Fluid dynamics simulation of the high shear mixing process

The Eulerian–Eulerian two-fluid approach for modelling multiphase flows is used to simulate the flow in a high shear mixer. The results are compared with experimental velocity profiles for the solids phase at the wall in the mixer obtained using a high speed camera (Darelius et al. Chem. Eng. Sci. 62 (2007) 2366).The governing equations are closed using relations from the Kinetic Theory of Granular Flow (KTGF) combined with a frictional stress model due to Johnson and Jackson and Schaeffer and inter-phase drag due to Wen and Yu. In addition, calculations are presented for a model with a constant particle phase viscosity (CPV). Free slip and partial slip boundary conditions for the solid phase velocity at the vessel wall and the impeller have been utilized.The results show that the bed height could be well predicted by the partial slip model, whereas the free slip model could not capture the experimentally found bed height satisfactorily. For the KTGF model, the swirling motion of the rotating torus that is formed by the moving powder bed was over-predicted and the tangential wall velocity was under-predicted, probably due to the fact that the frictional stress model needs to be further developed, e.g. to tackle cohesive particles in dense flow. The CPV model gave predictions in good agreement with the experiments for a solids viscosity of 0.1 Pa s and a wall slip parameter of 0.005 m/Pa s. However, for a very low or very high value of the particle phase viscosity and for a high value of the wall slip parameter the agreement with experiments was poor. Interestingly, values of the viscosity that are commonly employed for fluidized beds seem applicable also in the present case.