On Flow Simulation Strategy for Industrial Mixed Vessels

The CFD-based analyses, optimizations, and troubleshooting of industrial-scale mixing tanks require a substantially simplified yet sufficiently accurate simulation strategy. Although there are numerous numerical studies on the simulation of various mixing vessels, most lack validation; based on a thorough review of studies reporting validated results, it is difficult to recommend a simulation methodology. This contribution summarizes a three-year effort to develop and validate such a recommended methodology. The methodology provides recommendations on mesh density, mesh structure, and the choice of turbulence model. The resulting strategy is first based on simulations of the flow field in a cylindrical baffled vessel, for which there is sufficient experimental data in the literature. Next, the strategy is validated using original experimental data obtained from a rectangular mixing tank with single- and double-impeller arrangements, two impeller types, and three impeller speeds.