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Department of Chemical Engineering, Institute of Chemical Technology, Matunga, Mumbai 400 019, India
Homi Bhabha National Institute, Anushakti Nagar, Mumbai 400 094, India
c
Indira Gandhi Centre for Atomic Research, Kalpakkam, TN 603 102, India
d
Techno-Force Pvt. Ltd., Ambad D-34, Nashik 422 010, India
b
h i g h l i g h t s
" Axial mixing in annular centrifugal extractors was studied for different rotor sizes.
" Effect of rotor speed and ow rate on axial mixing was quantied.
" The effect of helical bafes was studied on axial mixing.
" Helical bafes were found to impart a plug ow behavior.
" For application in scale-up, correlations were proposed for Peclet number.
a r t i c l e
i n f o
Article history:
Available online 20 July 2012
Keywords:
TaylorCouette ow
Annular centrifugal extractor
Axial mixing
Residence time distribution
Peclet number
Computational uid dynamics (CFDs)
Helical bafes
a b s t r a c t
Annular centrifugal extractors (ACEs) based on TaylorCouette ow, have found various applications,
some of which include liquidliquid extraction and as bio and polymerization reactors. The residence
time distribution (RTD) was measured in three size extractors having 50, 150 and 250 mm rotor diameter. The rotational speed was varied in the range of 1030 r/s so that the power consumption per unit
mass in the annular region was in the range of 25750 W/kg. The extent of axial mixing was substantially
reduced by providing helical bafes in the annular region. The effect of pitch was also studied. All the
geometries were simulated using computational uid dynamics (CFDs). A good agreement was obtained
between the CFD predictions and the experimental measurements. Also, correlations have been proposed
for Peclet numbers in the absence and presence of helical bafes.
2012 Elsevier B.V. All rights reserved.
1. Introduction
Annular centrifugal extractors (ACEs) nd wide applications in
chemical process industries involving liquidliquid extractions. A
schematic diagram of ACE is shown in Fig. 1. It consists of a stationary outer cylinder, concentric to which is a rotating inner cylinder.
The annular gap between the two cylinders is kept small. The inner
cylinder is rotated at a high speed which creates a large shearing
force on the liquid in the annulus. The ow developed inside the
annulus is referred to as the Taylorcouette ow. This ow is quantied by a dimensionless number, known as Taylor number (Ta),
which is the ratio of centrifugal force to the viscous force and ex2
4 2
pressed as Ta 1g g2 d Xm .
Annular centrifugal extractors, also called annular centrifugal
contactors [15] offer several advantages over the other conven Corresponding author at: Department of Chemical Engineering, Institute of
Chemical Technology, Matunga, Mumbai 400 019, India. Tel.: +91 22 33332106, +91
22 25597625; fax: +91 22 33611020.
E-mail addresses: jbjoshi@gmail.com, jb.joshi@ictmumbai.edu.in (J.B. Joshi).
1385-8947/$ - see front matter 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.cej.2012.06.151
463
Nomenclature
C(t)
Cijk
Ce1, Ce2
d
Deff
Di
DL
Dm
Dt
E
Eh
f
g
H
k
L
n
p
P
P0
hPi
Pe
Pk
Q
r
Re
Ri
Sc
Sct
t
Ta
time (s)
2
4
Taylor number Ta 1g g2 d Xm 2 ()
Tk
ui
u0i
huii
Us
Uz
VC
VL
VZR
xi
z
Greek Symbols
X
rotor speed (rad/s)
g
radius ratio of the inner cylinder to the outer cylinder ()
m
kinematic viscosity of the working uid (m2/s)
r2
2
h
r
sij
e
q
s
h
re
rt
lt
Pij
variance (s2)
ratio of r2/s2 ()
Reynolds stress (N/m2)
turbulent energy dissipation rate (m2/s3)
density (kg/m3)
mean residence time (s)
ratio of t/s ()
turbulent Prandtl number for energy dissipation rate ()
turbulent Prandtl number for kinetic energy ()
turbulent viscosity (Pa s)
pressurestrain correlation (m2/s3)
rates (when extraction is accompanied by chemical reaction) together with the extent of axial mixing is important. The latter is
the subject of present work.
2. Previous work
During the past 35 years, some studies have been reported
regarding the axial mixing in Taylor Couette ow over a wide range
of design and operating parameters. Table 1 gives a summary of
the published work. Kataoka et al. [26] performed RTD experiments and found that the Taylor vortex ow with a small constant
axial ow can be an ideal plug ow for the range of 51.4 < Ta < 640
and 0 < Re < 90 for the geometry d/Ri = 0.333. Each cellular vortex,
considered as a well-mixed batch vessel, was found to move axially
with no intermixing over the cell boundary. When Ta exceeded
640, the plug ow could not be maintained owing to the occurrence of longitudinal intermixing over the cell boundary, which
was attributed to the transition from singly to doubly periodic
ow.
The study on axial mixing in Taylorcouette contactors was further carried out by Pudjiono et al. [27]. These authors measured the
residence time distribution in a continuous Taylor Couette device
having 23.5 mm rotor. They found a near plug ow behavior at
Ta = 60 and have described the axial mixing by dispersed plug ow
model. Legrand and Coeuret [28] carried out the experimental
investigation of circumferential mixing in a Taylorcouette ow.
They proposed that each vortex unit be considered as an ideal stirred tank. In single and two phase studies carried out by them, they
used tanks in series model. Also, they observed practically no
464
Fig. 1. Conceptual diagram of annular centrifugal extractor. (1) Stationary cylinder, (2) rotating cylinder, (3A) light phase inlet, (3B) heavy phase inlet, (4A and B) region
below rotating cylinder, (5) central opening for rotating cylinder, (6) radial bafes on the stationary bottom plate, (7) deecting bafe in the rotor, (8) vertical bafes in the
rotor, (9) interface between air and light phase, (10A and B) overow weirs for lighter and heavier phase respectively, (11) clean width for heavy phase, (12) clean width for
light phase, (13A and B) outlets for light and heavy phases respectively, and (14) liquid level in the annulus.
Table 1
Summary of the work on axial dispersion in the annular region of TaylorCouette ow.
Author
Ri/Ro ()
Taylor number, Ta ()
0.75
0.5
0.642
0.94
0.703
0.750.93
0.548
0.240.89
0.5930.76
0.875
10
20
24
1.5
18.4
1.56.5
11.3
5.143.2
1830.5
0.005
090
035
06.3
0.035.5
0
17.570
0
324
60250
0.030.51
50640
50640
5035000
0118
02000
1 1062.9 108
435870
17098400
514838220
02209
The data was reported for a wide range of uid viscosities, annular
gaps and rotor speeds. It was noted through visual observations
that, the height of the Taylor vortices was somewhat greater than
the width of the annulus. They also found that, the circumferential
speeds of the rotor and of the vortices were proportional to each
other. These authors also observed that, there was a relative lowering in the value of average apparent diffusivity with rotor speed
which was attributed to the decrease in the scale of turbulence.
465
The authors stated that, the conclusions of that work, though not
very exact, could certainly provide a basis for estimating the
importance of the back-mixing effect of a physical operation or a
chemical process was carried out in this apparatus. Thus, this work
is certainly a value addition to the development of Taylor vortex
ow.
Desmet el al. [30,31] have studied the intra-vortex and intervortex axial dispersion in Taylor Couette devices. They refuted
the previously published notion that in Taylorcouette ows, the
inter-vortex dispersion is absent. Also they showed that the intra-vortex dispersion depended on various factors such as the tangential velocity and the dimensions of the vortices. Also, they
showed that a single vortex cannot always be considered as a completely mixed stirred tank and depended upon the concentration
gradients within the vortices.
Vedantam et al. [5] and Deshmukh et al. [3234] have carried
out CFD simulations for RTD and compared it with the available
experimental data in the Taylor vortex regime and the turbulent
regime. It has been shown that the plug ow behavior is obtained
in small scale equipment. However, substantial axial mixing was
found to occur when the size is larger than 50 mm and/or the rotor
speed is high. They further found that, the effect of net axial ow
on the axial mixing signicantly reduced at higher rotational
speeds. Effect of axial ow, annular gap width, and rotational speed
was investigated on the axial dispersion.
Deshmukh et al. [34] performed CFD simulation of ACE with
39 mm rotor and 52 mm stator. They found that the number of
vortices decreases with an increase in rotor speed. Further, they
made an important observation that the Taylor vortices cannot
be considered as non-interacting and substantial intervortex recirculation was found by PIV measurements and CFD simulations.
They have proposed a procedure for the estimation of the number
of tanks in series based on the number of vortices and the inter-cell
circulation velocities. Based on the data obtained from CFD simulations and validation with the experiments, they could quantitatively state the difference between the observed number of
vortices and the number of tanks in series. They also carried out
an extensive analysis of the global and local dispersion. Also, the
mixing time due to turbulent transport was much larger than the
mixing time due to convective transport. Thus, it may be emphasized that, RTD and PIV measurements as well as the CFD simulations of Deshmukh et al. [34] (in agreement with Desmet et al.
[30,31]) indicated markedly different results as compared with
the hitherto well adopted notion that the number of counter rotating vortices can be considered to be equal to the number of completely stirred tanks in series resulting into a plug ow behavior.
In view of these important observations, Deshmukh et al. [34]
thought it desirable to introduce a geometrical modication in
the annular region so that the number of vortices does not reduce
with either an increase in the rotor speed or change in the annular
gap (which is particularly expected as the size of ACE increases).
For this purpose, they introduced radial bafes with a very small
clearance between the stationary bafe and the rotating cylinder.
It was observed (by PIV) that a pair of counterrotating vortices
formed in each space between the two neighboring bafes. Thus,
the vortex size could be independent of rotor speed as well as
the annular gap. Further, the inter bafe recirculation was found
Table 2
Details of the experimental conditions used for the axial dispersion in the annular centrifugal extractor.
Diameter of the inner
cylinder (mm)
Ta
Mesh
size
y+
250
150
50
23
15
8
2
2
2
10
8
6
43 105
26 105
8.5 105
1520
1416
67
466
r2h
Motor
2DL
2
V L L Pe
Rotameter
Probe position
Storage tank
s R0t
tCt dt
Ct dt
0
In discrete form, if t is the time interval between successive readings, the above expression for s can be re-written as:
tCtDt
s P
CtDt
@ui
0
@xi
2
2
@ui @ui uj
1 Pi
@
@t
@xj
q xi @xj
CtDt
r2
s2
9
@hui i
0
@xi
11
@hui i
@hui i
1 hPi i 1 @
huj i
@t
@xj
q xi q @xj
@hui i
sij
xj
12
In Eq. (12), the term sij can be modeled using various turbulence
models. It has been shown that [3234] Reynolds Stress Model
(RSM) could model the highly turbulent Taylor vortex ow more
accurately than the ke model. Hence, in the present work, RSM
has been employed to model turbulence. In this model, individual
Reynolds stresses can be computed using the following transport
equation:
@ sij
@ sij
@huj i
@hui i
qsik
sjk
qhuk i
@xk
@xk
@t
@xk
@
2
2
C ijk Pij edij mr sij
xk
3
13
where
r2h
@ui
xj
E h sE
10
Ct
EP
CtDt
t 2 CtDt
r2 P
s2
ui hui i u0i
Rt
0 0
P @uj
q @xi
@u0i
@xj
The
diffusive transport in Eq. (13) has been modeled
turbulent
@s
as @x@ rlt @xij with the value of the constant rk taken as 0.82. Thus,
k
k
k
the term lt needs to be modeled. This is done as:
lt qC l
14
467
1
sii sjj skk
2
15
@e
@e
@ 1
l @e
e
C e1 P k
l t
huj i
@xj q
@t
@xj
re r @xj
k
C e2 q
e2
16
Pk sij
@hui i
@xj
17
C e1 1:44;
C e2 1:92 and
re 1:0:
@qT k
@qT k
@
@T
qDeff k
huk i
@t
@xk
@xk
@xk
18
Deff Dm Dt
19
Dm
Dt
m
Sc
mt
Sct
20
21
Fig. 3. Schematic diagram of the simulation geometry of ACE with parts shown: (1)
Stationary cylinder, (2) rotating cylinder, (3A) light phase inlet, (3B) heavy phase
inlet, (4) helical bafes, (5) central opening for rotating cylinder, (6) radial bafes on
the stationary bottom plate.
468
0.1
0.04
0.03
0.05
0.02
0.01
0
-0.01
-0.05
-0.02
-0.03
-0.1
-0.04
0
0.2
0.4
0.6
0.8
(A)
0.2
0.4
0.6
0.8
(B)
Fig. 4. Grid size dependence of axial velocity proles for: (A) ACE-50 at z/H = 0.6, (1) Grid size = 8.5 105, (2) Grid size = 10 105, (3) Grid size = 6.2 105, (B) ACE-150 at z/
H = 0.5 (1) 26 105 (2) Grid size = 29.5 105 and (3) Grid size = 21 105.
469
VL (mm/s)
Pe (Exp)
50
50
50
50
150
150
150
150
250
250
250
250
250
250
250
250
250
250
250
250
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
No bafes
25
25
25
25
37.5
37.5
37.5
37.5
9
9
14
14
55
55
146
146
278
278
1250
1250
278
278
1250
1250
278
278
1250
1250
10
30
10
30
10
20
10
20
10
30
10
30
10
30
10
30
10
30
10
30
10.4
10.4
16.2
16.2
7.15
7.15
18.8
18.8
12.9
12.9
57.9
57.9
566
566
2548
2548
252
252
1132
1132
2.34
1.16
3.11
1.26
0.81
0.48
1.56
0.91
0.93
0.42
2.78
2.29
7.74
5.78
7.86
6.71
4.71
3.62
5.91
4.41
1.2
1.2
1.2
0.8
0.8
0.8
0.6
0.6
0.6
0.4
0.4
0.4
0.2
0.2
0.2
0
0
2
4
6
8 10
DIMENSIONLESS
TIME,
VZR (mm/s)
Pe
2
2
2
2
2
2
2
2
2
2
2
2
6
6
6
6
6
6
6
6
6
18
3
24
12
45
22.5
45
30
120
25
44
193
264
840
1256
232
313
801
1107
0.58
1.73
0.185
1.48
1.68
6.3
1.19
2.39
2.33
9.33
0.43
0.76
0.34
0.47
0.33
0.49
0.92
1.24
0.71
0.98
1.86
0.89
2.92
1.01
0.92
0.29
1.18
0.69
0.7
0.20
2.14
1.58
7.13
6.21
7.23
6.04
4.22
3.44
4.97
4.06
0
0
2
4
6
8
DIMENSIONLESS
TIME,
(A)
10
5
DIMENSIONLESS
TIME,
10
(C)
(B)
0.9
DIMENSIONLESS EXIT AGE
DISTRIBUTION, E
CFD predictions
0.8
0.9
0.7
0.8
0.6
0.7
0.6
0.5
0.5
0.4
0.4
0.3
0.3
0.2
0.2
0.1
0.1
0
0
0
1
2
3
4
DIMENSIONLESS TIME,
(D)
1
2
3
4
DIMENSIONLESS TIME,
(E)
Fig. 5. Sample residence time distribution diagrams for the annular region (. . .) Experimental () CFD (A) ACE-50: 9 mL/s and 10 r/s, (B) ACE-150: 146 mL/s and 20 r/s, (C)
ACE-250 in the absence of bafes: 278 mL/s and 10 r/s, (D) ACE-250 in the presence of bafes with pitch 25 mm: 278 mL/s and 10 r/s, and (E) ACE-250 in the presence of
bafes with pitch 37.5 mm: 1250 mL/s and 30 r/s.
470
4.00e-1
3.33e-1
2.67e-1
2.00e-1
1.33e-1
6.67e-2
0
6.67e-2
-1.33e-2
-2.00e-1
--2.67e-2
-3.33e-1
-4.00e-1
(A)
(B)
Fig. 6. Comparison showing the contour plots for axial velocity in ACE-50 at 9 mL/s at (A) 10 r/s (B) 30 r/s.
30
25
20
15
10
25
20
15
10
5
0
0
0
0.5
0.2
0.4
0.6
0.8
DIMENSIONLESS RADIAL
DISTANCE (r-Ri)/d
(B)
(A)
Fig. 7. Sample proles for eddy diffusivity in the annular region of (A) ACE-50 at 9 mL/s and 62.8 rad s. (B) ACE-150 at 146 mL/s and 125.6 rad s.
It was thought desirable to explain this phenomenon on the basis of interstage recirculation velocities. The procedure for analysis
was based on the tanks-in-series model with interstage recirculation [38]. This approach has been used by Joshi [39] for the case
of bubble columns where multiple recirculation cells prevail. It
was shown that, if n is the number of interacting recirculation cells
in the column, the Peclet number is given by:
1
Pe n= f
2
22
where f is the ratio of inter-cell recirculation velocity to the supercial velocity. Joshi [39] has estimated the value of f on the basis of
ow pattern at the interface of the two adjacent cells. Further, he
has shown excellent agreement between the model predictions
and all the experimental data published in the literature over a wide
range of column diameter, column height, gas and liquid supercial
velocities and the physical properties of the gas and liquid phases. It
was shown that the value of interstage recirculation velocity, VZR
was equal to 0.3 times the average liquid circulation velocity within
the cell, VC.
The same approach was adopted for annular centrifugal extractors, where multiple Taylor vortices prevail in the annular region.
As has been shown by Desmet et al. [30,31], the Taylor vortices involve inter-vortex dispersion. Thus, the Taylor vortices could be considered as interacting. The inter-cell recirculation velocities were
calculated from the ow patterns obtained from CFD simulations.
471
7.5e-1
6.25e-1
5e-1
3.75e-1
2.5e-1
1.25e-1
0
-1.25e-1
-2.5e-1
-3.75e-1
-5e-1
-6.25e-1
(A)
-7.5e-1
(B)
Fig. 8. Comparison showing the contour plots for axial velocity in ACE-250 at
1250 mL/s and 20 r/s (A) without helical bafes (B) with helical bafes with 25 mm
pitch.
is a decrease in the inter-cell recirculation velocity at a constant rotor speed. Thus, the parameter f (=VZR/VL) decreases. Thus, from Eq.
(22), it can be seen that Pe decreases.
5.3. Effect of helical bafes in the annular region of ACE-250
As has been discussed in Section 1, Taylor vortex ow, which is
the characteristic of annular centrifugal extractors, has applications in numerous different areas, owing to the high values of mass
transfer coefcients, interfacial areas and low residence times
compared to conventional devices. However, this feature also imparts a drawback of backmixed behavior [34]. Backmixed behavior
is known to result in much larger reactor volumes as compared to
the plug ow behavior. For instance, for a rst order reaction and
98 per cent conversion, the volume of backmixed reactor is about
400% higher than a plug ow reactor. Thus, a backmixed behavior
3.5
10
9
Pe (PREDICTED)(-)
8
2.5
7
6
5
1.5
4
1
3
2
0.5
1
0
Pe (EXPERIMENTAL)(-)
(A)
10
Pe (EXPERIMENTAL)(-)
(B)
Fig. 9. Parity plots for showing comparison between the values of Peclet numbers predicted by experiments and by correlations (A) in the absence of helical bafes (B) in
presence of helical bafes.
472
attached externally and also through the sight glass provided at the
outer cylinder.
5.4. Scale-up aspects of annular centrifugal extractors from the
standpoint of current study
In this paper, we have undertaken experimental measurements
and CFD simulations of the annular centrifugal extractors over a
wide range of rotor size, rotor speed and supercial liquid velocity.
In previous section, an excellent agreement has been shown between the experimental and predicted (CFD) values of Peclet numbers. Thus, in the exercise of scale-up, one may argue that the tool
of CFD can be employed. However, implementation of CFD simulation may sometimes be difcult because of the unavailability of
computational power/experience. Therefore, it was thought desirable to propose correlations for Peclet numbers for the two cases:
In the absence of helical bafes:
Pe 16:03
!0:71
0:82
ND2i q
Di V L q
23
Pe 139:53
!0:23
0:098
ND2i q
Di V L q
1 p=d1:51
24
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