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Development of the Design Guidelines Using CFD Technology for a Particles Suspension Mixing Tank

Seven important variables having profound impact on the ability of a mixing tank to suspend particles have been investigated using computational fluid dynamics (CFD) technology. The results obtained from this study can be applied across a broad range of industries such as the chemical, biochemical, petrochemical and mineral processing industries. Finally, a design template incorporating the optimum operating range to suspend particles was developed as a result of this study. I. INTRODUCTION In the process industry, suspension of particles denser than its fluid media is one of the most common and important goals. Achieving complete suspension of the particles lead to homogeneous suspension while achieving partial success leads to inhomogeneity and eventually product quality issues. Despite the industrial relevance of this operation, the impact on the performance of the suspension mixing tank through changing several crucial variables has received poor research attention. Moreover, in many instances the design of a mixing tank for suspending particles is based on empiricism and rule-of-thumb. Consequently, such mixing tank or reactor designs lead to sub-optimum process condition which inevitably gives poor product quality consistency and yield. Significant improvements of the design capability and reliability of suspension mixing tank may be expected from advances in computational fluid dynamics (CFD) simulation. In current technology, CFD offers a cost-effective means of capturing the hydrodynamic phenomena and the ability to quantify the performance suspension mixing tank. The purpose of this paper is to therefore to provide a comprehensive coverage of this topic including providing design guidelines, to address the research gap and to equip operation engineers the knowledge to improve their process operation. In addition, the correlations provided in this paper can also be used to estimate the increase or decrease in the power requirement in response to changes made to the mixing tank configuration. The availability of such estimation allows for greater flexibility in process operation. The authors are with: