高剪切混合器研究与应用进展

doi:10.16085/j.issn.1000-6613.2018-0981

摘要/Abstract

摘要：

高剪切混合器作为一种能量密集型的过程强化手段，具有剪切速率高、局部能量耗散率高的特点，可以实现均质、乳化、溶解、分散、悬浮、结晶、破碎、反应等过程的强化，但尚缺少理性设计方法的系统研究。本文简述了高剪切混合器分类、工作模式，总结了操作参数、结构参数、物性参数等对高剪切混合器的流动与返混特性、微观混合特性、乳化和液液传质特性、气泡分散与气液传质特性、固体破碎与分散特性等的影响规律，简介了高剪切混合设备的工业实用案例；进而提出了该领域有待深入拓展的研究方向，包括高剪切混合器能量效率的提升途径、多相体系下高剪切混合器模型的建立方法、高剪切混合器与其他单元操作耦合规律、高剪切作用与外场协同强化机理、基于高剪切混合器的过程强化工艺优化等。

关键词: 高剪切混合器, 过程强化, 流动特性, 乳化, 传质, 分散, 微混合, 工业应用

Abstract:

High shear mixers (HSMs), as the energy intensive process intensification technique, have the feature of high shear rates and highly localized energy dissipation rates and will provide intensifications for homogenization, emulsification, dissolution, dispersion, suspension, crystallization, pulverization and reaction, etc. However, it lacks of systematic investigation on rational design method for HSMs. We briefly introduced the category and working mode of HSMs, summarized the effects of operation conditions, structural parameters and physical properties on the flow and backmixing characteristics, micromixing performance, emulsification and liquid-liquid mass transfer property, bubble dispersion and gas-liquid mass transfer property, solid pulverization and dispersion, etc. Several industrial application cases of HSMs were presented. Then we put forward the research aspects needed in future, involving how to improve the energy efficiency of HSMs and to establish the modeling method for HSMs in multiphase systems, to disclose the coupling principles with other unit operations and to understand the synergy effect of high shearing and external field, to explore optimal intensified technologies for HSMs, etc.

Key words: high shear mixer, process intensification, flow characteristic, emulsification, mass transfer, dispersion, micromixing, industrial application

中图分类号:

TQ051.7

廖启江,秦宏云,周鸣亮,张敏卿,张金利. 高剪切混合器研究与应用进展[J]. 化工进展, 2019, 38(03): 1160-1175.

Qijiang LIAO,Hongyun QIN,Mingliang ZHOU,Minqing ZHANG,Jinli ZHANG. Progress of researches and applications for high shear mixers[J]. Chemical Industry and Engineering Progress, 2019, 38(03): 1160-1175.

图/表 23

图1 商业化高剪切混合器的简单分类[5]

图2 高剪切混合器的工作模式[5]

图3 Rayneri Turbotest型（French VMI）高剪切混合器[7]

图4 配备不同定子开孔结构的4 LRT型高剪切混合器（单位： mm）[9,10]

图5 带圆孔式定子的4 LRT型高剪切混合器不同旋转位置下的速度矢量图（k-ε模型，2000r/min）[9]

表1 2000r/min和4000r/min下4 LRT型（Silverson）高剪切混合器的能量耗散速率分布[9]

区域	能量耗散
区域	2000r·min^-1	4000r·min^-1
转子扫略区	0.368W (48.5%)	3.037W (48.5%)
定子区	0.058W (7.6%)	0.488W (7.8%)
定子射流区	0.157W (20.7%)	1.317W (21.0%)
剩余区域	0.176W (23.1%)	1.426W (22.8%)
总能量耗散	0.759W (100%)	6.268W (100%)
总能量耗散/净功耗	67.8%	69.9%

图6 4 LRT的速度矢量图（k-ε模型，2000r/min）[10]

表2 4 LRT型高剪切混合器配备不同构型定子的能量耗散速率分布[10]

定子	转子扫略区/W	定子区/W	定子射流/W	剩余区域/W	总能量耗散/W
圆孔式定子	3.14 (47.1%)	0.56 (8.4%)	1.58 (23.7%)	1.39 (20.8%)	6.67
开缝式定子	3.73 (54.9%)	0.99 (14.6%)	1.73 (25.4%)	0.35 (5.1%)	6.80
方孔式定子	4.97 (60.3%)	0.99 (12.0%)	2.18 (26.5%)	0.10 (1.2%)	8.24

图7 转子位置对转子齿尖速度归一化后平均速度的影响[11]

图8 不同定子几何构型下的速度分布(转子齿尖速度3.28m/s归一化)[12]

图9 3种连续型高剪切混合器速度矢量图[13]

图10 两种连续型高剪切混合器的流动特性

图11 Silverson 150/250 MS型高剪切混合器在不同定子构型下的流量[16]

图12 实验和模拟得到的超细齿连续高剪切混合器本征量纲为1的RTD曲线[19]

图13 高剪切混合器腔室与出口构型对RTD的影响[20]

图14 不同定转子构型的高剪切混合器[23]

图15 一种带液体分布器的高剪切混合器[26]

表3 高剪切混合器内乳化过程中的平均液滴直径关联式[27]

液滴平均直径关联式	备注	文献
$d 3,2 D = 0.038 W e - 0.6 d 3,2 D = 0.0037 W e - 1 R e 1 / 2$	间歇型高剪切混合器；无表面活性剂；稀乳液体系，分散相黏度和含率都很低	[28,29]
$d 3,2 D = 0.055 W e - 3 / 5 1 + 2.06 V i d 3,2 D 1 / 3 3 / 5 d 3,2 D = 0.093 W e R e - 1 / 3 1 + 24.44 V i R e 1 / 2 d 3,2 D 1 / 3$	间歇型高剪切混合器；表面活性剂添加与否都进行考察；将有无表面活性剂测定的d _3,2进行关联	[30]
$d 3,2 ∝ 1 + 20 Φ W e R e 4 - 1 / 7$	连续型高剪切混合器；无表面活性剂；非聚并的煤油-水体系	[31]
$d 3,2 ∝ N 3 Q - 0.55 Φ 4.13 μ d μ c - 0.53$	连续型高剪切混合器；有表面活性剂；高浓度、对温度敏感以及快速聚并的沥青乳液	[32]
$d 3,2 D = 0.250 1 + 0.459 Φ W e - 0.58 d 3,2 D = 0.201 μ d μ c 0.066 W e - 0.6 d 3,2 ∝ E V - 0.45, ? ? ? ? d 3,2 ∝ E V - 0.39$	连续型高剪切混合器；有表面活性剂；分散相黏度和含量为低到中等水平	[33]
$d 3,2 D = 0.29 W e - 0.58, ? ? ? ? ? d 3,2 D = 0.41 W e - 0.66$	连续型高剪切混合器；有表面活性剂；稀乳液体系。Webber数的指数与高剪切混合器的规格关系不大，随分散相的黏度变化	[34]
$d 3,2 D = 0.048 (μ d μ c) 0.0074 W e - 0.55$ $d 3,2 D = 0.11 (μ d μ c) - 0.021 W e - 0.63$	连续型高剪切混合器；有表面活性剂；稀乳液体系	[35]

表3 高剪切混合器内乳化过程中的平均液滴直径关联式[27]

液滴平均直径关联式	备注	文献
$d 3,2 D = 0.038 W e - 0.6 d 3,2 D = 0.0037 W e - 1 R e 1 / 2$	间歇型高剪切混合器；无表面活性剂；稀乳液体系，分散相黏度和含率都很低	[28,29]
$d 3,2 D = 0.055 W e - 3 / 5 1 + 2.06 V i d 3,2 D 1 / 3 3 / 5 d 3,2 D = 0.093 W e R e - 1 / 3 1 + 24.44 V i R e 1 / 2 d 3,2 D 1 / 3$	间歇型高剪切混合器；表面活性剂添加与否都进行考察；将有无表面活性剂测定的d _3,2进行关联	[30]
$d 3,2 ∝ 1 + 20 Φ W e R e 4 - 1 / 7$	连续型高剪切混合器；无表面活性剂；非聚并的煤油-水体系	[31]
$d 3,2 ∝ N 3 Q - 0.55 Φ 4.13 μ d μ c - 0.53$	连续型高剪切混合器；有表面活性剂；高浓度、对温度敏感以及快速聚并的沥青乳液	[32]
$d 3,2 D = 0.250 1 + 0.459 Φ W e - 0.58 d 3,2 D = 0.201 μ d μ c 0.066 W e - 0.6 d 3,2 ∝ E V - 0.45, ? ? ? ? d 3,2 ∝ E V - 0.39$	连续型高剪切混合器；有表面活性剂；分散相黏度和含量为低到中等水平	[33]
$d 3,2 D = 0.29 W e - 0.58, ? ? ? ? ? d 3,2 D = 0.41 W e - 0.66$	连续型高剪切混合器；有表面活性剂；稀乳液体系。Webber数的指数与高剪切混合器的规格关系不大，随分散相的黏度变化	[34]
$d 3,2 D = 0.048 (μ d μ c) 0.0074 W e - 0.55$ $d 3,2 D = 0.11 (μ d μ c) - 0.021 W e - 0.63$	连续型高剪切混合器；有表面活性剂；稀乳液体系	[35]

图16 高剪切混合器处理CMC过程[5]

图17 PLM固/液混合系统[5]

表4 电池浆料分散纳米SiO2粉体应用对比[5]

项目	原工艺	新工艺
分散时间/h	8～10	1～2
电机功率/kW	45	22
投料方式	人工	在线自吸
分散效果	有团聚	均匀

表5 农药悬浮剂分散工业应用对比[5]

项目	原工艺	新工艺
生产时间/h	1	0.5
粒径/μm	100～300	50～80

图18 高剪切混合器用于制备石墨烯[49,50]

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