Experimental and computational investigation of solid suspension and gas dispersion in a stirred vessel

Hydrodynamics and residence time distribution (RTD) of fluid elements are key parameters to characterize the performance of stirred vessel. They are governed by geometric and operating parameters of the stirred vessel (SV). In the present work, the performance of the stirred vessel is studied using computational fluid dynamics (CFD) with realizable k−ε turbulence model. The multiple reference frame and sliding mesh approach are used for impeller motion. The solid–liquid flow and associated solid suspension characteristics are predicted using the two-fluid model (Euler–Granular). The performance of the stirred vessel is characterized by analyzing predicted velocity magnitude, solid concentration (suspension quality), and solid sedimentation. This is compared with the stirred vessel with draft tube baffle configuration (three inner baffles and six outer baffles). The recirculatory flow in draft tube SV helps to achieve uniform suspension and less sedimentation. Further, CFD simulations are carried out in Lagrangian way to analyze chaotic mixing among fluid elements. This is qualitatively analyzed using Poincaré map and quantitatively evaluated using Shannon entropy. The extent of chaotic mixing in draft tube SV is found to be high. The performance of the stirred vessel is further investigated through stimulus–response tracer techniques (RTD) to detect design flaws such as bypass and dead zones. This is analyzed for a wide range of operating parameters and identified optimum conditions (flow rate, impeller speed) for the operation of SV. The four different outlet pipe locations are chosen in SV. The bypass and dead volume are analyzed accordingly, and an optimum outlet pipe location is found. To reduce the extent of non-ideal parameters, three different gas source locations are considered and gases are dispersed in the form of bubbles. The gas dispersion at optimum gas injection point is found to reduce non-ideal parameters and improve the design of stirred vessel.