Mixing process scale

TATTERSON Fluid Mixing and Gas Dispersion in Agitated Tanks TATTERSON Scale-up of Industrial Mixing Processes VVILLIG Environmental TQM... 

The reason for this is simple. If the reaction chemistry is not "clean" (meaning selective), then the desired species must be separated from the matrix of products that are formed and that is costly. In fact the major cost in most chemical operations is the cost of separating the raw product mixture in a way that provides the desired product at requisite purity. The cost of this step scales with the complexity of the "un-mixing" process and the amount of energy that must be added to make this happen. For example, the heating and cooling costs that go with distillation are high and are to be minimized wherever possible. The complexity of the separation is a function of the number and type of species in the product stream, which is a direct result of what happened within the reactor. Thus the separations are costly and they depend upon the reaction chemistry and how it proceeds in the reactor. All of the complexity is summarized in the kinetics. 

The failure of conventional criteria may be due to the fact that it is not only one mixing process which can be limiting, rather for example an interplay of micromixing and mesomixing can influence the kinetic rates. Thus, by scaling up with constant micromixing times on different scales, the mesomixing times cannot be kept constant but will differ, and consequently the precipitation rates (e.g. nucleation rates) will tend to deviate with scale-up. 

The conventional scale-up criteria scale-up with constant stirrer speed , scale-up with constant tip speed and scale-up with constant specific energy input are all based on the assumption that only one mixing process is limiting. If, for example, the specific energy input is kept constant with scale-up, the same micromixing behaviour could be expected on different scales. The mesomixing time, however, will change with scale-up as a result, the kinetic rates and particle properties will be different and scale-up will fail. 

Mersmann, A. and Laufliiitte, H.D., 1985. Scale-up of agitated vessels for different mixing processes. 5th European Conference on Mixing 1985, Wurzburg, pp. 273-284. 

First, let us consider batch mixing processes, as exemplified by ordinaiy laboratory practice in solution kinetics. A portion of one solution (say, of the substrate) is added by pipet to a second solution (containing the reagent) in a flask, the flask is shaken to achieve homogeneity, and then samples are withdrawn at known times for analysis, or the solution is subjected to continuous observation as a function of time, for example, by spectrophotometry. For reactions on a time scale (measured by the half-life) of hours or even several minutes, the time consumed in these operations is a negligible portion of the reaction time, but as the half-life of the reaction decreases, it becomes necessary to consider these preliminary steps. Let us distinguish three stages ... 

Deposition commonly reflects a combination of physicochemical processes and localized effects. It may occur through fouling as a result of contamination by process materials, perhaps plus scaling from the supersaturation of dissolved salts, and coupled with some active under-deposit corrosion. As a consequence, deposits forming within a boiler are almost never single mineral scales but typically consist of a variable mix of scale and corrosion debris, chemical treatment residuals, process contaminants, and the like. 

One extremely important point to realize is that different propellant types may have different rate-controlling processes. For example, the true double-base propellants are mixed on a molecular scale, since both fuel and oxidizing species occur on the same molecule. The mixing of ingredients and their decomposition products has already occurred and can therefore be neglected in any analysis. On the other hand, composite and composite modified-double-base propellants are not mixed to this degree, and hence mixing processes may be important in the analysis of their combustion behavior. 

Accurate description of mixing processes on each of these scales is only possible in a few selected and idealized cases. One of the best understood cases is that of a turbulent PBL over flat terrain and a point source of a trace substance. In this case, the concentration downwind of the source is often described as a plume. Figure 7-3 shows such an idealized plume. 

Suppose now that a pilot-plant or full-scale reactor has been built and operated. How can its performance be used to confirm the kinetic and transport models and to improve future designs Reactor analysis begins with an operating reactor and seeks to understand several interrelated aspects of actual performance kinetics, flow patterns, mixing, mass transfer, and heat transfer. This chapter is concerned with the analysis of flow and mixing processes and their interactions with kinetics. It uses residence time theory as the major tool for the analysis. 

The spatio-temporal variations of the concentration field in turbulent mixing processes are associated wdth very different conditions for chemical reactions in different parts of a reactor. This scenario usually has a detrimental effect on the selectivity of reactions when the reaction time-scale is small compared with the mixing time-scale. Under the same conditions (slow mixing), the process times are increased considerably. Due to mass transfer inhibitions, the true kinetics of a reaction does not show up instead, the mixing determines the time-scale of a process. This effect is known as mixing masking of reactions [126]. 

If the feed time of a concentrated fluid is short the reaction will often be completed within the circulation zone, outside the impeller zone. Macromixing can then be important and the blend time will be an important scale-up parameter. For long feeding times and low concentrations in the feed all the important mixing processes could be completed almost immediately in the vicinity of the outlet of the feed pipe. 

Tatterson, G. B. (1993) Scale-up and Design of Industrial Mixing Processes (McGraw-Hill). 

The measurements of isotopic anomalies in meteorites has contributed greatly to the understanding of mixing processes and time scales in the formation of the solar system as well as strong constraints on presolar stellar evolution but it also left unanswered questions and revealed new complexities which are discussed here. 

Electrochemical Processes. The reductive cleavage of azo-group-containing dyes has been applied on a full scale for the decolorization of concentrates from batch dyeing. Depending on the color, decolorization of up to 80% of the initial absorbance can be obtained. Mixed processes consist of combinations of electrochemical treatment and precipitation by use of dissolving electrodes [43,49]. Such techniques have been described in the literature and have, in part, also been tested on a full scale. Anodic processes that form chlorine from oxidation of chloride have also been proposed to destroy dyes, but care has to be taken with regard to the chlorine and chlorinated products (AOX) formed [114,115]. 

A complete mix reactor can also be used to simulate a larger water body when the process under consideration has a larger time scale than the mixing processes in the lake, as the next example demonstrates. 

Table 6.2 Temporal or spatial means and scales used in association with various mixing processes...

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