ChemEngineering 02 00026 PDF

Article
Performance of Helical Ribbon and Screw Impellers

for Mixing Viscous Fluids in Cylindrical Reactors
Houari Ameur 1, *, Youcef Kamla 2 and Djamel Sahel 3
1 Institute of Science and Technology, University Center Ahmed Salhi of Naâma (Ctr Univ Naâma),
P.O. 66, Naâma 45000, Algeria
2 Faculty of Technology, University Hassiba Ben Bouali, Chlef 02000, Algeria; kamla_youcef@yahoo.fr
3 Department of Technical Sciences, University Amar Thilidji, Laghouat 03000, Algeria;
djamel_sahel@ymail.com
* Correspondence: houari_ameur@yahoo.fr or h.ameur@mail.cuniv-naama.dz; Tel.: +213-770343722

Received: 21 March 2018; Accepted: 3 June 2018; Published: 11 June 2018
Abstract: The present paper deals with the mixing of a highly viscous fluid by close-clearance
impellers in cylindrical vessels. The study is performed via numerical simulations. Calculations are
achieved by the discretization of continuity and momentum equations with the finite volume method.
The effect of blade diameter and its shape on the well-stirred region size and the power consumption
is investigated. For highly viscous fluids, the obtained results suggest the use of impellers rotating at
low Reynolds number, and having a blade with the same shape of the tank to ensure mixing near the
vessel base. A comparison is made between the performance of a simple helical ribbon (HR), a simple
small screw (SS), helical ribbon-small screw (HR-SS) and a large screw (LS) impeller. The predicted
results allow the following classification of impellers studied, based on less power requirements and
small size of well-agitated region: SS < HR < HR-SS < LS.
Keywords: mixing; viscous fluids; cylindrical tank; close-clearance impeller; helical-screw impeller
1. Introduction
Mixing of highly viscous fluids is widely used in many industrial processes, e.g., for the production
of foods, polymers or paints. Obtaining an efficient mixing with high quality of homogenization at
low impeller rotational speeds is a challenging task, due the high power consumption required for
moving the viscous fluid.
Among the several stirrers available in industries, the helical ribbon and screw impellers are
efficient for the mixing of highly viscous liquids. These impellers are often operated in the laminar regime of
fluid flows. Depending on the purpose of the mixing operation, the helical ribbon impeller may be used
with one or more helical ribbons mounted on a central shaft, supported or not by cross-beams [1,2].
In a stirred tank fermenter, Mohd et al. [3] compared the performance of a Rushton turbine
and a double-flight helical ribbon impeller (HRI). They reported that the HRI operating at moderate
conditions (250 rpm) performs better and requires less energy than a double Rushton turbine operating
at an optimum condition (600 rpm). Yao et al. [4] and Ameur [5] studied numerically the total and local
dispersive mixing performance of double helical ribbons (DHR) and Maxblend impellers. Their results
showed that the DHR can achieve a good total circulation throughout the agitated vessel, but it can’t
give a promising local mixing performance.
Via numerical simulations and using the smoothed particle hydrodynamics (SPH) method,
Robinson and Cleary [6] explored the mixing performance of helical ribbon impellers with a Newtonian
fluid. They reported that the addition of an extra ribbon to the single helical ribbon (SHR) doubles the
number of smaller circulation cells of fluid; thereby improving the overall mixing rate.
ChemEngineering 2018, 2, 26; doi:10.3390/chemengineering2020026 www.mdpi.com/journal/chemengineering

ChemEngineering 2018, 2, 26 2 of 9
Delaplace et al. [7] proposed an approximate analytical model to predict the power required for
stirring shear-thinning fluids with helical ribbon impellers at low Reynolds numbers. Zhang et al. [8]
simulated the 3D non-Newtonian flows generated by a double helical ribbon (DHR) agitator and
they used three CFD (Computational Fluid Dynamics) methods to calculate the Metzner constant.
Ameur et al. [9,10] studied the effect of blade pitch and other operating conditions on the flow patterns
and power consumption with helical screw impellers. Maingonnat et al. [11] studied the link between
the power consumption, operating conditions and the rheological behavior of fluids stirred by a double
ribbon impeller (Ekato-Paravisc). Driss et al. [12] simulated the Newtonian laminar flows in vessels
stirred by double helical ribbons (DHR) and double helical screws (DHS) impellers. Their results
revealed that the double helical ribbons impeller yields more active velocity field and pumping flow.
Also, the energy efficiency reaches the highest values at the same Reynolds number with DHR impeller.
Ameur et al. [13] compared, via numerical simulations, the performance of a Simple Helical
Ribbon (SHR) and Double Helical Ribbon (DHR) impellers for mixing shear thinning fluids. They found
that the DHR impeller enhances the fluid circulation but an additional power is consumed.
Anne-Archard et al. [14] discussed the distributions of shear rates and their link to power
consumed when mixing power-law fluids with helical and anchor impellers. They established a
Metzner–Otto correlation for mixing in power-law fluids (Bingham, Herschel-Bulkley and Casson
fluids). The comparison made by Iranshahi et al. [15] between the anchor, DHR and EkatoParavisc
impellers in term of mixing characteristics revealed that the DHR is more efficient than the
EkatoParavisc. The simulation results given by Yu et al. [11] suggest a great potential for using
the helical ribbon impeller for the mixing of high solids digester. Dieulot et al. [16] used a non standard
helical ribbon agitator fitted with an anchor at the bottom in unsteady agitation conditions. They found
that energy savings can reach up to 60% compared to the energy required to obtain the same mixing
time with a constant agitation speed.
Kuncewicz et al. [17] used a two-dimensional numerical model describing the Newtonian laminar
fluid flows with a screw impeller. They proposed an optimization criterion of the tank-impeller system
regarding mixing time. Masiuk and Rakoczy [18] modeled the mixing of granular materials by a multi
ribbon blender. They showed in their study that the theory of information can be employed to describe
the random process of mixing of granular materials by this kind of impellers. Rivera et al. [19] mounted
a Maxblend impeller and a double helical ribbon agitator on two independent coaxial shafts rotating
at different speeds, for obtaining the so called Super blend coaxial stirrer. This mixer configuration is
found as a good alternative for tough mixing applications.
Practical designs of mixers are generally performed based on experiments and measurements,
which are often expensive and not an easy task [20–22]. However, CFD (Computational Fluid
Dynamics) simulations may be an efficient alternative. The analysis of mixing characteristics may be
achieved in less time and with a greater flexibility in visualizing the fluid motions in the whole vessel
volume [23].
The present paper investigates via numerical simulations the mixing characteristics of this class of
industrial stirrers. We focus on the effect of impeller geometry on the flow fields and power consumption.
Effects of the blade width of a helical ribbon are explored. Also, a comparison between the performance
of a Helical Ribbon (HR), a Small Screw (SS), a Large Screw (LS) and a Helical Ribbon-Small Screw
(HR-SS) is made.
As stated above, some papers have been published on the performance of double helical ribbon
(DHR) and double helical screw (DHS) impellers. However, in this paper, we compare the efficiency of
HR and HS impellers used alone and in combination.
2. Geometry of the Mixing System

The base structure of the stirrer is a cylindrical unbaffled vessel with a diameter D = 300 mm.
The agitation of fluid is ensured by a rotating helical ribbon stirrer (Figure 1). In this paper, effects of
ChemEngineering2018, 2, x FOR PEER REVIEW 3 of 9
the impeller bladegeometrical

Two other width are investigated by are
configurations realizing threeingeometrical
performed configurations,
order to explore the effects namely Case 1
of the vessel
to 3base
(details are summarized in Table 1).
design, namely Case 4 and 5 (details are available in Table 2).
Figure 1. Stirred system.

Table 1. Geometrical parameters of mixing vessels with a flat bottom vessel.
Table 1. Geometrical parameters of mixing vessels with a flat bottom vessel.
Case H/D d1/D d2/D h1/D h2/D h3/D c/D ds/D
No. 1 Case
1 H/D
0.89 d1 /D 0.89d2 /D h1 /D
0.445 h20.445
/D h3 /D 0 c/D ds /D
0.052 0.033
No. 2 11
No. 1 0.4 0.89 0.890.89 0.445
0.445 0.445
0.445 0 0 0.052 0.052
0.033 0.033
No. 3 12
No. 1 0.4 0.4 0.890.89 0.779
0.445 0.111
0.445 0 0 0.052 0.052
0.033 0.033
No. 3 1 0.4 0.89 0.779 0.111 0 0.052 0.033
Table 2. Geometrical parameters of mixing systems with a dished bottom vessel.
Two
Caseother geometrical
H/D d1configurations
/D d2/D are h performed
1/D hin order tohexplore
2/D 3/D
thec/D
effects of dthe
s/D
vessel
base design,
No. 4 namely
1 Case 4 and
0.89 5 (details
0.89 are available
0.445 in Table
0.445 2). 0.222 0.052 0.033
No. 5 1 0.4 0.89 0.445 0.445 0.338 0.052 0.033
Table 2. Geometrical parameters of mixing systems with a dished bottom vessel.
3. Materials and Methods

Case H/D d1 /D d2 /D h1 /D h2 /D h3 /D c/D ds /D
No. 4
3.1. Variable Definition 1 0.89 0.89 0.445 0.445 0.222 0.052 0.033
No. 5 1 0.4 0.89 0.445 0.445 0.338 0.052 0.033
Malt syrup solution is used as a working medium which is a typical Newtonian fluid. The Malt
syrup is colorless, transparent, tasteless and nontoxic. The viscosity changes with concentration, for
3. Materials and Methods
a concentration of 71% it has the dynamic viscosity η = 0.8 Pa.S and the density ρ = 1338 kg/m3. We
3.1.note that these
Variable fluid properties are determined experimentally by Liu et al. [24].
Definition
The continuity equation for incompressible fluids is given by the following equation:
Malt syrup solution is used as a working medium which is a typical Newtonian fluid. The Malt
∇ V = 0The viscosity changes with concentration,(1)for a
syrup is colorless, transparent, tasteless and nontoxic.
concentration of 71% it has the dynamic viscosity η = 0.8 Pa.S and the density ρ = 1338 kg/m3 . We note
Navier-Stokes equations are written in a rotating frame reference. So, the centrifugal and the
that these fluid properties are determined experimentally by Liu et al. [24].
Coriolis accelerations terms are added. These equations, written in cylindrical coordinates (r, θ, z),
The continuity equation for incompressible fluids is given by the following equation:
are expressed in the general conservation form as follows:

( ) +∇
→
∂ ρV
( ) ()
  ∇ V = 0   (1)
∂t
(
ρV ⊗ V + pI = ∇ τ + ρ ω 2 r − 2ω ∧ V ) (2)
Navier-Stokes equations are written in a rotating frame reference. So, the centrifugal and the
CoriolisFor
accelerations
a Newtonianterms are
fluid, theadded. These
Reynolds equations,
number written
is given by theinfollowing
cylindrical coordinates (r, θ, z), are
equation:
expressed in the general conservation form as follows: 2
ρ Nd 2
Re = (3)
η
→

∂ ρV
→ →

→

→
ω 2 dr2 −

+ ∇in ρRPM
where N is the stirring rate V⊗V (rounds = ∇minute)
+ pI per τ + ρ and the∧ impeller
in2ω V diameter. In(2)
∂t
dimensionless form, we define the power number as:
For a Newtonian fluid, the Reynolds number is given by the following equation:
ρNd22
Re = (3)
η
where N is the stirring rate in RPM (rounds per minute) and d2 in the impeller diameter. In dimensionless
form, we define the power number as:
P
Np = (4)
ρN 3 d52
where PChemEngineering2018,
is the power consumption calculated as:
2, x FOR PEER REVIEW 4 of 9
Z
P=η P Qv dv (5)
Np = (4)
ρN
vessel volume
3 5
d2
where Qwhere P isviscous
v is the the power consumption
dissipation calculated
and v is theas:
vessel volume. We define also the radial and axial
coordinates and velocity in dimensionless form, respectively, as:
P =η 
vessel volume
Qv dv (5)
* * *
R = 2R/D; R = Z/D; V = V/πNd2 (6)
where Qv is the viscous dissipation and v is the vessel volume. We define also the radial and axial
where Dcoordinates anddiameter,
is the vessel velocity in R
dimensionless
is the radialform, respectively,
coordinate and Zas:is the axial coordinate.
R* = 2R/D; R* = Z/D; V* = V/πNd2 (6)
3.2. Numerical Simulation
where D is the vessel diameter, R is the radial coordinate and Z is the axial coordinate.
Simulations were performed by using the CFD code CFX 17.0 (Ansys Inc., Canonsburg, PA, USA).
3.2. Numerical
For modeling Simulation
fluid flows in unbaffled vessels, the Rotating Reference Frame (RRF) approach is used,
i.e., the stirrer is kept stationary
Simulations were performedand the by outer wallCFD
using the of the
codetank
CFXis17.0
given an angular
(Ansys velocity equal
Inc., Canonsburg, PA, in
magnitude USA). andForopposite
modelingin direction
fluid flows intounbaffled
the velocity of the Rotating
vessels, rotatingReference
frame. The RRF(RRF)
Frame method has been
approach
used foris several
used, i.e.,applications
the stirrer is kept stationarystirred
in unbaffled and thetank
outerreactors
wall of the tank is
[15,25] given
and an angularresults
satisfactory velocityhave
equal
been obtained. in magnitude and opposite in direction to the velocity of the rotating frame. The RRF method
has been used for several applications in unbaffled stirred tank reactors [15,25] and satisfactory
In the laminar and stationary regime and for an incompressible fluid, the momentum equations
results have been obtained.
(i.e., Navier-Stokes equations) were solved by using the finite volume method. The first step is the
In the laminar and stationary regime and for an incompressible fluid, the momentum equations
generation of grids, i.e., dividing
(i.e., Navier-Stokes equations)the calculation
were solved bydomain
using theinto small
finite volumecontrol volumes.
method. A step
The first pre processor
is the
(ICEM CFD 17.0, Ansys Inc) was used to create the geometry of the mixing system and
generation of grids, i.e., dividing the calculation domain into small control volumes. A pre processor to discretise the
flow domain
(ICEM intoCFD tetrahedral
17.0, Ansys Inc)cells (Figure
was used to2).create
The the
density of cells
geometry needs
of the mixingto system
be fineand
enough to capture
to discretise
the flowthe flow domain
details, but notinto tetrahedral
so fine, cells (Figure
since problems 2). The density
described by largeofnumbers
cells needs ofto be fine
cells enough
require more to time
capture the flow details, but not so fine, since problems described by large numbers
to be solved. After achieving mesh tests, the total number of elements was about 1.2 million. Solutions of cells require
more time to be solved. After achieving mesh tests, the total number of elements was about 1.2 million.
were considered to be converged when the residual targets of velocities and pressure drop below 10−6 .
Solutions were considered to be converged when the residual targets of velocities and pressure drop
For this value of residual targets, the computational time was about 2–3 h with a computer machine
below 10−6. For this value of residual targets, the computational time was about 2–3 h with a computer
having machine
a 2.20 GHz Pentium(R)
having a 2.20 GHz i7 Pentium(R)
Core CPU i7 with
Core8.0CPU
GB with
of RAM.
8.0 GB Further
of RAM. details candetails
Further be found
can bein our
previous paper [26].
found in our previous paper [26].
(a) (b)
Figure 2. Meshing of the computational domain with tetrahedral elements: (a) Horizontal view;
Figure 2. Meshing of the computational domain with tetrahedral elements: (a) Horizontal view;
(b) Isometric View.
(b) Isometric View.
4. Validation of the Predicted Results
As a first step, we have seen necessary to check the reliability of the computer code and the
correctness of the numerical method performed. To this end, we refer to the experimental work of
Liu et al. [24]. For the same geometry and operating conditions, the variation of power number vs.
Reynolds number is given in Figure 3. The comparison between our predicted results and the
experimental data of Liu and his co-authors shows a satisfactory agreement.
Np
Num. [Present work]
4. Validation of the Predicted
5.0 Results
Exp. [24]
As a first step, we have 4.5

seen necessary to check the reliability of the computer code and the correctness
ChemEngineering2018, 2, x FOR PEER REVIEW To this end, we refer to the experimental work of Liu et al.
of the numerical method performed.
4.0 [24].
5 of 9
For the same geometry and3.5 operating conditions, the variation of power number vs. Reynolds number
Reynolds number
is given in Figure 3.is The
given in Figure between
comparison 3. The comparison
our predicted between our the
results and predicted resultsdata
experimental andofthe
Liu
3.0
experimental data ofshows
and his co-authors Liu and his co-authors
a satisfactory shows a satisfactory agreement.
agreement.
2.5
Np
2.0
1.5 Num. [Present work]

5.0
Exp. [24]
4.5
50 100 150 200 250 300 Re
4.0 Figure 3. Power number for n = 0.4.
3.5
5. Results and Discussion
3.0
5.1. Effect of the Blade Width2.5

2.0
This section describes the fluid flows around the stirrer and investigates its mixing
characteristics. 1.5
The flow generated by the helical 50 ribbon impeller

100 150 is tangential;
200 250 this is
300 Rewhy we focus here on the
variation of the tangential velocity along the vessel radius (Figure 4). The tangential velocity is
presented on a line located at a vertical Figure
Figure3. 3.Power
Powernumber
position number
Z* = Z/D for =n0.45
for n= =
0.4.
0.4.
and an angular position θ = 90°. We
note the plane passing through the blade tip represents θ = 0°. For any case studied, the tangential
5.velocity
5.Results
Results and
andDiscussion
increases Discussion
continually from the impeller shaft until the blade tip, where the maximum value
is reached. Then, it (Vθ*) decreases again until becoming negligible at the tank wall. For this angular
5.1.
5.1.Effect
Effectofofthe
theBlade
BladeWidth
Width
position (i.e., θ = 90°), the tangential velocity increases with the increase of the blade diameter.
For
Thishighly
This sectionviscous
section describes
describes fluids,
thethethe
fluid agitation
fluid
flowsflows is usually
around around donethewith
the stirrer and a low-speed
stirrer rotary
and investigates
investigates its mixer.
mixing its While the
mixing
characteristics.
impellerThe is
characteristics. rotating
flow at lowbyspeeds
generated the helicaland the ribbonfluidimpeller
flow is is laminar,
tangential;the mixing is ensured
this is why we focusby here
chaotic
on
folding
the The and
flowstretching
variation generated actions on
by the helical
of the tangential the fluid,
velocity ribbon
along which
impelleris necessary
the vessel radiusin(Figure
is tangential; anythisagitation
is
4).why
Thewe process
focusthat
tangentialhere does not
on the
velocity is
based
variation
presented onof diffusion
on line[27].
thea tangential
locatedvelocity
at a vertical alongposition
the vessel Z* = radius
Z/D = (Figure
0.45 and 4). an
Theangular
tangential velocity
position is ◦ .
θ = 90
presented
We note If the ondiameter
the plane of theat
a line passing
located blade
a vertical
through isthe
small, it tip
position
blade is likely
Z* = Z/Dto have
represents = 0.45 ◦ . For
θ = less
0and stirred
anany areasstudied,
angular
case near the
position θvessel
the wall
=tangential
90°. We
(Figure
note the 5c).
velocity plane Hence
increases the necessity
passing throughfrom
continually of design
the blade of close-clearance
tip
the impeller represents
shaft until θ =theimpellers
0°.blade
For any with
tip, casea blade
where studied,which reaches
the tangential
the maximum valuetheis
vessel
velocity
reached. walls
increases
Then,(Figure * ) decreases
(V θ5a).
itcontinually Increasing
from againthe the diameter
impeller
until of until
shaft
becoming the negligible
blade increases
the blade attip, the
tankgood
thewhere mixing
the maximum
wall. For thiszone, but
value
angular
iswith
positionan additional
reached. Then,
(i.e., θ =it90(V◦ ),
energy
θ*)the cost (Table
decreases
tangential again 3).until becoming
velocity increases with negligible at the of
the increase tank
thewall.
bladeFor this angular
diameter.
position (i.e., θ = 90°), the tangential velocity increases with the increase of the blade diameter.
*
For highly viscous fluids,Vthe θ
agitation Case is
No 1usually done with a low-speed rotary mixer. While the
Case No 2
impeller is rotating at low speeds and the fluid flow is laminar, the mixing is ensured by chaotic
0.20
folding and stretching actions on the fluid, which is necessary in any agitation process that does not
based on diffusion [27]. 0.15
If the diameter of the blade 0.10

is small, it is likely to have less stirred areas near the vessel wall
(Figure 5c). Hence the necessity of design of close-clearance impellers with a blade which reaches the
0.05
vessel walls (Figure 5a). Increasing the diameter of the blade increases the good mixing zone, but
with an additional energy cost0.00 (Table 3).
-0.05
*
Vθ Case No 1
*
0.0 Case
0.1 No 2 0.2 0.3 0.4 0.5 R
0.20
Figure 4. Tangential velocity for Re = 10, Z** ==0.45, 90◦ .
0.45,θθ ==90°.
0.15
0.10 the agitation is usually done with a low-speed rotary mixer. While
For highly viscous fluids,
the impeller is rotating at low
0.05 speeds and the fluid flow is laminar, the mixing is ensured by chaotic
0.00
-0.05
*
0.0 0.1 0.2 0.3 0.4 0.5 R
*
folding and stretching actions on the fluid, which is necessary in any agitation process that does not
based on diffusion [27].
If the diameter of the blade is small, it is likely to have less stirred areas near the vessel wall
(Figure 5c). Hence the necessity of design of close-clearance impellers with a blade which reaches the
vessel walls (Figure 5a). Increasing the diameter of the blade increases the good mixing zone, but with
an additional energy cost (Table 3).
(a) Case No. 1 (b) Case No. 2 (c) Case No. 3

(a) Case No. 5.
Figure 1 Velocity contours
(b) Case No.
for Re 2
= 10. (c) Case No. 3
Figure 5. Velocity contours for Re = 10.
Figure 5. Velocity contours for Re = 10.
Table 3. Power number for Re = 10.
Case No. 1 No. 2 No. 3
Np Case 4.28 No. 1 No. 2 3.75 No. 3 1.793
Case No. 1 No. 2 No.
Np Np 4.28 4.28 3.75 3.75 1.79 1.79
5.2. Effect of the Bottom Shape
5.2. Effect of the Bottom Shape
In the same context as the previous section, we show here the influence of the blade shape.
As illustrated
In the same in Figure
context 6, the tip of
as the the impeller
previous blade
section, weshould
show not
show herebethe
farinfluence
from the bottom
influence of the
of of the curved
the blade
blade shape.
shape.
tank
As if it is desired
illustrated
illustrated in to improve
in Figure
Figure 6, the tipthe
6, mixing
of the quality
impeller in should
blade this region (near
not be the bottom
far from of theoftank).
the bottom We’ll
the curved
haveifan
tank increase
it is desiredintothe power the
improve consumption
mixing qualitywith inthe broadening
this of the
region (near the blade
bottom stirrer
of the(Table
tank).4), but
We’ll
this increase
have an an increaseis small
increasein inthesince
thepower the forces
powerconsumption of interaction
consumptionwith with
thethe
with the
broadeningcurved
broadening bottom
of the blade
of the are low.
stirrer
blade (Table
stirrer 4), but
(Table 4), this
but
increase
this increaseis small sincesince
is small the forces of interaction
the forces withwith
of interaction the curved bottom
the curved are low.
bottom are low.
Case No. 4 Case No. 5

Case
Figure 6. No. 4contours for Re Case
Velocity = 10. No. 5
Figure 6.
Figure 6. Velocity contours for
Velocity contours for Re
Re == 10.
10.
Table 4.
4. Power
Power number
number for
Table
Case No. 4 for ReRe == 10.
No. 510.
Np
Case 4.494
No. 4.665
No.
Case No. 4 No. 5
Np 4.49 4.66
5.3. Comparison between the Helical RibbonNp (HR), Small
4.49 Screw 4.66
(SS), Large Screw (LS), Helical Ribbon-
Small
5.3. Screw (HR-SS)
Comparison Impellers
between the Helical Ribbon (HR), Small Screw (SS), Large Screw (LS), Helical Ribbon-
SmallFor
Screw (HR-SS)
a large tankImpellers
filled with a highly viscous fluid, is the helical ribbon sufficient to ensure a good
circulation of fluid
For a large tankparticles in athe
filled with whole
highly vesselfluid,
viscous volume?
is theThe objective
helical ofsufficient
ribbon this section is to compare
to ensure a good
the performance of four agitators (Figure 7).
circulation of fluid particles in the whole vessel volume? The objective of this section is to compare
From Figureof8,four
the performance withagitators
a single(Figure
screw (Case
7). No. 8) rotating at low speed, the area near the vessel
The best between

5.3. Comparison configuration is a large
the Helical Ribbonhelical screw
(HR), with
Small blades
Screw close
(SS), to Screw
Large the walls of Helical
(LS), the tankRibbon-Small
(Case No.
7), since it just requires
Screw (HR-SS) Impellers a slight increase in power compared to the Case No. 6.
From all cases studied and at the same impeller rotational speed, Case No. 7 yields the widest
For a large tank filled with a highly viscous fluid, is the helical ribbon sufficient to ensure a good
well-stirred region (Figure 8). And since the size of dead zone is the lowest with this impeller design,
circulation
so it mayofgive
fluid particles
the reducedinmixing
the wholetime.vessel
Also, volume? The objective
the comparison between ofCase
this section is to
No. 6 and compare
7 in terms ofthe
performance of four agitators (Figure 7).
power consumption (Np) reveals that Case No. 7 requires just a slight increase in Np (Figure 9).
The best configuration is a large helical screw with blades close to the walls of the tank (Case No.
7), since it just requires a slight increase in power compared to the Case No. 6.
ChemEngineering2018,
From all cases2,studied
x FOR PEERandREVIEW
at the same impeller rotational speed, Case No. 7 yields the widest 7 of 9
The best configuration is a large helical screw with blades close to the walls of the tank (Case No.
so it may give the reduced mixing time. Also, the comparison between Case No. 6 and 7 in terms of
7), since it just requires a slight increase in power compared to the Case No. 6.
Case No. 1 (HR) Case No. 6 (HR-SS) Case No. 7 (LS) Case No. 8 (SS)
From Figure 8, with a single screw (Case No. 8) rotating at low speed, the area near the vessel
walls is no longer agitated. With a helical ribbon (Case No. 1), the flow velocity is low near the impeller
shaft. IfCase
we place a small screw
No. 1 (HR) with
Case No.the helical ribbon (Case
6 (HR-SS) No.
Case No. 6), the circulation
7 (LS) Case of
No.fluid
8 (SS)particles
will be improved but with an increase inFigure
the power consumption.
7. Stirred system.
Case No. 1 (HR) Case No. 6 (HR-SS) Case No. 7 (LS) Case No. 8 (SS)
Case No. 1 FigureNo.

Case 7. Stirred
6 system.Case No. 7 Case No. 8
Figure 8. Velocity contours Re = 100, Z* = 0.5.
5
Re = 10
Re = 30
4 Re = 60
Case No. 1 Case No. 6 Case No. 7 Case No. 8
Figure8.8.Velocity
3Figure Velocity contours
contours Re == 100,
Re 100,Z*
Z*==0.5.
0.5.
Np
Case No. 15 Case No. 6 Case No. 7 Case No. 8

The best configuration is2 a large helical screw with blades close Re = to
10 the walls of the tank (Case
Figure 8. Velocity contours Re
0.5.= Case
Re = 100, Z*to= the 30
No. 7), since it just requires a slight increase in power compared Re = 60
No. 6.
4
1
5
3 Re = 10
0 Re = 30
Case No. 1 Case No. 6 Case No. 7 Case
Re = No.
60 8
Np
4
2
Figure 9. Power number for different cases.
3
1
6. Conclusions
Np
2
The present contribution focuses on the performance of helical ribbon mixers in unbaffled stirred
0
tanks. The problem is analyzed under
Case No. 1numerical
Case No.simulations.
6 Case No.Visualization
7 Case No. 8of the 3D flow fields and
1
power consumption of a Newtonian fluid within the laminar regime are illustrated.
Figure
Effects of the blade diameter 9. Power
and number
the design of for
thedifferent cases.
lower part of impeller on the flow patterns
and power input are examined.0 The obtained results proved the necessity of close clearance impellers
6.
forConclusions
mixing highly viscous fluidsCase
at No.
low1 Reynolds 6 Case No.
Case No.numbers. The Case of
7 shape No.the
8 lower part of impeller
blade should follow the design of the tank to ensure mixing near the vessel
The present contribution focuses on the performance of helical ribbon mixers base.in unbaffled stirred
Figure9.9.Power
Figure Powernumber
number for
for different
different cases.
cases.
tanks. The problem is analyzed under numerical simulations. Visualization of the 3D flow fields and
6. Conclusions
Effects of the blade diameter and the design of the lower part of impeller on the flow patterns
and power input are examined. The obtained results proved the necessity of close clearance impellers
for mixing highly viscous fluids at low Reynolds numbers. The shape of the lower part of impeller
blade should follow the design of the tank to ensure mixing near the vessel base.
Effects of the blade diameter and the design of the lower part of impeller on the flow patterns
6. Conclusions
Effects of the blade diameter and the design of the lower part of impeller on the flow patterns and
power input are examined. The obtained results proved the necessity of close clearance impellers for
mixing highly viscous fluids at low Reynolds numbers. The shape of the lower part of impeller blade
should follow the design of the tank to ensure mixing near the vessel base.
A comparison between the performance of simple helical ribbon (HR), a simple small screw (SS),
helical ribbon-small screw (HR-SS) and a large screw (LS) is made. At the same impeller rotational
speed, the large screw impeller yielded the widest well-stirred region, followed by the SS, HR and
then by the HR-SS impeller, respectively.
In terms of less power consumption and when these impellers are rotating at the same rotational
speed, the following classification is obtained: SS < HR < HR-SS < LS. Compared to the power required
by small screw impellers, the increase in Np is estimated to be 31.92%, 35% and 35.5% for HR, HR-SS
and LS impellers, respectively. Also, the increase in impeller rotational speed yields a decrease in
power consumption, due to the decrease of viscous dissipation rates.
However, further studies are needed for other fluids and especially for rheologically complex
fluids. Also, the case of unsteady flows may give further insight on the performance of these impellers,
especially the mixing time at the same power input.
Author Contributions: Conceptualization, H.A. and Y.K.; Methodology, H.A. and Y.K.; Software, H.A. and Y.K.;
Validation, Y.K.; Formal Analysis, H.A., Y. K. and D.S.; Investigation, H.A. and Y.K.; Resources, H.A., Y.K. and
D.S.; Data Curation, H.A. and Y.K.; Writing-Original Draft Preparation, H.A. and Y.K.; Writing-Review & Editing,
H.A.; Visualization, Y.K.; Supervision, H.A.; Project Administration, H.A.; Funding Acquisition, Y.K.
Conflicts of Interest: The authors declare no conflict of interest.
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© 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access
article distributed under the terms and conditions of the Creative Commons Attribution
(CC BY) license (http://creativecommons.org/licenses/by/4.0/).

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Performance of Helical Ribbon and Screw Impellers

ChemEngineering 2018, 2, 26; doi:10.3390/chemengineering2020026 www.mdpi.com/journal/chemengineering

2. Geometry of the Mixing System

the impeller bladegeometrical

Figure 1. Stirred system.

3. Materials and Methods

As a first step, we have 4.5

1.5 Num. [Present work]

5.1. Effect of the Blade Width2.5

The flow generated by the helical 50 ribbon impeller

If the diameter of the blade 0.10

(a) Case No. 1 (b) Case No. 2 (c) Case No. 3

Case No. 4 Case No. 5

The best between

Case No. 1 FigureNo.

Case No. 15 Case No. 6 Case No. 7 Case No. 8

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