Issues in Crystallization and Precipitation Operations 665Alvin W. Nienow and Edward L. Paul25-1 Introduction 66525-2 Basic Crystallization Concepts 66725-3 Impact of Mixing on Primary Heterogeneous Nucleation 67325-4 Impact of Mixing on Secondary Nucleation 67825-5 Impact of Mixing on Crystal Growth and Dissolution Rates 68425-6 Selecting Operating Conditions to Optimize Crystal Suspension and Withdrawal 68725-7 Damkoehler Number for Nucleation and Subsurface Feeding of Reactants 69525-8 Stirred Vessel Crystallizers 70025-9 Other Types of Equipment 70425-10 Precipitation 70625-11 Agglomeration and Oiling Out 71225-12 Conclusions 714Nomenclature 716Greek Symbols 717Subscripts 718References 718Appendices 72226 Mixing in the Water and Wastewater Industry 729Michael K. Dawson26-1 Introduction 72926-2 Mixing in Drinking Water Treatment 73526-3 Mixing in Wastewater Treatment 75826-4 Mixing in Sludge Treatment 76526-5 Conclusions 775Nomenclature 775Greek Symbols 776References 77727 Mixing in the Food Industry 783P. J. Cullen, Wesley Twombly, Robin Kay Connelly, and David S. Dickey27-1 Introduction 78327-2 Building or Reducing Texture Through Mixing 78427-3 Role of Mixing in Food Treatment 79627-4 Food Homogeneity 80227-5 Advances in the Science of Food Mixing 80327-6 Other Food Mixers 80327-7 Typical Food Groups 818Nomenclature 823Greek Symbols 823References 82328 Mixing and Processes Validation in the Pharmaceutical Industry 827Otute Akiti and Piero M. Armenante28-1 Introduction 82728-2 Validation in Pharmaceutical Industry 82828-3 Pharmaceutical Processes and Role of Mixing in Pharmaceutical Production 83628-4 Examples of Process Validation in Pharmaceutical Industry 85228-5 Example of Process Validation for API Manufacturing: Manufacturing of EX123 API 85228-6 Example of Process Validation for Drug Product Manufacturing: Manufacturing of EX123 Drug Product 864Verification 884Acknowledgment 885References 885Index 891