Progress of researches and applications for high shear mixers

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

Abstract

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

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

CLC Number:

TQ051.7

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.

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.

Figures/Tables 23

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%

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

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]

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]

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

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

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