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Process Optimization
The flow in a mixing tank depends on several parameters:
Digital simulations exist to support the optimization of
the tank geometry, the fluid, the filling level, the impeller blade geometry and the rotation speed.process but how can one be sure that they accurately depict reality ?
The smartINST system allows true measurement of the way each parameter impacts the flow and therefore the mixing.
A smartCAPS in the tank will characterize the flow and provide new possibilties for process study and optimization.
Measuring agitation
The Agitation Rate
The agitation rate represents the energy supplied in the fluid. This rate is obtained in real time thanks to an accelerometer embedded in the smartCAPS.
The agitation rate studied during a defined time is illustrated by the hydrodynamic signature.
The hydrodynamic signature
The hydrodynamic signature characterizes flow, providing detaileds understanding of it, arising from the agitation rate statistics.
It forms a measurable quantitative description of the flow.
This new measurement allows:
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Definition of an average rate of agitation
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Analysis of the variations around this rate
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Detection of zones of very strong agitation which can damage the fluid or
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Detection of dead areas, areas to avoid to obtain efficient mixing.
EXAMPLE
Comparing Flows
The hydrodynamic signature is a simple tool to compare flows from real time experimental measurements.
Each flow can be characterized by the details of its motion, fluctuations around the target value, in reponse to variations, etc.
These are precisely measured at each phase of the process, providing a comparison of the flows, to the replicate them or adjust them.
Determining the mixing time by actual experience
The mixing time can be determined through actual experience by studying typical parameters such as conductivity or pH.
By placing 2 or 3 smartCAPS in the flow, the mixing time will be determined in a very effective manner.
In the graph below, the fixed probe detects that the conductivity is stable, yet the conductivity measured by the smartParts is not the same until the NaCl pocket detected (time 140) is totally mixed.
Following temperature at the core of the process
Measuring the temperature at the core of the process allows the desired temperature to be reached faster.
Because the smartINST system can measure the temperature at the core of the process, adjustments permit the targeted temperature to be reached more rapidly and safety margins become nearly unnecessary.
During a chemical reaction, thanks to the temperature follow-up at the core, the final quality product will be increased.
Detecting dead areas
To optimize a process, it is crucial to detect if any dead areas are present.
These areas create problems of homogeneity and increase the mixing times.
A smartCAPS ACC detects the presence of dead areas in the flow.
Indeed, if a smartCAPS approaches an area of low turbulence, the agitation rate decreases and the smartCAPS movement is specific.
In the example below, the agitation contains a dead area on the Signature 1 whereas the agitation on the Signature 2 is constant.
EXAMPLE
