Hydrodynamics of wall-bounded turbulent flows through screens: a numerical study

The hydrodynamic performance of turbulent flows in circular pipes equipped with screen-type static mixers is numerically assessed in this study. A three-dimensional computational fluid dynamics model is used to study the effect of changing the operating conditions and reactor configuration on the flow field. The accuracy of the numerical results is validated by comparing pressure drop predictions to empirical correlations where a maximum relative error of 13.3% is recorded. The macro-mixing performance of screen type static mixers is also assessed using residence time distributions. The study shows that the flow through screens is three-dimensional by nature with secondary flows being prominent near the pipe walls. Moreover, the presence of the screen has a major impact on the turbulent velocity profile both up- and down-stream. The flow field and velocity gradients are interpreted using strain rate and vorticity. These parameters also show that the flow through screens is highly dispersive where 39.3% of the reactor volume has an extensional efficiency value greater than 0.6. This explains their good performance in processing multiphase flows and gives an insight on how to design systems that maximize this dispersive effect in their volume. The residence time distribution study shows that the presence of screens renders the flow closer to plug flow with the effect being more pronounced using finer mesh screens operating at high flow velocities.