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Flow simulations approach for flocculation tanks
Idžakovičová, Kristýna ; Bílek, Vojtěch ; Haidl, Jan ; Isoz, M. ; Pivokonský, Martin
Flocculation in water treatment facilities plays a key role in the separation of colloidal inorganic and organic substances. Its optimization leads to a significant increase in its efficiency and savings of operational costs. However, it is currently based on trial-and-error experimental approaches. In this contribution, we focus on flow modeling in stirred flocculation tanks that would, after coupling with a calibrated model of particle aggregation, enable simulationbased flocculation optimization. Despite the abundance of literature on stirred tank modeling, there is no universal agreement on the methodology used to describe turbulence nor on the approach to the computational mesh creation. Consequently, there is no unified methodology for simulations and their validation. To address this, we present a best-practice methodology for economical, yet reliable flow simulations in the said device. This methodology includes the choice of the turbulence model, the approach to the design of a high quality mesh suitable for arbitrary geometries, and results evaluation. It is developed based on an extensive literature review, a multitude of flow simulations using several meshes of progressively higher quality and resolution, and various strategies to converge to steady-state flow conditions. The simulation quality indicators used here involve comparison with the experimental data on fluid velocity, stirrer power output, and flow rate through the impeller zone. Additionally, the resulting flow simulation models are compared using tracer transport simulations, hinting at their potential for coupling with particle aggregation models.
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Flow simulations approach for flocculation tanks
Idžakovičová, Kristýna ; Bílek, V. ; Haidl, J. ; Isoz, Martin ; Pivokonský, M.
Flocculation in water treatment facilities plays a key role in the separation of colloidal inorganic and organic substances. Its optimization leads to a significant increase in its efficiency and savings of operational costs. However, it is currently based on trial-and-error experimental approaches. In this contribution, we focus on flow modeling in stirred flocculation tanks that would, after coupling with a calibrated model of particle aggregation, enable simulationbased flocculation optimization. Despite the abundance of literature on stirred tank modeling, there is no universal agreement on the methodology used to describe turbulence nor on the approach to the computational mesh creation. Consequently, there is no unified methodology for simulations and their validation. To address this, we present a best-practice methodology for economical, yet reliable flow simulations in the said device. This methodology includes the choice of the turbulence model, the approach to the design of a high quality mesh suitable for arbitrary geometries, and results evaluation. It is developed based on an extensive literature review, a multitude of flow simulations using several meshes of progressively higher quality and resolution, and various strategies to converge to steady-state flow conditions. The simulation quality indicators used here involve comparison with the experimental data on fluid velocity, stirrer power output, and flow rate through the impeller zone. Additionally, the resulting flow simulation models are compared using tracer transport simulations, hinting at their potential for coupling with particle aggregation models.
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Mixing characteristics of a magnetically driven Rushton turbine in an unbaffled stirred tank reactor
Idžakovičová, Kristýna ; Haidl, Jan ; Gebouský, Ondřej ; Isoz, Martin
The standard and well-researched stirred vessel configuration comprises a tank equipped with one or more impellers positioned in the vessel’s axis and multiple wall-mounted baffles preventing the central vortex creation. However, particular industries, such as biotechnology, have an increased need for a sterile environment that often results in the usage of atypical stirred vessel configurations. An example of a commonly equipped atypical stirred vessel is an unbaffled stirred tank with an eccentric magnetically driven impeller. However, there is only a little knowledge about the mixing characteristics of such designs. In this work, we list experimental results for both the standard and atypical stirred vessel configurations. Furthermore, we present a CFD model of the atypical configuration. The model is used to calculate its mixing characteristics that are subsequently compared against our experimental results. It is shown that for the liquid height (H) to the vessel diameter (T) ratio H/T ≲ 1.2, the characteristics of both the standard and atypical designs coincide. For higher liquid heights (i) the characteristics of the atypical design decrease dramatically, and (ii) the characteristics estimates based on approaches developed for the standard configuration become unreliable.
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