卧式单轴捏合反应器流动与混合特性的数值模拟

doi:10.11949/0438-1157.20211618

化工学报 ›› 2022, Vol. 73 ›› Issue (5): 1995-2007.DOI: 10.11949/0438-1157.20211618

• 催化、动力学与反应器 • 上一篇下一篇

卧式单轴捏合反应器流动与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:2021-11-12 修回日期:2022-02-26 出版日期:2022-05-05 发布日期:2022-05-24
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 hydrodynamics and mixing characteristics in a horizontal single-shaft kneader

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:2021-11-12 Revised:2022-02-26 Online:2022-05-05 Published:2022-05-24
Contact: Xianming ZHANG,Lianfang FENG

摘要/Abstract

摘要：

选取卧式单轴捏合反应器为研究对象，搭建了一个可视化实验装置来研究其分布混合过程，并且通过三维有限元数值模拟方法和网格重叠技术获取了高黏牛顿流体在反应器中的流速分布、剪切速率分布与混合指数分布，进一步采用粒子示踪技术分析了全局与局部分布混合过程，对示踪粒子的运动轨迹进行统计分析得到了拉伸率与混合效率，并且考察了搅拌结构对流动与混合过程的影响。结果表明，实验与数值模拟结果吻合较好。捏合反应器中几乎不存在流动死区，搅拌轴上的动态捏合杆与搅拌槽壁面上的静态捏合杆之间存在周期性的捏合作用，可以强化自清洁性能、剪切作用、整体与局部分布混合过程、分散混合性能以及混合效率。拉伸率随着混合时间以指数形式增加，时均混合效率大于零。

关键词: 单轴捏合反应器, 数值模拟, 计算流体力学, 流体动力学, 混合

Abstract:

A visual experimental device was built to study the distributive mixing process in a horizontal self-cleaning single-shaft kneader. Meanwhile, the finite element method (FEM) with the mesh superposition technique (MST) was adopted to obtain the velocity distribution, shear rate distribution and mixing index distribution in the single-shaft kneader with a highly viscous Newtonian fluid. Then the particle tracking technique was used to analyze the whole and local distributive mixing process in the kneader. The statistical analysis was performed based on the particles’ trajectories to calculate the length of stretch and mixing efficiency. The effect of kneader configuration on the flow filed and mixing process was also investigated. Results show that the experimental data agree well with the FEM simulation results. There exists the periodical intermeshing interaction between the static kneading bars on the kneader wall and the dynamic kneading bars on the rotating shaft, which improves the self-cleaning performance, shear rate, whole and local distributive mixing process, disperse mixing ability and mixing efficiency. The length of stretch exponentially increases with time and the time averaged mixing efficiency remains positive during the mixing process.

Key words: single-shaft kneader, numerical simulation, CFD, hydrodynamics, mixing

中图分类号:

TQ 320.5

成文凯, 张先明, 王嘉骏, 冯连芳. 卧式单轴捏合反应器流动与混合特性的数值模拟[J]. 化工学报, 2022, 73(5): 1995-2007.

Wenkai CHENG, Xianming ZHANG, Jiajun WANG, Lianfang FENG. Numerical simulation of hydrodynamics and mixing characteristics in a horizontal single-shaft kneader[J]. CIESC Journal, 2022, 73(5): 1995-2007.

图/表 14

图1 卧式单轴捏合反应器示意图

Fig.1 Schematic sketch of two types of horizontal single-shaft kneaders

图2 计算网格与网格无关性验证

Fig.2 Computational grid and grid independence verification

图3 SK1和SK2的可视化实验装置

Fig.3 Visual experimental device for SK1 and SK2

图4 SK1的混合过程实验与CFD模拟对比图

Fig.4 Mixing process comparison between experiment and CFD simulation for SK1

图5 SK2的混合过程实验与CFD模拟对比图

Fig.5 Mixing process comparison between experiment and CFD simulation for SK2

图6 SK2中Z=0.055 m平面上速度矢量图随时间的变化

Fig.6 Evolution of velocity vectors on plane Z=0.055 m in SK2

图7 不同平面上速度分布云图

Fig.7 Contours of velocity magnitude on different planes

图8 轴向分布混合过程与分离尺度（左侧红色点浓度为1，右侧蓝色点浓度为0）

Fig.8 Axial distributive mixing process and segregation scale

图9 径向分布混合过程与分离尺度（左侧红色点浓度为1，右侧蓝色点浓度为0）

Fig.9 Radial distributive mixing process and segregation scale

图10 局部分布混合过程与粒子簇分布指数

Fig.10 Local distributive mixing process and particle cluster distribution index

图11 不同平面上剪切速率分布云图

Fig.11 Contours of shear rate on different planes

图12 不同平面上混合指数分布云图

Fig.12 Contours of mixing index on different planes

图13 对数拉伸率随时间的变化

Fig.13 Evolution of natural log of length of stretch with time

图 14 搅拌结构对平均对数拉伸率(a)和时均混合效率(b)的影响

Fig.14 Effect of kneader configuration on mean length of stretch (a) and mean time averaged mixing efficiency (b)

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卧式单轴捏合反应器流动与混合特性的数值模拟

Numerical simulation of hydrodynamics and mixing characteristics in a horizontal single-shaft kneader

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