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HANDBOOK OF INDUSTRIAL MIXING
SCIENCE AND PRACTICE
Edited by
Edward L. Paul
Merck & Co., Inc.
Rahway, New Jersey
Victor A. Atiemo-Obeng
The Dow Chemical Company
Midland, Michigan
Suzanne M. Kresta
University of Alberta
Edmonton, Canada
Sponsored by the North American Mixing Forum
A JOHN WILEY & SONS, INC., PUBLICATION
Cover
: The jet image is courtesy of Chiharu Fukushima and Jerry Westerweel, of the Laboratory
for Aero and Hydrodynamics, Delft University of Technology, The Netherlands.
Copyright
2004 by John Wiley & Sons, Inc. All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data:
Paul, Edward L.
Handbook of industrial mixing : science and practice / Edward L. Paul,
Victor A. Atiemo-Obeng, Suzanne M. Kresta
p. cm.
“Sponsored by the North American Mixing Forum.”
Includes bibliographical references and index.
ISBN 0-471-26919-0 (cloth : alk. paper)
1. Mixing—Handbooks, manuals, etc. I. Atiemo-Obeng, Victor A. II.
Kresta, Suzanne M. III. Title.
TP156,M5K74 2003
660’.284292—dc21
2003007731
Printed in the United States of America.
10987654321
CONTENTS
Contributors
xxix
Introduction
xxxiii
Edward L. Paul, Victor A. Atiemo-Obeng, and Suzanne M. Kresta
Mixing in Perspective
xxxiv
Scope of Mixing Operations
xxxvi
Residence Time Distributions: Chapter 1
xxxvii
Mixing Fundamentals: Chapters 1 – 5
xxxix
Mixing Equipment: Chapters 6, 7, 8, and 21
xxxix
Miscible Liquid Blending: Chapters 3, 7, 9,
and 16
xl
Solid – Liquid Suspension: Chapters 10, 17,
and 18
Gas – Liquid Contacting: Chapter 11
xli
Liquid – Liquid Mixing: Chapter 12
xlii
Mixing and Chemical Reactions/Reactor Design:
Chapters 13 and 17
xlii
Heat Transfer and Mixing: Chapter 14
xliii
Specialized Topics for Various Industries: Chapters 15 – 20
xliii
Conversations Overheard in a Chemical Plant
xliv
The Problem
xliv
Competitive-Consecutive Reaction
xlv
Gas – Liquid Reaction
xlvi
Solid – Liquid Reaction
xlvi
Liquid – Liquid Reaction
xlvii
Crystallization
xlvii
Using the Handbook
xlix
Diagnostic Charts
l
Mixing Nomenclature and Unit Conversions
lv
Acknowledgments
lix
References
lx
v
xl
vi
CONTENTS
1 Residence Time Distributions
1
E. Bruce Nauman
1-1 Introduction
1
1-2 Measurements and Distribution Functions
2
1-3 Residence Time Models of Flow Systems
5
1-3.1 Ideal Flow Systems
5
1-3.2 Hydrodynamic Models
6
1-3.3 Recycle Models
7
1-4 Uses of Residence Time Distributions
9
1-4.1 Diagnosis of Pathological Behavior
9
1-4.2 Damping of Feed Fluctuations
9
1-4.3 Yield Prediction
10
1-4.4 Use with Computational Fluid Dynamic
Calculations
14
1-5 Extensions of Residence Time Theory
15
Nomenclature
16
References
16
2 Turbulence in Mixing Applications
19
Suzanne M. Kresta and Robert S. Brodkey
2-1 Introduction
19
2-2 Background
20
2-2.1 Definitions
20
2-2.2 Length and Time Scales in the Context of
Turbulent Mixing
24
2-2.3 Relative Rates of Mixing and Reaction:
The Damkoehler Number
32
2-3 Classical Measures of Turbulence
38
2-3.1 Phenomenological Description of Turbulence
39
2-3.2 Turbulence Spectrum: Quantifying Length
Scales
45
2-3.3 Scaling Arguments and the Energy Budget:
Relating Turbulence Characteristics to Operating
Va r i a b l e s
5 3
2-4 Dynamics and Averages: Reducing the Dimensionality of
the Problem
61
2-4.1 Time Averaging of the Flow Field: The Eulerian
Approach
62
2-4.2 Useful Approximations
63
CONTENTS
vii
2-4.3 Tracking of Fluid Particles: The Lagrangian
Approach
69
2-4.4 Experimental Measurements
71
2-5 Modeling the Turbulent Transport
72
2-5.1 Time-Resolved Simulations: The Full Solution
74
2-5.2 Reynolds Averaged Navier – Stokes Equations:
An Engineering Approximation
78
2-5.3 Limitations of Current Modeling: Coupling
between Velocity, Concentration, Temperature,
and Reaction Kinetics
81
2-6 What Have We Learned?
81
Nomenclature
82
References
83
3 Laminar Mixing: A Dynamical Systems Approach
89
Edit S. Szalai, Mario M. Alvarez, and Fernando J. Muzzio
3-1 Introduction
89
3-2.1 Simple Mixing Mechanism: Flow Reorientation
90
3-2.2 Distinctive Properties of Chaotic Systems
92
3-2.3 Chaos and Mixing: Some Key Contributions
94
3-3 How to Evaluate Mixing Performance
96
3-3.1 Traditional Approach and Its Problems
96
3-3.2 Measuring Microstructural Properties of a
Mixture
99
3-3.3 Study of Microstructure: A Brief Review
102
3-4 Physics of Chaotic Flows Applied to Laminar Mixing
103
3-4.1 Simple Model Chaotic System: The Sine Flow
103
3-4.2 Evolution of Material Lines: The Stretching
Field
108
3-4.3 Short-Term Mixing Structures
108
3-4.4 Direct Simulation of Material Interfaces
110
3-4.5 Asymptotic Directionality in Chaotic Flows
110
3-4.6 Rates of Interface Growth
112
3-4.7 Intermaterial Area Density Calculation
114
3-4.8 Calculation of Striation Thickness Distributions
116
3-4.9 Prediction of Striation Thickness Distributions
117
3-5 Applications to Physically Realizable Chaotic Flows
119
3-5.1 Common 3D Chaotic System: The Kenics Static
Mixer
119
3-2 Background
90
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