反向旋转卧式双轴捏合反应器混合特性的数值模拟

doi:10.11949/0438-1157.20211211

化工学报 ›› 2022, Vol. 73 ›› Issue (1): 162-174.DOI: 10.11949/0438-1157.20211211

反向旋转卧式双轴捏合反应器混合特性的数值模拟

成文凯¹(),张先明¹(),王嘉骏²,冯连芳²()

^1.浙江理工大学材料科学与工程学院，纺织纤维材料与加工技术国家地方联合工程实验室，浙江杭州 310018
^2.浙江大学化学工程与生物工程学院，化学工程联合国家重点实验室，浙江杭州 310027

收稿日期:2021-08-23 修回日期:2021-10-10 出版日期:2022-01-05 发布日期:2022-01-18
通讯作者: 张先明,冯连芳
作者简介:成文凯（1988—）, 男, 博士, chengwenk@163.com
基金资助:
国家自然科学基金项目(51973196);浙江省人才项目(2019R52012);浙江省重点研发计划项目(2020C01010)

Numerical simulation of mixing process in different opposite-rotating horizontal twin-shaft kneaders

Wenkai CHENG¹(),Xianming ZHANG¹(),Jiajun WANG²,Lianfang FENG²()

^1.National Engineering Laboratory for Textile Fiber Materials and Processing Technology (Zhejiang), School of Materials Science and Engineering, Zhejiang Sci?Tech University, Hangzhou 310018, Zhejiang, China
^2.State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, Zhejiang, China

Received:2021-08-23 Revised:2021-10-10 Online:2022-01-05 Published:2022-01-18
Contact: Xianming ZHANG,Lianfang FENG

摘要/Abstract

摘要：

以差速反向旋转卧式双轴捏合反应器为研究对象，选用高黏牛顿流体糖浆为模拟物料，通过三维有限元数值模拟方法研究了高黏糖浆在捏合反应器中的流动过程，获取了流速和剪切速率的空间分布，进一步结合粒子示踪技术探究了分布混合过程与混合效率，并且考察了搅拌结构对流动与混合过程的影响规律。研究表明，捏合反应器中几乎不存在流动死区，桨叶末端和重叠区域的流速和剪切速率较高，且高流速和高剪切区域均随着捏合杆数目和捏合杆长度的增加而增大。捏合杆可以推动物料在圆周方向上的运动，在重叠区域存在周期性交互作用，进而可以强化分布混合过程。拉伸率随着混合时间以指数形式增加，且随着捏合杆数目和捏合杆长度的增加而增加。时均混合效率大于零，随着捏合杆数目的增大而增大，随着捏合杆长度的增加呈现先增大后减小的趋势。

关键词: 双轴捏合反应器, 计算流体力学, 有限元方法, 流体动力学, 混合

Abstract:

The finite element method(FEM) was adopted to study the hydrodynamics in the horizontal opposite-rotating twin-shaft kneader with different rotating speeds in a highly viscous Newtonian fluid syrup solution. The particle tracking technique was used to investigate the mixing process. The effect of kneader configuration on hydrodynamics and mixing process was analyzed. Studies have shown that there is almost no dead zone in the kneading reactor, and the flow velocity and shear rate at the end of the blade and the overlapping area are high. And the high flow velocity and high shear area increase with the increase of the number of kneading bars and the length of the kneading bars. The kneading bars, pushing material points into the angular position, periodically intermesh in the overlapping zone. Hence, the distributive mixing process in the kneader can be greatly enhanced. The length of stretch exponentially increases with time and with the increasing of the number and length of kneading bars. The time averaged mixing efficiency remains positive during the mixing process, which increases with the number of kneading bars. When the length of kneading bars increases, the time averaged mixing efficiency tends to increase in the beginning and then decrease.

Key words: twin-shaft kneader, computational fluid dynamics, finite element method, hydrodynamics, mixing

中图分类号:

TQ 320.5

成文凯, 张先明, 王嘉骏, 冯连芳. 反向旋转卧式双轴捏合反应器混合特性的数值模拟[J]. 化工学报, 2022, 73(1): 162-174.

Wenkai CHENG, Xianming ZHANG, Jiajun WANG, Lianfang FENG. Numerical simulation of mixing process in different opposite-rotating horizontal twin-shaft kneaders[J]. CIESC Journal, 2022, 73(1): 162-174.

图/表 16

图1 卧式双轴捏合反应器示意图

Fig.1 Schematic sketch of horizontal twin-shaft kneaders

图2 不同结构的捏合杆示意图

Fig.2 Schematic sketch of different kneading bars

表 1 卧式双轴捏合反应器

Table 1 Different horizontal twin-shaft kneaders

反应器	搅拌单元捏合杆数目		搅拌转速/(r/min)		捏合杆结构	圆盘
反应器	左侧	右侧	左侧	右侧	捏合杆结构	圆盘
OPK24-15 mm	2	4	60	30	图2(b)	无
OPK36-15 mm	3	6	60	30	图2(b)	无
OPK48-15 mm	4	8	60	30	图2(b)	无
OPK24-7 mm	2	4	60	30	图2(a)	无
OPK24-23 mm	2	4	60	30	图2(c)	无
OPK24-disk-15 mm	2	4	60	30	图2(b)	光滑圆盘

图3 计算网格示意图

Fig.3 Schematic sketch of computational grid

图4 网格数目对OPK24-15 mm局部速度的影响

Fig.4 Effect of number of cells on local velocity magnitude on Line 1 in OPK24-15 mm (t=1 s)

图5 Z=0.0525 m平面上速度矢量图

Fig.5 Velocity vectors on plane Z=0.0525 m

图 6 Z=0.0525 m平面上速度分布云图

Fig.6 Contours of velocity magnitude on plane Z=0.0525 m (t=1 s)

图7 Y=0 m平面上速度分布云图

Fig.7 Contours of velocity magnitude on plane Y=0 m (t=1 s)

图8 Z=0.0525 m平面上剪切速率分布云图

Fig.8 Contours of shear rate on plane Z=0.0525 m (t=1 s)

图9 Y=0 m平面上剪切速率分布云图

Fig.9 Contours of shear rate on plane Y=0 m (t=1 s)

图10 轴向分布混合过程（右侧红色点浓度为1，左侧蓝色点浓度为0）

Fig.10 Axial distributive mixing process

图11 搅拌结构对轴向分布混合分离尺度的影响

Fig.11 Effect of kneader configuration on segregation scale for axial distributive mixing process

图12 径向分布混合过程（左侧红色点浓度为1，右侧蓝色点浓度为0）

Fig.12 Angular distributive mixing process

图13 搅拌结构对径向分布混合过程分离尺度的影响

Fig.13 Effect of kneader configuration on segregation scale for angular distributive mixing process

图14 搅拌结构对平均对数拉伸率的影响

Fig.14 Influence of kneader configuration on mean length of stretch

图15 搅拌结构对时均混合效率的影响

Fig.15 Effect of kneader configuration on mean time averaged mixing efficiency

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反向旋转卧式双轴捏合反应器混合特性的数值模拟

Numerical simulation of mixing process in different opposite-rotating horizontal twin-shaft kneaders

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