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1. INTRODUCTION
Mixing in the laminar ow regime is mainly driven by
molecular diusion. Liquid-phase mixing generally inuences
the heat and mass transfer rates and reactant conversion in any
reactor. However, a careful analysis of the data reported in
literature shows that very high uid ow rate is required in order
to induce signicant mixing in coiled tubes.1,2 It is not possible to
narrow the residence time distribution (RTD) beyond a certain
limit in coils with xed curvature ratio. Hence, in order to reduce
axial dispersion, many devices such as motionless mixers,39 ow
inverters,10 and chaotic congurations1114 have been reported
in the past. Static mixers have limitations for very viscous uids as
it can induce prohibitive pressure drop resulting in higher
pumping cost. To overcome this limitation a novel concept
was introduced to develop an economical and eective alternative named as the coiled ow inverter (CFI).1
The conguration of a CFI is a novel design, which works on
the principle of complete ow inversion. The geometrical conguration of a CFI consists of 90 bends at equal intervals of
length in coiled tube geometry. This device helps in intensifying
the convective transfer processes and provides enhanced transfer
area per unit volume of space. Its performance is substantially
closer to plug ow. A modied axial dispersion model has been
presented to describe the liquid-phase RTD in gasliquid ow
under the conditions of both negligible and signicant molecular
diusion in a CFI.2 It was observed that the axial dispersion was
reduced with an increase in liquid ow rate and number of bends.
The reduction in dispersion number was 2.6 times in the CFI
having 15 bends as compared to a coiled tube for two phase
gasliquid ow under identical process conditions. Further
experiments have been carried out to investigate the eect of
design parameters such as gas and liquid ow rates, curvature
ratio, pitch, and the number of bends on pressure drop for
gasliquid ow in the CFI.15 The transition of ow regimes in
gasliquid ow was observed at critical Reynolds numbers of
800010000. Pitch had negligible eect on the pressure drop of
gasliquid ow in the CFI. The empirical correlations for the
friction factor have been reported for the dierent gasliquid
regimes in the CFI. These correlations take into account the
r 2011 American Chemical Society
2. NUMERICAL MODEL
The coiled ow inverter device with circular cross-sectional
having diameter, d; coil diameter, D, and pitch, H was considered
Special Issue: Ananth Issue
Received: February 2, 2011
Accepted: June 1, 2011
Revised:
May 24, 2011
Published: June 01, 2011
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for the present study. The details of the geometry considered for
computation has been shown in Figure 1.22
2.1. Governing Equations. The governing equations for
mass, momentum, and scalar transport in the CFI were solved
with the control volume finite difference method (CVFDM)
using commercial CFD code Fluent 6.3.23 In the present study,
the mixture model was used to model the liquidliquid flow in
the tube. This model is used to study flows where the phases
move at different velocities. It works for the case where phases are
interpenetrating. This model has been previously used to simulate mixing of liquids in different configurations.8,9 The mixture
model approach is used which assumes homogeneous flow with
variable volume fraction of each phase. The summed up momentum equation of the phases with phase averaged physical
properties is solved. Unlike the Eulerian model, where the
conservation equations are coupled via interphase interactions
terms, in the mixture model, the mixture continuity, momentum
equation, and energy equation are solved along with additional
transport equations for the volume fraction of secondary phases.
In the present study, the governing continuity equation may be
written as
1
Rp Fp r 3 Rp Fp uBm r 3 Rp Fp uBdr, p
t
F u r 3 Fm uBm uBm
t m Bm
rP r 3 m r uBm r uBTm Fm gB
B
F r3
k1
Fm Ck
r 3 Fm uBm Ck km rCk Skm k 1, ::::, N 5
t
where km = Rlkl and Skm = lSkl are the mixture diusivity and
source term for transport variable Ck.
The mesh of the geometry was built in GAMBIT software. It
was then computed in FLUENT 6.3 software. Segregated solver
was used to model the ow of liquids. Liquids with constant
velocity were employed at the inlet. No-slip boundary condition
and the zero derivative conditions for the scalars were treated on
the tube wall. Flow was considered as fully developed at the
outlet. The scalar transport technique was used to compute the
mixing characteristics of liquids. Dierent scalar concentrations
were employed in the two halves of the tube inlet. The interface
for initializing the scalar concentration was perpendicular to
the direction of the secondary ow. Second-order upwind
scheme was used to model the convection term in the governing
equations. The coupling between velocity and pressure was
resolved using SIMPLE algorithm. The computation was considered converged when the residual summed over all the
computational nodes at nth iteration, Rn, satised the following
m
8
criterion: Rn/ Rm
e 10 , where R denotes the maximum
residual value of variable after m iterations, applied for p, ui,
and for scalars.
The mixing performance of the geometry was measured in
terms of coecient of variation (COV). It is represents the
standard deviation of concentration to the mean concentration of
liquids.
!0:5
Z
Cavg Ci 2 dA
F rFm uBm m_
t m
Rk Bv k Fk Ek p r 3 kef f rT
k1
COV
where
Cavg
where r(FmB
u mB
u m) represents convection term, 3P, represents
T
pressure, r 3 [m(ru
Bm ru
Bm )] represents viscous forces,
Cavg
Z
1 A
Ci dA
A 0
Cavg is the ow weighted average value of the scalar concentration over the cross-sectional area.
A systematic grid sensitivity investigation was performed.
Grid-sensitivity tests were carried out with three grids consisting
of 625 2050, 625 3100, 690 3100 (cross-section x axial).
The pressure drop values calculated for the three grids is shown
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cell density,
pressure drop
cells/mm3
(100 Pa/m)
625 2050
parameter
inlet 1
inlet 2
density (kg/m3)
780
872
1.75
0.007
0.069
625 3100
1.69
10 108
10 108
690 3100
1.69
3.1. Comparison of Numerical Predictions with Experimental Results. There is lack of quantitative analysis for
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The mixing performance of the CFI was also compared with the
existing experimental data available for the HEM.7 It was also
observed that the COV value for the CFI was found to be 5 to
8 times lower than that for an equivalent length of motionless
mixer such as HEM having 18 elements over the range of 98 e
Re e 1020. This shows that the CFI performance is superior
as compared to a motionless mixer under identical process
conditions
3.3.2. Effect of Number of Bends. Figure 6 represents the effect
of number of bends on COV of liquids flowing at Re = 490 in
straight, coiled, and CFI tube having d = 0.01 m. The figure shows
that there was no substantial variation in mixing performance
with an increase in length of straight tube. It was observed for the
CFI having one bend and the coiled tube having equivalent
length that the COV value of liquids was nearly the same.
Nevertheless, the mixing efficiency increased with the introduction of bends in the CFI as compared to that of the straight tube
and coiled tube of equal lengths. This shows that the mixing of
the two liquids increased with an increase in the number of
bends. The figure shows that significant mixing was taking place
in the CFI within three bends. The length of CFI is not effectively
utilized for mixing after the third bend. This observation agrees
with the uniformity of scalar concentration shown in Figure 3.
COV values for an SMX static mixer46 were calculated for an
equivalent length of CFI from the following equation:
bL
8
COV a exp
d
Here a and b are adjustable constants and are predicted from
laminar flow experimental results of the SMX static mixer with
liquid viscosity ratio greater than 1. The values of the exponents
in eq 8 were a 15 and b 0.505 for the SMX static mixer in
laminar flow.5,6 Figure 6 shows that COV values for the static
mixer are significantly higher with respect to coiled and CFI tube
having length an equivalent one bend. The COV values decrease
with an increase in mixer length. Nevertheless, the COV value is
still nearly 4 times higher for the static mixer as compared to that
for the CFI at the outlet (n = 4).
3.4. Friction Factor in CFI. The multiphase flow studies in
coiled tubes mostly use the correlations based on the Lockhart
Martinelli parameter.24 Studies show that the pressure drop for
two-phase gasliquid flow through coiled tubes satisfies the
LockhartMartinelli correlation.2527 In the present study, the
friction factor was computed from the pressure drop in different
geometries. The details for calculation have been reported in our
previous papers.28 The friction factor values for different configurations
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4. CONCLUSION
In the present study, the physics of ow of two miscible liquids
was examined in a complex ow generated in CFI geometry. It
was observed that the mixing performance in the CFI increased
with increase in Reynolds number as well as number of bends.
This was further substantiated by velocity and scalar concentration contours of two liquids. The product of COV and friction
factor, a new parameter, has been dened to quantify the mixing
of two liquids in ow systems. It was found that the enhancement
of mixing eciency in the CFI as compared to that of coiled tube
and HEM is higher than the increase in pressure drop of the
liquids. It was observed that the CFI oers higher mixing
eciency as compared to a coiled tube and motionless mixers
(HEM) of equivalent length. Hence, it may be concluded that the
CFI is a more ecient motionless mixer with reasonably lower
pumping cost as compared to conventional static mixer.
AUTHOR INFORMATION
Corresponding Author
NOTATIONS
A = cross-sectional area (m2)
d = internal diameter of tube (m)
D = coil diameter (m)
g = gravity (m2/s)
H = dimensionless pitch, H = p/d
L = length (m)
Re = Reynolds number
p = pitch (m)
P = pressure (N/m2)
Rc = coil radius (m)
u = velocity, m/s
x = spatial position in x-direction, m
y = spatial position in y-direction, m
Greek symbols
r = volume fraction
k = curvature of free surface
= curvature ratio (D/d)
= surface tension (N/m)
= viscosity (kg/(m 3 s))
F = density of uid (kg/m3)
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