In-line monitoring of mixing performance for smart processes in tubular reactors

This work is focused on the experimental analysis of the fluid dynamics characteristics of a tubular reactor equipped with Kenics static mixers working under turbulent flow conditions, with the specific aim of demonstrating the advantages of in-line monitoring tools for continuous process applications. Electrical Resistance Tomography, pressure transducers and Particle Image Velocimetry are employed to evaluate the mixing performance, the pressure drop and the flow field, respectively, considering the standard configuration of the mixers, consisting in mixing elements with alternating orientation, a single mixing element or multiple elements with the same orientation. The applicability of Electrical Resistance Tomography for offering insight into continuous reactors is assessed and the potential of monitoring the mixing performance inside the static mixers is shown. The experimental data suggest that alternatives to the standard element configurations might be adopted for optimizing the fluid mixing process, taking into account the mixing performances and the pressure drop, for which a novel correlation based on distributed and concentrated contributions is proposed.