Beruflich Dokumente
Kultur Dokumente
503517 (2014)
Department of Civil Engineering, City College of New York, New York 10031, USA
NIREAS International Water Research Center, University of Cyprus, P.O. Box 20537,
1678 Nicosia, Cyprus
#
E-Mail: htang@ccny.cuny.edu (Corresponding Author)
ABSTRACT: This paper investigates behaviors of three dimensional, full-scale flows generated by the newly
developed INVENT HyperClassic mixers in a primary influent channel of a wastewater treatment plant in the New
York City. The ANSYS FLUENT, in conjunction with the standard k- turbulence closure and a multiple reference
frame model, is employed for the investigations. Numerical simulations reveal large-scale circulations on cross
sections perpendicular to the channel direction as a main feature of the flows, and such circulations are expected to
be a key mechanism to enhance their mixing and keep solid particles in suspension. Stronger turbulence mixing in
terms of turbulence kinetic energy and dissipation rate and more intensive mixing in the sense of time average and
evaluated by the Lyapunov exponent are observed in the presence of two mixers than those with a single mixer.
Additionally, a larger inlet velocity of the channel results in an increase in turbulence kinetic energy and dissipation
rate but not necessarily a growth of the Lyapunov exponent.
Keywords:
stirred tank, influent channel, INVENT HyperClassic mixer, mixing, Lyapunov exponent
1. INTRODUCTION
Stirred tanks are widely used in mixing processes
in waste water treatment plants (WWTPs)
(Elnekave et al., 2006; Vaiopoulou and Gikas,
2012). The mixing processes are designed to keep
solids in suspension, both organic and inorganic
types, and their effectiveness determines the
performance and efficiency of a WWTP (Kuscu
and Sponza, 2006). In addition, operation of
mixers consumes energy, which becomes
significant when a plant operates round the clock,
and there is a strong impetus to minimize the
energy consumption (Sharma et al., 2011).
Therefore, development of a new generation of
mixers plays a significant role in optimizing
mixing efficiency and energy saving in a WWTP.
The recently introduced INVENT HyperClassic
evolution 6 hyperboloid mixer, together with the
motor assembly outside the water line and light
weight construction, is a significant entrant in the
wastewater industry that has generally been
dominated by submersible mixers (INVENT
2004; INVENT 2010). The impeller of the
hyperboloid mixer rotates near the bottom of a
tank and the motion of its eight fins produces
radially outward streams, which generate largesize circulations and promote mixing and
homogenization of the flow. This mixer is
2. METHODOLOGY
2.1 CFD model
The ANSYS FLUENT 14.1 is used for mesh
generation and three dimensional (3D) CFD
modeling in this study (ANSYS Inc., 2011). A
MRF approach is employed and steady-state
simulations are performed with a rotating
reference frame in the impeller region and a
stationary reference frame in the outer region
containing the rest of the tank and the baffles. The
impeller blades, discs (in case of the Rushton
impeller), and baffles are treated as walls with
zero thickness. The non-slip boundary condition
is applied at the walls, and symmetrical boundary
conditions are selected at the top of the tanks to
approximate free surfaces.
In general, structured meshes provide more
accurate solutions than unstructured meshes. In
view of the fact that the configurations of flow
boundaries such as the surface and the fins of the
impeller are complicated, it is difficult to generate
structured meshes of good quality. Therefore,
fully unstructured, non-uniform grids with
primarily tetrahedral body-fitted control volumes
are used in this study. Since large flow gradients
are expected to appear in the region near the
impellers, the grids are refined there to resolve the
flow structures. In the computations, the standard
k- turbulence model and its constants are used. A
second-order QUICK scheme is selected to
discretize governing equations. The discretized
equations are solved iteratively, and the iteration
is deemed to have converged when the residuals
reduce to a value below 10-4. In addition, mesh
convergence tests are performed to ensure mesh
independent solutions.
2.2 Flow analysis
Impeller power number Np has been commonly
used to characterize performance of mixers in
stirred tanks, and it can be expressed as (e.g.,
Delgon and Meyer, 2006):
P
(1)
Np
N 3 D6
(2)
E d
(5)
H/T
1
w/T
1/10
D/T
1/3
d/D
3/4
a/D
1/4
h/D
1/5
Baffle
width,
W (m)
Diameter,
D (m)
Off bottom
clearance,
C/D
Blade
width,
w/D
0.122
0.609
0.5
0.20
b/D
1/5
(b)
Dimension
3. MODEL VALIDATION
3.1 Mixing
tank
configurations
computational meshes
C/T
1/3
T,H=
1.22 m
Hub
diameter,
dh/D
0.13
and
Fig. 1 Tank configurations. (a) Rushton impeller. (b)
45 PBT impeller (thickness of blade is
simplified as zero).
Mesh
Number of
mesh elements
Grid 1
960,000
Grid 2
2,625,277
Grid 3
8,200,000
Medium, D=0.45 m
Grid 4
2,625,277
Large, D=1.22 m
Grid 5
7,422,222
Small, D=0.15 m
505
Hub
height,
h/D
0.11
3.2 Validation
3.2.1 Small-size tank
Approaches
Np
Nq
5.02
0.71
5.07
4.5-5
4.5
0.73
506
Np
This study
5.49
5.50
Approaches
Np
Nq
This study
1.21
0.76
1.20
Wu et al. (2001)
0.76
(a)
(b)
508
Engineering
Applications
of Computational
Mechanics
8, 4,
No.
(2014) (2014)
Engineering
Applications
of Computational
FluidFluid
Mechanics
Vol. Vol.
8, No.
pp.4 503517
(a)
(b)
Fig. 8 A mesh for influent channel and INVENT mixers. (a) Mesh at center, vertical plane. (b) Mesh at horizontal
plane at 0.254 m above channel bottom.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Fig. 9 Simulation of velocity magnitude and streamline in the presence of a single mixer by coarse and fine mesh,
which respectively have 1,297,760 and 2,648,684 elements. Re=7.0x105, in terms of entrance velocity and
width of the channel. (a), (c), (e), (g), (i) Coarse mesh. (b), (d), (f), (h), (j) Fine mesh. (a), (b) x=0. (b), (c) x=-13
m. (e), (f) z=0. (g), (h) y = 0.254 m. (i), (j) y=3.5 m.
509
Engineering
Applications
of Computational
Mechanics
8, No.
4 (2014)
Engineering
Applications
of Computational
FluidFluid
Mechanics
Vol.Vol.
8, No.
4, pp.
503517 (2014)
(a)
(b)
(c)
510
(a)
(b)
(c)
(d)
(e)
(f)
(a)
(b)
Fig.13
k0(m2/s2)
1.87e-4
0(m2/s3)
6.49e-6
K (m5/s2)
1.15
E (m5/s3)
0.92
1.87e-4
6.49e-6
2.04
1.80
7.46e-4
5.19e-5
5.11
2.99
i (s )
0.004
0.045
0.038
i (s 1 )
0.032
0.077
0.074
5. CONCLUDING REMARKS
On the basis of validation against both
computational data and laboratory measurements
for a set of flows in stirred tanks, FLUENT is
employed to simulate flows associated with the
newly developed INVENT HyperClassic mixers
installed in an influent channel at a NYC WWTP.
One of the main features of the flows within the
influent channel installed with INVENT mixers
revealed by the simulations is the presence of
large-scale circulations or secondary flows on x
cross sections, from the bottom- to the top-wall,
and from the left- to the right-wall, which is
believed to favorably promote mixing and be a
key mechanism to keep solid particles in
suspension. It is demonstrated that, in comparison
with a single impeller, two impellers introduce
not only higher total turbulence kinetic energy
and total dissipation rate but also a larger value
for the Lyapunov exponent, and thus stronger
mixing of the flows. An increase of inlet velocity
also increases total turbulence kinetic energy as
well as dissipation rate, and thus small-scale
turbulence mixing. However, it does not
necessarily lead to higher values for the
Lyapunov exponent, or, mixing in the sense of
time averages. The effort in this paper provides
an insight on mixing of flows associated with the
ACKNOWLEDGEMENT
This research is sponsored by the NYCEP.
Special thanks go to Mr. Yuklong Ma, the Project
Manager, BWT and Mr. Steven Moltz, the
Process Engineer, at the Wards Island WWTP,
NYC for their support in executing this project.
We are grateful to Dr. Y. Andreopoulos for his
valuable suggestions. Assistance from the
FLUENT technical team is also acknowledged.
NOMENCLATURE
abC-
513
Coordinate of point
1 (m)
x1
6.85
6.85
6.85
6.85
6.85
4.85
4.85
4.85
4.85
4.85
2.85
2.85
2.85
2.85
2.85
0.85
0.85
y1
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
z1
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
z-
Greek symbols
0 -
Abbreviations
CFD - computational fluid dynamics
LES large eddy simulation
MRF - multiple reference frames
PBT - pitched blade turbine
RANS - Reynolds-averaged Navier-Stokes
WWTP - wastewater treatment plant
LYAPUNOV EXPONENT AT SELECTED
LOCATIONS
Ten cross sections are evenly distributed in the
main stream direction. Lyapunov exponent is
evaluated at five locations on each cross section,
totally 50 locations at the ten cross sections. At
every location, a pair of particles are released, one
at (x1,y1,z1) and the other at (x2,y2,z2), and then
they move with the flow.
coordinate of point
2 (m)
x2
6.85
6.85
6.85
6.85
6.85
4.85
4.85
4.85
4.85
4.85
2.85
2.85
2.85
2.85
2.85
0.85
0.85
y2
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
z2
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
514
2 mixers & U0
2 mixers & U0
i (1/s)
-0.000115
-0.000116
-0.000071
0.000275
-0.000365
-0.000476
-0.003266
-0.002129
0.009972
-0.010306
-0.047167
-0.035288
-0.060826
-0.049891
-0.021387
0.037203
-0.049979
i (1/s)
-0.000081
0.000079
-0.000153
0.000271
-0.000298
-0.002476
-0.004016
-0.001434
0.00972
-0.011825
-0.066008
-0.035577
-0.069541
-0.043269
-0.019351
0.088795
-0.040063
2 mixers &
2U0
i (1/s)
-0.000093
0.000012
-0.000198
0.000304
-0.000413
0.000009
0.000244
-0.00094
0.009722
-0.010058
0.00422
0.007651
-0.002717
0.029116
-0.043351
0.23286
-0.115684
10
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
0.85
0.85
0.85
-1.15
-1.15
-1.15
-1.15
-1.15
-3.15
-3.15
-3.15
-3.15
-3.15
-5.15
-5.15
-5.15
-5.15
-5.15
-7.15
-7.15
-7.15
-7.15
-7.15
-9.15
-9.15
-9.15
-9.15
-9.15
-11.15
-11.15
-11.15
-11.15
-11.15
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
1.75
1.75
1.75
0.85
2.55
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
-0.85
0
0.85
0
0
0.85
0.85
0.85
-1.15
-1.15
-1.15
-1.15
-1.15
-3.15
-3.15
-3.15
-3.15
-3.15
-5.15
-5.15
-5.15
-5.15
-5.15
-7.15
-7.15
-7.15
-7.15
-7.15
-9.15
-9.15
-9.15
-9.15
-9.15
-11.15
-11.15
-11.15
-11.15
-11.15
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
1.75
1.75
1.75
0.9
2.6
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.8
0.05
0.9
0
0
-0.013442
0.120852
0.021372
0.130088
-0.078761
-0.061999
0.09892
0.052887
0.01944
0.08216
-0.033909
-0.075293
0.101699
0.007107
0.056696
0.005136
-0.053938
0.046151
-0.0308
0.021847
0.032525
-0.028278
0.025451
-0.011908
-0.002029
0.015314
-0.005598
0.010958
-0.010435
-0.00661
0.010203
-0.002965
0.008563
-0.016352
0.123763
0.023285
0.092918
-0.088919
-0.033082
0.088144
0.043086
0.057668
0.021481
0.063197
-0.084934
0.114645
-0.036908
0.078446
0.047307
0.321767
0.035662
-0.044695
0.32479
0.098081
1.286008
0.058615
-0.006054
0.009737
-0.075772
-0.034815
0.023109
-0.016649
-0.025482
-0.014778
-0.025561
0.025636
-0.140907
0.214428
-0.047573
-0.052288
-0.010937
-0.074886
0.231069
0.037947
0.041643
-0.082245
-0.009249
-0.089281
0.125253
-0.021913
0.070416
0.050995
0.240004
0.128825
-0.016711
0.085874
0.075596
0.922968
0.184939
0.009747
0.020785
-0.051638
-0.087413
0.058603
-0.015415
0.000058
-0.026089
-0.022216
0.016316
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