FLUENT SIMULATIONS

Clearwater AIChE - June 2006

 SCOPE

• What is FLUENT ?
• What are objectives and interests ?
• Focus on Agitation operation
• Some general examples of agitation
results
• Conclusions
 FLUENT

WHAT IS FLUENT ?
 Presentation of FLUENT
• Program for Fluids simulations in any
geometry (standard and not standard)
• Based on Computational Fluid Dynamics
• Based on resolution of equations for
conserved properties:
– Heat transfer
– Mass transfer
– Momentum transfer
 FLUENT strategy
• Modelisation of the geometric system
• Meshing of this geometry: discretization
in small cells
• Resolution of continuity equations by
successive calculations in each cell
 FLUENT strategy
• Geometry
definition
 FLUENT strategy
• meshing
 FLUENT

WHAT ARE THE OBJECTIVES

AND INTERESTS ?
 FLUENT objectives
Objectives: to be able

– To study and visualize the fluid motion in

any size tank
– To improve process performances by
simulating alternative designs
– To have flexiblity for changing quickly any
parameters (optimization)
 FLUENT objectives
NUMERICAL SIMULATIONS allow:

⇒To create a large potential of investigation

⇒To obtain prediction of fluid motion
⇒To favour development, optimization and innovation
⇒To save time, money and man power
 FLUENT activities
Main FLUENT interests for chemical process:

– Chemical reactions
– Heat and mass transfer
– Sedimentation of solids particles
– Multi-phasis systems (absorption, separation, …)
– Agitation operation
– Etc….
FLUENT simulations

FOCUS ON
AGITATION
Agitation with FLUENT

How to design a
good agitator ?

Stirred tank
Agitation with FLUENT
Loocking for :

– Quick dispersion and homogeneization

– Adequate pumping flow
– Efficient solids suspension
– Efficient mixing and chemical reaction
– Minimum of dead zone and by-pass
flows
– Optimization of power consumption
FLUENT simulations

AGITATION PARAMETERS
• type of impeller (axial or radial)
• type of tank
• Number of impeller
• position of impeller(s)
• Standard or not standard geometry
Type of impeller
Types of tank
Number of impeller
 FLUENT simulations
SOME GENERAL EXAMPLES...

- flow patterns
- blending time
- solids suspension
- some ‘’sexy’’ video
FLUENT simulations

Tank fitted with

1 or 2 impellers
 FLUENT simulations
Impellers 4 PPR30° Case 0
N
• N=55 rpm
• D=6600 mm
• H=7200 mm
H
• Dag1=2500 mm
• Hag1=1600 mm
Hag1
Dag1 • Down pumping
D
 Single impeller
Poor agitation NOT
on upper zone OPTIMAL
FLOW
FIELD

OK
 single vs multi impeller(s)
Position of single impeller:
• To avoid solids sedimentation
• Risk to create poor agitation on surface

Solution:
• Increase rotation speed? No (danger abrasion)
• Install a second impeller? Yes but…
 FLUENT simulations
Impellers 4 PPR30° Case A
N
• N=55 rpm
• D=6600 mm
• H=7200 mm
Hag2
H
Dag2
• Dag1=2500 mm
• Hag1=2.5 m
Hag1 • Dag2 =2500 mm
Dag1
• Hag2 = 5.5 m
D
 Multi impellers
• Baffles effect

• Second
impeller
action
 Multi impellers
2 impellers could
improve the mixing,

BUT…
 Multi impellers
• Poor
mixing at
OK
tank
bottom

BAD
Multi impellers
 Multi impellers
• Incorrect
distribution
OK
of fluid
velocity

• Danger if
solids
BAD
 Multi impellers
• No
cleaning
effect at
the bottom

• Not down
pumping
action
 FLUENT simulations
Impellers 4 PPR30°
Case B (change of
position)
N • N=55 rpm
• D=6600 mm
Hag2 • H=7200 mm
H
Dag2 • Dag1=2500 mm
• Hag1=1.6 m
Hag1 • Dag2 =2500 mm
Dag1
• Hag2 = 5.1 m
D
 Multi impellers
• Better fluid
motion and
mixing at
the bottom

OK
 Multi impellers
• Good
agitation at
the bottom
 Multi impellers
• Correct
velocity
field

OK
 Multi impellers
•Cleaning
effect on the
bottom
FLUENT simulations
Influence of impellers position
and number:

Impact on flow patterns

Impact on agitation efficiency
Impact on blending time
Impact on solids suspension
FLUENT simulations
Influence of impellers position

Impact on solids
suspension
 Solids suspension
Initial situation (solids deposit at bottom)
Case A Case B
liquid

solids
 Solids suspension
Case A Case B

37 sec 6 sec
 Solids suspension
Case A Case B

115 sec 20 sec

 Solids suspension
Case A Case B

2317 sec 720 sec

Very slow quicker
suspension suspension
 FLUENT simulations
Influence of impellers…number

Impact on the
Blending time
 Blending time
What
What isis itit ?? What is the
target ?

• Required time for uniformity

• Based on pulse of tracer
• Monitoring over time of
concentration at # locations
top
mid
• To be minimized
• To have good mixing
• To avoid over-concentration
• To avoid loss of recovery
as P2O5 UN and CO

bottom
cone
 Blending time
Case A Case B
1 impeller 2 impellers

+/- 80 sec +/- 60 sec

FLUENT simulations

EXCITING
DYNAMIC VIDEOS
FLUENT simulations

CONCLUSIONS
ON FLUENT
 Conclusions
• Large potential of utilities
• Development and improvement of designs
• Save time and $$
• PRAYON uses CFD to optimize its technologies
 Thank you

Have a good day