Professional Documents
Culture Documents
ardh
Andreas Hakansson
, Laszlo Fuchs b, Fredrik Innings c, Johan Revstedt b, Christian Trag
,
a
Bjorn
Bergenstahl
a
Lund University, Department of Food Technology, Engineering and Nutrition, P.O. Box 124, SE-221 00 Lund, Sweden
Lund University, Department of Energy Sciences, P.O. Box 118, SE-221 00 Lund, Sweden
c
Tetra Pak Processing Systems, Lund, Ruben Rausings Gata, SE-221 86 Lund, Sweden
b
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 26 September 2011
Received in revised form
21 December 2011
Accepted 22 December 2011
Available online 3 January 2012
Keywords:
Emulsion
Fluid mechanics
Turbulence
Computational Fluid Dynamics
Homogenisation
Hydrodynamics
1. Introduction
The emulsication in a High Pressure Homogenizer (HPH) can
be seen as a combination of three simultaneous processes;
fragmentation of drops, recoalescence of insufciently covered
0009-2509/$ - see front matter & 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ces.2011.12.039
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
265
Table 1
Some previous CFD-models of High Pressure Homogenizer valves.
Reference
Geometry
Cells
Kohler
et al. (2007)
Raikar et al. (2009)
Casoli et al. (2010)
Hakansson
et al. (2010)
Inlet chamber
Outlet chamber
Complete valve
Complete valve
Complete valve
Complete valve
In-house valve
In-house valve
Complete valve
Complete valve
Complete valve
2D
2D
2D
2D
2D
2D
3D
2D
2D axisymmetric
2D axisymmetrical
2D
5852
5015
20 000
350 000
65 000
65 000
850 000
Laminar
High-Re k e
Standard k e
RNG k e
Standard k e, RNG k e, Realizable ke
Realizable k e
Standard k e
RNG k e
Standard k e
Standard k e
Standard k e
Phases
Wall treatment
1
Laminar
1
WF
1
WF
1
LReF
a
1
a
1
1
LReF
a
a
1
a
a
1
350 000 1 Cavitation model LReF
278 000 1
WF
Trag
2007; Hakansson
et al., 2011) were performed without
disperse phase and/or cavitation, this study is restricted to one
phase HPH ow only.
investigated by Hakansson
et al. (2011), obtaining high resolution
measurements of the turbulence in the outlet chamber as well as
detailed information about the mean velocity in inlet chamber
and gap.
The aim of this paper is to investigate to what extent the
turbulent ow eld in a HPH valve can be predicted using
RANS-CFD techniques combined with the turbulence models used
2. Experimental measurements
Mean velocities and mean uctuations were measured in a scale
model of a high pressure homogenizer using 2D Particle Image
U g hrC
mC
266
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
Fig. 2. 2D Mesh (Mesh B) containing 800 000 cells. Inserts show zoomed in images of the region close to the gap inlet and outlet.
denition
P k /ui uj S
@/U i S
@xj
earlier (Hakansson
et al., 2011).
3
@xj
@xi
In the Standard ke turbulence model (Launder and Spalding,
1974) the turbulent viscosity, nT, is modeled by
2
nT C m
where
Sij
1 @/U i S @/U j S
:
2
@xj
@xi
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
267
Fig. 3. Mesh sensitivity and wall treatment. Comparison of turbulent kinetic energy, k, over three positions: (A) line I in the inlet chamber, (B) line III in the gap and (C) line
IV in the outlet chamber (lines dened in Fig. 1). Simulations performed with Enhanced Wall treatment (EWT) on meshes A and B and Low Reynolds number formulation
(LReF) on mesh C.
268
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
Fig. 4. (A) Calculated velocity prole in the gap (RNG k e turbulence model). The velocity magnitudes are scaled with gap velocity, Ug. (B) Elongation rate, Ey, versus
distance downstream of gap entrance versus distance from the gap entrance on the dashed line in (A).
Fig. 5. (A) Contours of velocity magnitude in the gap inlet region from CFD with RNG k e turbulence model. Velocity magnitudes have been scaled with mean gap
velocity, Ug. (B) Boundary layer thickness, d70, at the right wall (A) versus downstream distance from gap entrance.
@U y
@Y
ow eld of Hakansson
et al. (2011) and is shown in Fig. 4B versus
upstream distance from the gap entrance on the dashed line in
Fig. 4A. Elongation increases up to a maximum of 0.49Ug/h at a
position close to the gap inlet, which is in good agreement with
previous studies in the same experimental model (Innings and
ardh,
Trag
2007).
experimentally by Hakansson
et al. (2011, Fig. 3A). The development of a boundary-layer zone with separation is well known
from previous experiments for this type of geometries (Phipps,
1974) and has been discussed in relation to cavitation (Phipps,
1974; Hakansson
et al., 2010). It was suggested that the high local
velocity and thus low static pressure close to this zone can induce
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
269
Fig. 6. Velocity magnitude (A) and turbulent kinetic energy, k (B) for line II (see Fig. 1). Comparison of experimentally obtained values with simulations using three
different turbulence models.
Fig. 7. Contours of turbulent kinetic energy in the early part of the gap from CFD with three different turbulence models: Standard k e (A), RNG k e (B) and Realizable
k e (C).
270
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
Fig. 8. The jet created in the outlet chamber at the jet exit: (A) velocity vectors from PIV experiments (Hakansson
et al., 2011) compared with CFD simulations using
Standard k e (B), RNG k e (C) and Realizable k e (D) turbulence model. All velocities have been scaled with the mean gap velocity, Ug.
(Hakansson
et al., 2011). The ow exits the gap creating a
turbulent jet. The jet attaches to the right wall roughly 10 gap
heights downstream in the chamber. A small recirculation zone is
created between the jet and the right wall. Earlier experiments
using a larger eld of view also show how a second, larger and
slow moving, recirculation region is formed on the left side of the
ardh,
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
271
Fig. 9. Turbulent kinetic energy in the turbulent jet exiting the outlet chamber: (A) PIV, (B) Standard k e, (C) RNG k e and (D) Realizable k e. Note the different scales for
k from PIV and CFD. Stream lines have been inserted for BD.
Fig. 10. Production of turbulent kinetic energy on line IV (dened in Fig. 1).
272
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
Hakansson
et al., 2009). This study shows that the qualitative
velocity prole and turbulence as a function of gap distance could
be estimated approximately, however, the exact position of the
jet is highly sensitive to the choice of turbulence model and
the turbulence is signicantly overestimated in the part closest to
the small recirculation zone at the right wall using all three models.
This difference can lead to large errors in substantial parts of the
outlet chambers when describing the effect of drops from turbulent
forces on emulsion drops with the studied RANS models.
5. Conclusions
4.6. Dimensionality
The experimental investigations were conducted in a scaleup model (see Section 2). The models presented thus far are two
dimensional, describing the middle plane where PIV data was
obtained. The walls in the experimental model are 7.8 gap
heights above and below the middle plane. An interesting
question is to what extent the walls in the experimental model
have any signicant effect on the ow in the middle plane where
measurements were made. This could give rise to an apparent
difference between measurements and simulations. A 3D simulation was therefore performed over the full cubical experimental geometry with RNG k e turbulence models and either
symmetry or wall boundary conditions on the upper and lower
walls. Differences in turbulent kinetic energy were less than 1%
on all investigated positions indicating that the walls in the
experimental model have no signicant inuence on the ow in
the center plane.
4.7. Generality
This study is focused on validating the models for a specic
geometry, through scaling it applies directly to a production scale
homogenizer with a short gap and long impact ring distance
ardh,
A. H
akansson et al. / Chemical Engineering Science 71 (2012) 264273
Nomenclature
Symbols
/US
Cm
d
Ey
h
k
L
r
Reg
t
u
Ug
X,Y
x,y
y
dij
dp
e
mC
rC
uC
uT
Sij
Pk
Abbreviations
BFS
CFD
DNS
EWT
HPH
LES
LReF
PIV
RANS
Acknowledgments
This study was nanced by the Swedish Research Council (VR).
References
ANSYS, 2009. Theory GuideFLUENT 12.0. ANSYS, Canonsburg, PA.
Casoli, P., Vacca, A., Berta, G., 2010. A numerical procedure for predicting the
performance of high pressure homogenizing valves. Simul. Model. Pract.
Theory 18, 125138.
273
Floury, J., Bellettre, J., Legrand, J., Desrumaux, A., 2004. Analysis of a new type of
high pressure homogeniser. A study of the ow pattern. Chem. Eng. Sci. 59,
843853.
ardh,
Hakansson,
A., Trag
T., Bergenstahl,
B., 2009. Dynamic simulation of emulsion
formation in a high pressure homogenizer. Chem. Eng. Sci. 64, 29152925.
ardh,
Hakansson,
A., Fuchs, L., Innings, F., Revstedt, J., Bergenstahl,
B., Trag
C., 2010.
Visual observations and acoustic measurements of cavitation in an experimental model of a high-pressure homogenizer. J. Food Eng. 100, 504513.
ardh,
Hakansson,
A., Fuchs, L., Innings, F., Revstedt, J., Trag
C., Bergenstahl,
B., 2011.
High resolution experimental measurement of turbulent ow eld in a high
pressure homogenizer model and its implications on turbulent drop fragmentation. Chem. Eng. Sci. 66, 17901801.
ardh,
isierdusen.
Doctoral Thesis, Karlsrhue Technische Hochschule, Karlshue.
Kelly, W.J., Muske, K., 2004. Optimal operation of high-pressure homogenization
for intracellular product recovery. Bioprocess. Biosyst. Eng. 27, 2537.
Kim, J.-Y., Ghajar, A.J., Tang, C., Foutch, G.L., 2005. Comparison of near-wall
treatment methods for high Reynolds number backward-facing step ows.
Int. J. Comput. Fluid Dyn. 19, 493500.
Kleinig, A.R., Middelberg, A.P.J., 1996. The correlation of cell disruption with
homogenizer valve pressure gradient determined by computational uid
dynamics. Chem. Eng. Sci. 51, 51035110.
Kleinig, A., Middelberg, P., 1997. Numerical and experimental study of a homogenizer impinging jet. AIChE J. 43, 11001107.
Kohler,
K., Aguilar, F., Hensel, A., Schubert, K., Schubert, H., Schuchmann, H.P.,
2007. Design of a microstructured system for homogenization of dairy
products with high fat content. Chem. Eng. Technol. 30, 15901595.
Launder, B.E., Sharma, B.I., 1974. Application of the energy-dissipation model of
turbulence to the calculation of ow near a spinning disc. Lett. Heat Mass
Transfer 1, 131137.
Launder, B.E., Spalding, D.B., 1974. The numerical computation of turbulent ows.
Comput. Method Appl. Mech. Eng. 3, 269289.
Miller, J., Rogowski, M., Kelley, W., 2002. Using a CFD model to understand the
uid dynamics promoting E. coli breakage in a high-pressure homogenizer.
Biotechnol. Prog. 18, 10601067.
Nellasamy, M., 1987. Turbulence models and their applications to the prediction of
internal ows: a review. Comput. Fluids 15, 151194.
Phipps, L.W., 1974. Cavitation and separated ow in a simple homogenizing valve
and their inuence on the break-up of fat globules in milk. J. Dairy Res. 41,
18.
Phipps, L.W., 1985. The High Pressure Dairy Homogenizer. The National Institute
for Research in Dairying, Reading.
Pope, S.P., 2000. Turbulent Flows. Cambridge University Press, Cambridge.
Patankar, S.V., Spalding, D.B., 1972. A calculation procedure for heat, mass and
momentum transfer in three-dimensional parabolic ows. Int. J. Heat Mass
Transfer 15, 17871806.
Raikar, N.B., Bhatia, S.R., Malone, M.F., Henson, M.A., 2009. Experimental studies
and population balance equation models for breakage prediction of emulsion
drop size distributions. Chem. Eng. Sci. 64, 24332447.
Shih, T.-H., Liou, W.W., Shabbir, A., Yang, Z., Zhu, J., 1995. A new k e eddyviscosity model for high Reynolds number turbulent ows. Comput. Fluids 24,
227238.
Steiner, H., Teppner, R., Brenn, G., Vankova, N., Tcholakova, S., Denkov, N., 2006.
Numerical simulation and experimental study of emulsication in a narrowgap homogenizer. Chem. Eng. Sci. 61, 58415855.
Stevenson, M.J., Chen, X.D., 1997. Visualization of the ow patterns in a highpressure homogenizing valve using a CFD package. J. Food Eng. 33, 151165.
Walstra, P., 1993. Principles of emulsion formation. Chem. Eng. Sci. 48, 333349.
Yakhot, V., Orszag, S.A., 1986. Renormalization group analysis of turbulence: I.
Basic Theory. J. Sci. Comput. 1, 351.