Leading computational fluid dynamics consultants Advantage CFD have now demonstrated the capability to simulate mixing tanks with greater accuracy, to improve the efficiency of mixing operations
Mixing is a fundamental operation in the process industry. One of the most versatile mixing techniques is the stirred vessel, which is used for a wide range of applications including blending, chemical reaction, dispersion, solid suspension, crystallisation and aeration. The efficiency of the mixing process can substantially influence production costs and product quality, yet the design of agitation systems is often problematic.

The customary approach is to carry out a series of physical tests.

This tends to be a long and expensive exercise with results that may not be fully replicated when test equipment is scaled up for full production.

Empirical correlations are also widely used but may have limited applicability, particularly if a novel system is being designed.

An alternative approach is to model the flow using CFD (computational fluid dynamics).

CFD offers the ability to quantify and visualise performance by modelling the true physical processes, and to do so whatever the scale.

Historically, however, the accuracy of CFD simulations has been limited by the ability of the model to resolve the complexity of internal components and the full benefits of numerical simulation have not always been realised.

Leading CFD consultants Advantage CFD have now demonstrated the capability to simulate mixing tanks with greater accuracy.

With its roots in motorsport as part of the Honda Formula 1 team, Advantage CFD deliver fluid flow solutions to customers in industries as diverse as food processing, pharmaceuticals and renewable energy.

By increasing the model resolution and including greater detail of heating coils, baffles, dip pipes and other components that can cause flow asymmetry, Advantage CFD were able to give added insight into the mixing and heat transfer processes within a stirred vessel.

In particular, they showed how an enhanced CFD model can enable quantities such as power consumption, levels of turbulence and local heat transfer coefficients to be correctly predicted.