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    Chap1F Scale Up

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    mohan804
    This document discusses principles for scaling up mixing processes from laboratory to commercial scale. It emphasizes maintaining geometric similarity by keeping dimensionless ratios like impeller size and vessel geometry constant. It also discusses maintaining dynamic similarity by preserving dimensionless groups like the Reynolds and Froude numbers. Finally, it provides guidelines for various processes, recommending equal tip speed, power per volume, gas velocity, or mixing time depending on the process objectives.

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    Chap1F Scale Up

    Uploaded by

    mohan804
    67 views19 pages
    This document discusses principles for scaling up mixing processes from laboratory to commercial scale. It emphasizes maintaining geometric similarity by keeping dimensionless ratios like impeller size and vessel geometry constant. It also discusses maintaining dynamic similarity by preserving dimensionless groups like the Reynolds and Froude numbers. Finally, it provides guidelines for various processes, recommending equal tip speed, power per volume, gas velocity, or mixing time depending on the process objectives.

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    Chap1F-Scale-Up

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    This document discusses principles for scaling up mixing processes from laboratory to commercial scale. It emphasizes maintaining geometric similarity by keeping dimensionless ratios like impeller size and vessel geometry constant. It also discusses maintaining dynamic similarity by preserving dimensionless groups like the Reynolds and Froude numbers. Finally, it provides guidelines for various processes, recommending equal tip speed, power per volume, gas velocity, or mixing time depending on the process objectives.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    67 views19 pages

    Chap1F Scale Up

    Uploaded by

    mohan804
    This document discusses principles for scaling up mixing processes from laboratory to commercial scale. It emphasizes maintaining geometric similarity by keeping dimensionless ratios like impeller size and vessel geometry constant. It also discusses maintaining dynamic similarity by preserving dimensionless groups like the Reynolds and Froude numbers. Finally, it provides guidelines for various processes, recommending equal tip speed, power per volume, gas velocity, or mixing time depending on the process objectives.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 19

    SCALE-UP PRINCIPLES

    SCALE-UP OBJECTIVES
    + Achieve same mixing quality in commercial tanks as in laboratory tanks
    +Understand differences in the process result on scale-up

    ⇨ NOT POSSIBLE TO MAINTAIN SAME COMBINATION OF FLOW AND


    SHEAR

    ⇨ GEOMETRIC SIMILARITY EMPHASIZED ON SCALE-UP — REFERS TO


    THE FOLLOWING PARAMETERS TO BE HELD CONSTANT

    — Impeller type
    — Impeller dimensions
    •D/T in the typical range of 0.25 to 0.65
    •b/D
    •C/T
    — Liquid height H1/T - increase in H1 would require multiple impellers
    — Baffles B/T and number
    g∆ρl/ρv2
    Reynolds number ρ N D2
    Re =
    µ
     Ratio of inertial forces to viscous forces
     If inertial forces dominate, Re is large, and the system is turbulent
     If viscous forces dominate, Re is small and the system is laminar
    Froude number N2 D
    Fr =
    g
    A ratio of inertial and gravitational forces
    Shape of liquid surface and surface flow patterns affected by gravitational fields
    Fr is relevant to vortex formation, surface aeration and splashing
    Weber number ρ N 2 D3
    We =
    σ
    Ratio of inertial forces to interfacial tension
    We is used when studying liquid-liquid dispersions, and is used for
    fitting predictions of droplet size distributions
    Q
    Flow number Fl =
    N D3
    Characterises the discharge flowrate of an impeller
    Used to compare pumping capacities of different impellers
    In gas-liquid mixing, an aerated flow number, FlG is used for QG
    FlG =
    comparing gas flow rate and impeller volumetric flowrate N D3
    Scale-up
    The basis of scale-up must be chosen:
    8 Geometric similarity
    8 Kinematic similarity
    8 Power per unit volume
    8 Dynamic similarity
    The skill required for reliable scale-up is
    selecting what basis to use
    Typically, two of these scaling rules can be
    used together for scale-up (but geometric
    similarity is usually one of these)
    Geometric similarity
    ⇨All linear dimensions are scaled up equally
    T1 = s x T2 D1 = s x D2 H1 = s x H2 etc.
    ⇨The large and small vessels look alike
    ⇨Any lack of data on e.g. the effect of changing aspect
    ratio or D/T ratio does not affect the design
    ⇨There can be a shortfall with geometric similarity, e.g.
    heat transfer area per unit volume
    ⇨Deviation from geometric similarity can be applied
    under certain circumstances
    Power per unit volume
    Often adopted as a first approach to scaling
    Correlations show whether P/V should
    increase, decrease or remain constant on
    scale-up
    Scale-up problems:
    @ Excessive power requirements at large scale
    @ Scaling rules must be identified from
    correlations or pilot scale tests
    @ Two process requirements may have different
    scale-up exponents
    Scale-Up by
    Power/Volume
    Dynamic Similarity
    Make use of dimensionless groups
    Each dimensionless group, being a ratio of two
    dynamic quantities may need to be preserved on
    scaleup
    Example: Dimensionless mixing time (Nθ) is constant
    for geometrically similar systems
    Constant Froude number for systems in which
    vortexing for gas entrainment is required
    The relationship between process performance at
    different scales and the dimensionless group may not
    be linear. Use pilot scale testing to confirm scale-up
    rule
    Kinematic similarity
    Operating conditions chosen based on
    characteristic velocities:
    o Constant tip speed
    o Constant superficial gas velocity
    o Constant maximum liquid velocity in impeller
    discharge
    Disadvantages
    o Other process parameters may not scale
    correctly
    o Liquid flow patterns, reaction rates, mass
    transfer
    Scale-Up NDX = Constant:
    Liquid Blending
    ∗ In the turbulent regime, Nθ=constant, but this leads to excessive power
    requirements (P∝T5)
    ∗ If very rapid mixing is required, a number of smaller vessel or a high-
    intensity in-line device should be considered
    ∗ Mixing time generally increases on scale-up
    Solid-liquid mixing
    If a solid-liquid system is scaled-up by keeping at Njs,
    solids distribution will be worse at large scale
    Maintain constant power per unit volume on scale-up
    Liquid droplet dispersion
    For constant droplet size in a non-coalescing system, keep
    constant maximum energy dissipation rate
    Liquid circulation times increase if scaling on constant εmax,
    so coalescence rates will increase. ε must be increased to keep
    droplet size constant in a coalescing system
    Gas-liquid Mixing
    For constant hold-up and mass transfer rate, keep P/V and Vsg constant
    P/V can be difficult to predict at large scale
    Scale up at constant VVM requires increase in P/V to overcome impeller flooding

    Heat transfer
    ⇨Heat transfer rate per unit volume = U A ∆T / V
    will decrease on scale-up for a geometrically similar system
    ⇨U cannot be increased dramatically without huge impeller power draws
    ⇨Increasing ∆T has limits (refrigerated cooling systems are expensive)
    ⇨Options can be sought for increasing A
    ⇨Recirculate fluid through an external heat exchanger
    ⇨Fit cooling coils inside the vessel
    ⇨Reflux a volatile chemical and remove the heat in the headspace through
    re-condensing (auto-refrigeration)
    ⇨Make the baffles into extra area for heat exchange (10-20% improvement)
    ⇨Tall, thin vessel
    Summary of scale-up rules
    Processes Rules
     Miscible liquid blending Equal tip speed ND = constant
     Solids suspension NjsD0.85 = constant
     Solids Distribution Equal Power/Volume
     Gas-liquid mixing: Constant hold-up Equal Power/Vol
    and mass transfer & equal Vsg
     Immiscible liquid mixing;
    constant droplet size Constant Vtip or constant P/V,
    (depends on breakage mechanism)
     Heat transfer Equal Reynolds number
     Fast chemical reactions Equal mixing time: N=constant

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