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    主动式微反应器的设计及其混合性能研究

    Design and Mixing Performance of Active Microreactors with Different Impeller Configurations

    • 摘要: 微反应器因具有显著优势,已在化学合成、药物生产与能源材料等多个领域实现广泛应用。在高黏度以及含固体颗粒反应体系中,被动式微反应器因其设计特性,普遍存在压降大和易堵塞等问题,限制了其实际应用。为解决该问题,将微通道放大至厘米级,本研究开发了一种以电机驱动搅拌轴进行混合的新型主动式微反应器,适用于高黏度以及含固体颗粒反应体系,兼具高混合性能与高生产通量的优势。围绕搅拌结构的流动特性,本研究设计了直叶桨、直叶桨加挡板、螺旋桨3种搅拌结构。结合计算流体力学(CFD)模拟与实验验证,以离集指数(XS)、混合效率(η)为评估指标,详细研究了时间、进口流速与搅拌转速对混合性能的影响,并对强化传质机理进行了分析。在3种搅拌结构中,直叶桨通过局部高剪切诱发径向射流强化混合过程;直叶桨加挡板通过抑制周向旋涡转化周向动量为径/轴向流动强化混合过程;螺旋桨通过轴向驱动形成贯通环流强化混合过程。研究表明,3种搅拌结构混合性能从高到低依次为直叶桨加挡板、直叶桨、螺旋桨,并且进口流速对混合效果的影响小于搅拌转速。

       

      Abstract: Microreactors are widely applied in fields including chemical synthesis, pharmaceutical production, and energy materials. However, passive microreactors are generally limited by inherent design constraints, such as significant pressure drops and a high risk of clogging, which restrict their practical application in reaction systems involving high-viscosity fluids and solid particles. To address these limitations, this study enlarges the microchannel dimensions to the centimeter scale and develops a novel active microreactor equipped with a motor-driven stirring shaft to enhance mixing. Suitable for high-viscosity and solid-particle-containing systems, this design offers superior mixing performance and high production throughput. Three impeller configurations were evaluated within a 100-mm-diameter flow domain: a 26-mm-high straight blade, a straight blade with baffles (incorporating four transverse baffles), and a propeller (with a 110-mm pitch). Through a combination of computational fluid dynamics (CFD) simulations and experimental validation, the effects of time, inlet velocity, and stirring speed on mixing performance were investigated using the segregation index (XS) and mixing efficiency (η) as evaluation metrics. Simulations utilized the RNG k-ε turbulence model and the sliding mesh technique for a water/glycerin system, with a grid size of 1.5 mm selected via grid independence testing. Analysis of mass transfer enhancement mechanisms revealed that the straight-blade impeller induced a radial jet via localized shear; the straight-blade impeller with baffles suppressed circumferential vortices to redirect momentum into radial and axial flows; and the propeller created an axially driven through-flow ring. The mixed fluid reached the outlet fastest with the propeller (0.9 s), followed by the straight-blade impeller (1.2 s) and the straight-blade impeller with baffles (1.3 s). Subsequently, η rose rapidly before stabilizing. Overall mixing performance was ranked as follows: straight-blade impeller with baffles > straight-blade impeller > propeller. Quantitative analysis indicated that the straight-blade impeller reached a peak efficiency of 90.74% at 358 r/min, whereas the straight-blade impeller with baffles further improved the peak efficiency to 93.70%. Although the propeller exhibited the lowest efficiency at low speeds, its performance surpassed that of the straight-blade impeller at a high speed (956 r/min). Furthermore, simulations demonstrated that η decreased with increasing inlet velocity (from 0.1 to 1.0 m/s) due to reduced residence time. To validate these simulation results, a test platform was constructed using the iodide-iodate reaction (with c(H+) = 0.01255 mol/L). Experimental results confirmed the reliability of the simulations and demonstrated that stirring speed had a significantly greater impact on mixing effectiveness than inlet velocity; specifically, increasing the stirring speed from 0 to 280 r/min substantially reduced XS from 0.978 to 0.268. This study demonstrates that combining centimeter-scale enlargement with forced mechanical shearing effectively resolves mixing challenges in high-viscosity systems, providing valuable theoretical insights and design criteria for industrial applications.

       

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