Professional Documents
Culture Documents
Chao Yang
Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences,
Beijing 100190, China, and
Jiangsu Institute of Marine Resource Exploitation, Lianyungang 222005, China
Zai-Sha Mao
Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences,
Beijing 100190, China
DOI 10.1002/aic.11516
Published online May 22, 2008 in Wiley InterScience (www.interscience.wiley.com).
Both the large eddy simulation (LES) technique and the k-e turbulent model were
used to simulate the gas-liquid turbulent ow in a stirred tank driven by a Rushton
impeller. A Eulerian-Eulerian two-uid model for gasliquid two-phase ow was developed using the large eddy simulation for both gas and liquid phases. The relative
movement of the rotating impeller to the static bafes was accounted for through the
improved inner-outer iterative algorithm. The spatial discretization of the governing
equations was performed on a cylindrical staggered grid. For the LES, a conventional
Smagorinsky sub-grid model was adapted to modeling the turbulence of the liquid
phase. The momentum and continuity equations were discretized using the nite difference method, with a third order QUICK (Quadratic Upwind Interpolation for Convective Kinematics) scheme used for convective terms. The phase-resolved predictions of
the LES were compared with the experimental data and the simulation results by the
standard k-e model, suggesting that the LES has much better accuracy than the k-e
model. 2008 American Institute of Chemical Engineers AIChE J, 54: 19631974, 2008
Keywords: large eddy simulation, gasliquid ow, stirred tank, computational uid
dynamics, turbulence
Introduction
Gasliquid stirred reactors are widely used in chemical and
biochemical industry. Many efforts have been made in simulation of the gasliquid ows in stirred tanks. Gosman et al.1
rstly extended the simulation of two-phase ow from twodimensional to three-dimensional cases with a simplied equaCorrespondence concerning this article should be addressed to C. Yang at
chaoyang@home.ipe.ac.cn, or Z.-S. Mao at zsmao@home.ipe.ac.cn.
AIChE Journal
August 2008
tion of the gas momentum and the impeller zone was dealt as a
black box. Bakker and van den Akker2 assumed that there was
little effect of the gas on the liquid phase and simulated the
gasliquid ow in a stirred tank with different impellers
including Rushton impeller, pitched-blade impeller, and A315
impeller. In comparison with the experimental data measured
by themselves, the prediction was rather poor and the authors
attributed it to the treatment of the impeller zone as a black
box. Ranade and van den Akker3 used the two-uid model to
describe the gasliquid ow and the movement of the impeller
relative to the bafes was modeled by the snapshot method.
Vol. 54, No. 8
1963
Morud and Hjertager4 simulated the two-dimensional gasliquid ow in a stirred tank employing the black box approach,
too. Ranade and Deshpande5 studied the trailing vortex behind
an impeller by the snapshot method. Mao and coworkers6,7
employed the improved inner-outer iterative algorithm and the
two-uid model to simulate the gasliquid ow in a threedimensional stirred tank. Lane et al.8,9 predicted the gasliquid
ow in a stirred tank using a multiple frames of reference
method to account for the relative movement of the impeller
with the consideration of coalescence and break-up of the bubbles. Khopkar et al.10,11 applied the two-uid model and snapshot method to simulate the gasliquid ow in stirred tanks.
Deen et al.12 employed a sliding mesh method to simulate the
interaction between the impeller and the bafes using a CFD
package. Sun et al.13 extended the two-uid model and the
improved inner-outer iterative algorithm to the gasliquid ow
in surface aerated stirred tanks.
Although the large eddy simulation was successfully
applied in the single phase simulation in stirred tanks,1420 to
date there is no work published on studying the gasliquid
ow in stirred tanks using the large eddy simulation (LES).
Several groups2124 have attempted to apply the large eddy
simulation to the two-phase ow, but in all of these papers
the Lagrangian frame of reference were employed to model
the disperse phase. The only study on the ow in a stirred
tank using LES is by Derksen,25 who simulated the liquid
solid ow describing the solid phase also by the Lagrangian
frame. As to the engineering application, the Eulerian formulation is preferred. Up to now, only Smith and Milelli26 and
Deen et al.27 applied a combination of the large eddy simulation and the Eulerian-Eulerian two phase ow approach to
simulate the gasliquid phase ow.
In this work, we used two different models for turbulent viscosity, i.e., LES model and standard k-e model. The EulerianEulerian approach is used to describe the gasliquid two-phase
ow. The relative movement between the rotating impeller and
the static wall bafes was accounted for through the improved
innerouter iterative algorithm.6 This article is the rst attempt
to apply the large eddy simulation to a gas-sparged stirred tank.
Mathematical Model
Governing equations
@qm am
@
q am um;i 0
@t
@xj m
k2
e
(6)
where Ge represents the effect of bubbles on energy dissipation. Cb is an experiential parameter, which is taken as
0.02.28 Cl, rk, and re are empirical constants recommended
by Launder and Spalding29:
Cl 0:09;
C1 1:43;
C2 1:92;
rk 1:0;
re 1:3
G 2llt
r @h
@r
r
@z
@ ulh l @ulr 2
@ulh l @ulz 2
llt r
lt
@r r
r @h
r @h
@z
@ulz @ulr 2
lt
@r
@z
For the LES, the space-ltered equations for the conservation of mass and momentum of an incompressible Newtonian
uid can be written as
@
am
@
qm
am umi 0
(8)
@t
@xj
@
@
@ p
qm am umi
qm am umi umj
qm am gi
@t
@xj
@xi
@ am umj
@
@ am umi
: 9
Fmi
l
@xj m
@xj
@xi
(1)
Momentum equation
@
@
@p
qm am umi
am
qm am umi umj
qm xm gi
@t
@xj
@xi
@ am umj
@
@ am umi
2
Fmi
lm
@xj
@xj
@xi
where umi, am are the instantaneous velocity components and
phase volume fraction for phase m, respectively, and Fmi is
the inter-phase momentum exchange terms.
DOI 10.1002/aic
(5)
qm
1964
0
umj umj
umj
(10)
am am a0m
(11)
p p p
(12)
umj ; am ; p represents
where uu
the part that will be
0
resolved in the simulation and u the unresolved part on a
AIChE Journal
scale smaller than the mesh. So, Eqs. 8 and 9 can be rewritten as
@ qm am
@
@
@
qm am umj
qm a0m u0mj
q a0 m umj
@t
@xj
@xj
@xj m
@
qm am u0mj 0 13
@xj
@
@
@
@
q a0 u0
q a0 umi
q am u0mi
q am umi
@t m
@t m m mi
@t m m
@t m
@
@
p
@xj
@xj
@xi
!
0
0
@ @am umj am umj @a0 m umi am u0mi
: 14
lm
@xj
@xj
@xi
The unresolved parts of the numerical simulations are the
uctuating velocity and holdup, which have to be omitted
because there are no proper closing methods yet. The mean
and the uctuating velocities are the grid scale and the subgrid scale terms through a ltering operation. The terms with
umi umj are formulated by a LES subgrid model. Omitting the
terms with the a0m and u0mi , the above equations become
@qm am
@
qm am umj 0
@t
@xj
@
@
@
p
qm am umi
qm am umi umj
qm am gi
@t
@xj
@xi
@ am umj
@ qm am smij
@
@
a
u
m
mi
Fmi lm
@xj
@xj
@xi
@xj
smij umi umj umi umj
(23)
where subscripts l and g denote liquid and gas phase, respectively. For the dispersed two-phase ow, Fm,i mainly consists
of four terms: the inter-phase drag force, the virtual mass
force, the Basset force, and the lift force. In most cases, the
magnitude of the Basset force and lift force are much smaller
than that of the inter-phase drag force. The virtual mass force
will be signicant in the gas-liquid ows with large accelerations such as the ow in bubble columns; however, the gas
hold-up values for the stirred vessels are usually rather low.
Compared to the drag force, the lift force and the virtual
mass force have little inuence.3 Gosman et al.1 examined
the effects of the inter-phase forces by an order of magnitude
analysis, the conclusion was that the lift force and the virtual
mass force were much less signicance compared to the drag
force in the stirred vessels. Recent report by Khopkar et al.11
also indicated that the effect of the virtual mass force is not
signicant in the bulk region of the stirred tank. So only the
inter-phase drag force was included in the momentum
(15)
16
(17)
(18)
Slij
2 @xj
@xi
(19)
(20)
(21)
DOI 10.1002/aic
1965
Figure 2. Instantaneous velocity elds in r-z plane at three different instants by the LES (x 5 41.9 rad/s).
(a) Gas phase (t 5 1.9 s); (b) Liquid phase (t 5 1.9 s); (c) Gas phase (t 5 2.6 s); (d) Liquid phase (t 5 2.6 s); (e) Gas phase (t 5 3.0 s);
(f) Liquid phase (t 5 3.0 s). [Color gure can be viewed in the online issue, which is available at www.interscience.wiley.com.]
1966
DOI 10.1002/aic
AIChE Journal
Figure 3. Instantaneous velocity eld in rz plane at two different instants by the LES (x 5 62.8 rad/s).
(a) Gas phase (t 5 2.6 s); (b) Liquid phase (t 5 2.6 s); (c) Gas phase (t 5 3.0 s); (d) Liquid phase (t 5 3.0 s). [Color gure can be
viewed in the online issue, which is available at www.interscience.wiley.com.]
Fr;m am qm v 3 r 3 x
(24)
Fc;m 2am qm v 3 um
(25)
Coriolis force :
Drag coefcient
The inter-phase drag force exerted on the gas phase is
given by
Fg;l
3ag al ql CD
4db
AIChE Journal
3
X
!0:5
ug;i uli
ug;i ul;i
il
(26)
2:667Eo
;
CD0 max
Eo 4:0
24
1 0:15Reb0:687
Reb
(28)
2 0:5
db ql X
Reb
ug;i ul;i
(29)
ll;lam
3 0:25
v
k l
el
DOI 10.1002/aic
(30)
1967
0:6
r
db 0:68 3 0:725
3 e0:4
l
ql
11
(31)
where db is the bubble diameter, k the Kolmogoroff microscale of dissipative eddies, and ll,lam the laminar viscosity of
the liquid. The above correlation takes account of the effect
of turbulence on the drag force of gas bubbles. Equation 31
introduces the effect of the turbulence on the bubble size distribution, but in the predicted results the bubble size is
actually in a narrow range about 5 mm.
Numerical Method
The geometry of the stirred tank simulated in this work is
depicted in Figure 1, consisting of a cylindrical tank with a
1968
DOI 10.1002/aic
AIChE Journal
Figure 5. Velocity vector plots predicted by the standard ke model (x 5 41.9 rad/s).
(a) Gas phase; (b) Liquid phase. [Color gure can be viewed in the online issue, which is available at www.interscience.wiley.com.]
Figure 6. Predicted liquid velocity proles by the LES compared with the experimental data by Lu and Ju33 and the
standard ke model prediction at different radial positions.
(a) x 5 62.8 rad/s; (b) x 5 62.8 rad/s; (c) x 5 41.9 rad/s; (d) x 5 41.9 rad/s. [Color gure can be viewed in the online issue, which is
available at www.interscience.wiley.com.]
AIChE Journal
DOI 10.1002/aic
1969
was enforced at the axis below the impeller to allow the possible ow across the axis.
The tank was modeled with a uniform grid in cylindrical
coordinates. The discretization of the partial differential
equations was achieved by control volume formulation with
a staggered arrangement of primary variables, and then the
pressure-velocity coupling was dealt with the SIMPLE algorithm.34 In the LES, high-order accuracy was needed to
decrease the numerical dissipation. To avoid the physical
phenomena being masked, a third-order QUICK scheme was
used for convective terms and a second-order central scheme
for diffusive terms. The time integration was discretized by a
Crank-Nicolson implicit scheme.
The implementation of the modied inner-outer iterative
procedures was involved with the numerical solution of the
governing equations in the inner zone including the impeller
1970
DOI 10.1002/aic
Phase-resolved velocity
Figures 6 and 7 shows the proles of the phase-resolved
resultant velocities at different radial positions in contrast to
the experimental data of liquid resultant velocity. It can be
AIChE Journal
Figure 8. Predicted Gas holdup proles by the LES compared with the experimental data by Lu and Ju33 and the
standard ke model prediction at different radial positions.
(a) x 5 62.8 rad/s; (b) x 5 62.8 rad/s; (c) x 5 62.8 rad/s; (d) x 5 41.9 rad/s; (e) x 5 41.9 rad/s. [Color gure can be viewed in the
online issue, which is available at www.interscience.wiley.com.]
DOI 10.1002/aic
1971
Gas holdup
Figure 8 shows the proles of the phase-resolved velocities
at positions r 5 0.053 m, r 5 0.073 m, and r 5 0.103 m.
The predicted holdups by the LES agree better with the experimental values than those by the k-e model. However,
there are still great deviations between the predictions and
the measurements, because that there is no any proper model
to describe accurately the very complex two-phase ow in
the impeller zone.
Figure 9 shows the contours of the gas holdup in the r-z
plane located midway between two blades predicted by the
LES and the k-e model, respectively. Because some gas bubbles are inhaled by the impeller, the isolines of the gas
holdup around the blades are very close. In the bulk ow,
the results of the two turbulent models give very similar patterns of gas holdup distribution. In the swept region, however, the k-e model gives bigger values than the LES does as
showed in Figure 8.
Energy dissipation is an important quantity in a stirred
tank since it provides a direct measure of energy input into
Figure 10. Phase-resolved energy dissipation e(m2/s3) in the plane between two impeller blades by the LES (x 5
41.9 rad/s).
(a) Liquid phase; (b) Gas phase. [Color gure can be viewed in the online issue, which is available at www.interscience.wiley.com.]
1972
DOI 10.1002/aic
AIChE Journal
Conclusions
The LES turbulent model has great potential in understanding the uid ow behaviors. In this article, a EulerianEulerian two-uid model for gas-liquid two-phase ow was
rst developed using the large eddy simulation for both gas
and liquid phases in a three-dimensional frame.
A conventional Smagorinsky sub-grid model was adapted
to modeling the turbulence of the liquid phase, with a third
order QUICK scheme used for convective terms. The relative
movement between the rotating impeller and the static bafes
was accounted for through the improved inner-outer iterative
algorithm. The spatial discretization of the governing equations was performed on a cylindrical staggered grid. A k-e
model was also carried out for the purpose of the comparison
to the LES.
The complex ow pattern of gas-liquid ow in a gas spargered tank was well predicted. There are many small vortexes in both the gas and the liquid ow elds and the ow
patterns change with the time. The ow in the tank is not
symmetrical as most work presumed to be. The phaseresolved predictions of the LES were compared with the experimental data and the results by k-e model suggesting that
LES is much better than the k-e model. The present study
has shown the suitability of the LES coupled with a two-uid
model for simulating the gasliquid ow in a stirred tank.
Because much computer time is needed in the large eddy
simulation, only the drag force was considered in this article.
Other inter-phase interactions, such as the virtual mass force,
may also be considered in future work. The two-uid model
coupled with the LES can be extended to the numerical simulation of other two-phase ows, such as liquidsolid, gas
solid and liquidliquid ows.
Acknowledgments
The authors acknowledge the nancial support from the National Natural Science Foundation of China (Nos. 20236050, 20676134, 50574081)
and 973 Program (Nos. 2004CB217604, 2007CB613507).
AIChE Journal
Notation
b 5 Length of the blades, m
cs 5 Smagorinsky coefcient
CD 5 Inter-phase drag coefcient
d 5 Diameter of the bubble, m
D 5 Impeller diameter, m
Eo 5 Evotos number
F 5 body force, kg m2 s22
g 5 gravity acceleration, m s22
G 5 turbulence generation rate, kg m21 s23
Ge 5 extra source of turbulence due to bubble phase, kg m21 s23
Hc 5 clearance of the impeller, m
k 5 kinetic energy, m2 s22
N 5 impeller speed, revs21
p 5 pressure, Pa m3 kg21
Re 5 Reynolds number
2
@ru
Ri 5 Richardson number (Ri ke2 urh @r h )
21
S 5 strain-rate tensor, s
t 5 time, s
T 5 tank diameter, m
u, u 5 velocity, m s21
utip 5 impeller tip speed, m
w 5 width of the blades, m
z 5 axial coordinate
a 5 gas holdup
q 5 density, kg m23
k 5 Kolmogoroff microscale, m
l 5 viscosity, kg m21 s21
x, v 5 angular velocity, rad s21
y 5 angular coordinate, rad
s 5 sub-grid stress, N m22
m 5 kinematical viscosity, m2 s21
d 5 distribution function
e 5 dissipation, m2 s23
D 5 lter width, m
Subscripts
l, g 5 liquid and gas phase
b 5 bubble
eff 5 effective
i, j, k 5 principal direction
r, y, z 5 cylindrical coordinate directions
b 5 bubble
Overbar
2
5 space ltered
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Manuscript received July 5, 2007, and revision received Apr. 11, 2008.
AIChE Journal