VisiMix

Simulation of Mixing Processes

VisiMix Ltd,

PO Box 45170,

Jerusalem, 91450,

Israel

Tel: 972 - 2 - 5870123

Fax: 972 - 2 - 5870206

E-mail: info@visimix.com

Contents

• Introduction

• Applications – R&D

– Design

– Production

– QdD

– Management – Saving more than 1 M$

• VisiMix Products

• Conclusions

About Us

VisiMix is a unique software enabling

chemical engineers, process engineers and

R&D personnel to visualize mixing processes

via a simple, user friendly interface.

Our products allow significant savings in time

and costs by drastically reducing the need for

trial-and-error. They have been successfully

adopted by hundreds of companies.

Customers and Markets

What Our Customers Say About Us From the Dow Chemicals Intranet Website

“VisiMix: This is a highly accessible PC software for mixing

calculations available from VisiMix Ltd., an Israeli

company. It is a rating calculation tool for both non-

reactive and reactive mixing involving blending, solid

suspension, gas dispersion, liquid-liquid dispersion, or

heat transfer processes in stirred vessels. It calculates the

important process parameters for single- and two-phase

systems – power consumption, circulation rates, local

concentrations of solutes and suspended particles, drop

size, concentrations of reactants, etc … ”

Dr. Victor Atiemo-Obeng

Dow Chemicals Co.

What Our Customers Say About Us

“We have been using VisiMix. We have found it an accurate tool ...

Based on our success with the product, our Japanese colleagues at

Fuji Xerox have bought a copy for their work.”

Emily Moore,

Xerox Research Center of Canada

Customers and Markets 1.3M, USA 2.Afton, USA 3.Air Products, USA 4.Alkermes 5.AllessaChemie 6.ASEPCO 7.Ashland Hercules 8.BASF, USA 9.Belinka Belles 10.Celgene 11.Chemagis 12.DeDietrich 13.Dow chemical 14.Eni - Milan 15.Evonik Degussa 16.GE Technologies 17.GE Healthcare 18.Global Tungsten & Powders .

19.Honeywell-UOP 20.Ineos Styrenics 21.Lubrizol 22.Merck - Schering-Plough 23.Mitsubishi 24.NALAS-Jerry Salan 25.Nan Ya Plastic 26.Nippon 27.Novartis 28.NRDC, India 29.Ocean 30.Pfizer 31.Polimeri 32.Praxair 33.Ranbaxy 34.Samsung, Korea 35.Sunovion Sepracor 36.SES

37.Solvay 38.Tecnicas Reunidas 39.Tecnimont, Italy 40.Teva Global 41.US Navy, USA 42.Alcon, USA 43.Arizona Chemical 44.JM Huber 45.Jotun 46.Lek 47.Matrix\Mylan 48.MJN - Mead Johnson Nutrition 49.Ranbaxy 50.R.C.Costello 51.Styron 52.Tami 53.Taro 54.Xellia 55.Ash Stevens Inc…….

Total > 200 customers

Introduction

• This web seminar will focus on the influence of hydrodynamics and mixing parameters in the process for every step of a typical synthesis procedure, from reactions to crystallizations.

• We will make a connection between the process and the mixing parameters and complete our understanding of the main parameters we have to take in account in order to have a complete understanding of the process, through different examples, some of which were presented in our International Conference in Boston – June 2011.

Simple and Effective Technology - Simulation of Mixing Processes

Simple and Effective

The First and the only tool in the Industry

Reliable and accurate results

Based on More Than 300 Man Years of R&D and

Industry Experience

Replacing Pilot Experiments

Accelerated Time-to-Market process

User Friendly and easily accessible

Technology - Simulation of Mixing Processes

Common Questions

Did we cover the main parameters during the process

development?

Will our facilities will be appropriate for the developed

process?

Does the equipment offer is good for the process?

What about safety and runaway scenario?

Do our process is robust?

Does the operational range parameters are large enough for

the manufacture facilities?

The Goal Once the Science of the process (Chemistry, Biology or physics) is known well, a common situation during the process transfer from lab to production or from site to site is the gap between the old and new results. Our first goal is to develop a process that will run properly in

the first trial on a new scale or site, similar to our successful results in the lab or in the old facility.

In order to achieve this, we need to evaluate the process with the same conditions we will have in the production phase. The main parameters we change are the hydrodynamics of

the system. If we are able to identify and control these parameters we will be able to achieve to the available and optimal solution.

Pharmaceutical Industry

• Active Pharmaceutical Ingredient (API)

16יוני 02

Pharmaceutical Quality by Design • This FDA imperative is best outlined in its report “Pharmaceutical

Quality for the 21st Century: A Risk-Based Approach.”[*]

• In the past few years, the Agency has made significant progress in implementing the concepts of "Quality by Design" (QbD) into its pre-market processes.

• The focus of this concept is that quality should be built into a product with a thorough understanding of the product and process by which it is developed and manufactured along with a knowledge of the risks involved in manufacturing the product and how best to mitigate those risks.

• This is a successor to the "quality by QC" (or "quality after design") approach that the companies have taken up until 1990s.

* Pharmaceutical Quality for the 21st Century: A Risk-Based Approach http://www.fda.gov/oc/cgmp/report0507.html

QbD activities within FDA Overall implementation of QbD:

• In FDA’s Office of New Drug Quality Assessment (ONDQA), a new risk-based pharmaceutical quality assessment system (PQAS) was established based on the application of product and process understanding.

• Implementation of QbD for a Biologic License Application (BLA) is progressing.

While QbD will provide better design predictions, there is also a strong recognition that industrial scale-up and commercial manufacturing experience provides new and very important knowledge about the process and the raw materials used therein. This vigilant and nimble approach is explained by FDA to be essential to best protect the consumer (patient).

http://en.wikipedia.org/wiki/Quality_by_Design

API Batch Process Simulation – Scale Up Methodology. Roberto Novoa and Moshe Bentolila

QUALITY BY DESIGN

Establish: Critical Quality Attributes

Determine:

Critical Process Parameters

Define: Design Space

Set: Control Strategy

Quality by Design – Statistical Challenges Yi Tsong,. CDER, FDA 2007 FDA/Industry Statistics Workshop

Mixing Simulation Software

R&D

Production

Design

QbD

Data and Results Management

Management Example

o The need for maximizing efficiency of a mixing

process by compiling all its elements into a

common database.

o The need for better understanding between the

mixing process and its impact on the entire process

and a simple solution to achieve this

o The need to create a common language within the

company in order to achieve better communication

with regards to these processes.

© The Lubrizol Corporation 2011, all rights reserved

Application & Adoption of

Rigorous Mixing Discipline

into a Pilot Plant Environment

Cliff Kowall, Senior Process Development Engineer

Lubrizol Corporation

July 15, 2011

© The Lubrizol Corporation 2011, all rights reserved

Mixing Scale-Up

20

Full-Scale

Manufacturing

(1,000’s of tons)

Pilot-Scale

Manufacturing

(10’s of tons)

Laboratory

Scale

(pounds) Blend Scale

(tons)

Typical development order

Special products

Final Customer

The goal is to make

consistent quality at

all levels of manufacture

© The Lubrizol Corporation 2011, all rights reserved

Trajectory for Development of Mixing Activity

Starting Point

• Define need

• Base knowledge

1st Steps

• Identify & current tools

• Correlation approach

• Identify new tools

2nd Steps

• Evaluate tools

• Demonstrate valve

Current Status

• Select best tools

• Implement among users

• Institutionalize within organization

21

© The Lubrizol Corporation 2011, all rights reserved

2nd Step Results

• Developed knowledge of correlation-based approaches

• Searched for non-CFD based mixing programs

• Found VisiMix™ software being used in other parts of company

• Established contact with VisiMix™ company

– Trial copy for evaluation

– Validation

• Tracer work in lab

• Compared with correlations

• Visual work was useful for communication to uninitiated

– Justified one license

• Applied to larger applications outside of the lab

• Realized the need for better archive data on mixing vessels

22

© The Lubrizol Corporation 2011, all rights reserved

Current Status

• Wide adoption of VisiMix™ software

– Network licenses

– Training for all engineers

– Identified both an operational and a computational focus person

– Communicated need for better data

– Began more formal archiving of key design information

• Vessel characteristics

• Internals

• Materials of construction

• Use as a daily tool for operational work as well as design

of new equipment

23

© The Lubrizol Corporation 2011, all rights reserved

Lessons Learned & Conclusions

• Mixing had been a neglected area of technical attention within our

company

• Value can best be generated by actual application in plants

• Value will be maximized by distributed knowledge among the plants

and technical areas

• Outside resources are useful but internal expertise is more timely for

actual applications

• Central expertise should be available for interpretation and deeper

study

• VisiMix™ software is a simple & effective tool which is easily used

by all engineers

24

© The Lubrizol Corporation 2011, all rights reserved

Confidential & Proprietary

For Internal MJN Use Only

© The Lubrizol Corporation 2011, all rights reserved

PRODUCTS

MANUFACTURED

Powder

Infant and Children’s

products packaged

in cans and pouches.

Liquid

Infant formula in Ready-to-

Use and Concentrate

formats in cans and plastic

bottles.

Whether powder or ready to

use, liquid mixing is

Is a common theme.

© The Lubrizol Corporation 2011, all rights reserved

- How MJN was introduced to VISIMIX

- Opportunities that developed for VISIMIX

- Troubleshooting

- Training

- Design enhancement

- Productivity

- Continuing training opportunities

- What is next?

© The Lubrizol Corporation 2011, all rights reserved

As in most cases, the introduction of new capabilities- the

question arises:

Do you have a scenario of – “ A Solution looking

for a Problem”

As the software program may be Intuitive in it’s use, the

applicability relies on how well one understands the capability of

the software.

- MJN requested additional training through Dr. Moshe Bentolila

- Reviewed internal manufacturing mixing requirements.

© The Lubrizol Corporation 2011, all rights reserved

Troubleshooting

Case study:

A multi-component mixing – a 2 solids – 2 liquids (one which

is immiscible) – the degree of reaction or result was not

consistent, causing failed batches.

The case was analyzed to help provide an answer to the

persistent issue.

- Understand the component individually.

- Understand the combined effect over time.

- Simulation of the mixing at varying points in time.

© The Lubrizol Corporation 2011, all rights reserved

Liquid-Solid Mixing Result Comparison- General Flow Pattern at Initial

60RPM 100RPM

© The Lubrizol Corporation 2011, all rights reserved

Productivity

Case study # 1: At one manufacturing plant, completion of

reaction was always achieved through an adjustment of the

quantity of a component. With calculated quantities, results

were lots that had to retested or reprocessed. Increased

component usage while inefficient, this became an accepted

practice.

An analysis of the mixing action was conducted, looking at

initial viscosities, mid-point in the reaction and end-point in the

reaction, solids levels, etc.

Results indicate the mixing was at times achieved but needed

to be enhanced through the use of baffles. Addition of the

baffles resulted in a 10% reduction of the component for the

reaction.

© The Lubrizol Corporation 2011, all rights reserved

Training

Visual aids in the Visimx software helps promote faster

learning to understand the nuances behind mixing for the

process engineers – both old and new.

Manufacturing infant formula requires controlled agitation

to prevent the introduction of the air into the mix for

reasons of preventing nutrient degradation and reduce

microbiological risks, thus it is desired that you have a

well controlled mixing in the tanks.

Understanding the axial, radial flow and pumping capacity

of the different agitator designs helps the engineers grasp

the concept of a good mixing action when setting

experimental trials of new formulations. The desire to

handle gently has been paramount to prevent any product

degradation throughout the system.

R&D - Example

Application of Visimix to the Characterization of Lab Reactors

Reinaldo M. Machado

2011 VisiMix International Conference: The Influence of

Mixing in Your Process Boston USA

July 13-15, 2011 rm2technologies LLC

• Reactor

– T = 70 mm

– Maximum recommended liquid height Z=140 mm

• Impeller

– 1, 2 or 3 depending up reactor fluid and liquid height

– Non - standard 4 blade pitched(45 o ) blade

– D = 38 mm

– C = 10 mm

– Distance between impellers = 29 mm

• Baffles

– 3 x 24 mm x 25 mm

– Pre - positioned between impellers

ppt00 35

rm2technologies LLC

Estimating blend time in the Mettler-Toledo RC1 MP10 reactor

Q

l/min

uniformit

y index

0.2 to 1

time, seconds,

to achieve 90%

uniformity

rp

m

VisiMix lab VisiMix

30

0

4.2 0.29 220 146

40

0

5.7 0.31 86 92

50

0

7.4 0.34 53 64

Time, seconds 0 30 60 90 120 150

4

6

2 Reacto

r D

T,

(To

p-B

ott

om

), O

C

0

400 rpm Re = 40

500 rpm Re = 50

300 rpm Re = 30

2 Liter Lab Reactor, T =10 cm; Marine Propeller, D =6.9 cm;

Fluid m =985 cp, r =1.25 gm/cc V =1.2 liters

VisiMix simulation for

500 rpm

Characteristic function of tracer distribution

0 50 100 150 Time, seconds

Loc

al c

once

ntra

tion

1

2

3

VisiMix model of MP10 showing “mean” velocity

pattern at 500 rpm

(c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 36

rm2technologies LLC

VisiMix predictions and Experiments for Heat Transfer with Anchor Impeller with Glycerol in the RC1 MP10 glass lab reactor

Inlet

Jacket

Temp. oC

Reactor

Temp. oC

Reactor

fluid

m, cP

Re Overall Heat

transfer coeff. U

W/(m2 K)

Heat

removal

rate, W

Experiment

14 25 940 13

58.1 25.0

VisiMix 59.5 27.0

Experiment

31 40 274 43

68.4 25.0

VisiMix 70.5 26.2

Experiment

48 55 89 133

83.7 25.0

VisiMix 80.0 23.2 (c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 37

rm2technologies LLC

Mettler Toledo AP01-0.5

• Reactor

– T = 70 mm

– Maximum recommended liquid height Z=140 mm

• Impeller

– 1, 2 or 3 depending up reactor fluid and liquid height

– Non - standard 4 blade pitched(45 o ) blade

– D = 38 mm

– C = 10 mm

– Distance between impellers = 29 mm

• Baffles

– 3 x 24 mm x 25 mm

– Pre - positioned between impellers

The unique baffle

and agitator design

is appropriate for

mixing diverse

liquid chemical

systems, from

high-viscosity

laminar flow to low-

viscosity multi-

phase turbulent

flow.

(c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 38

rm2technologies LLC

Comparison of Power Numbers and “macro-mixing” Number of impellers 1 1 2 2 3 3

Agitation rpm 900 300 300 120 300 100

Re 26.0 8.7 8.7 3.5 8.7 2.9

VisiMix 1/Tcirculatio

n 1/s 0.400 0.087 0.139 0.055 0.166 0.054

Experimental kmix thermal 1/s 0.113 0.035 0.044 0.017 0.050 0.017

VisiMix kmix

composition 1/s 0.0132 0.0015 0.0074 0.0026 0.0061 0.0020

VisiMix Power number 4.5 8.7 16.3 40.2 24.3 71.0

Experimental Power number 4.9 12.7 16.5 39.9 21.9 62.8

• Reactor

– T = 70 mm

– Maximum recommended liquid height Z=140 mm

• Impeller

– 1, 2 or 3 depending up reactor fluid and liquid height

– Non - standard 4 blade pitched(45 o ) blade

– D = 38 mm

– C = 10 mm

– Distance between impellers = 29 mm

• Baffles

– 3 x 24 mm x 25 mm

– Pre - positioned between impellers

Note that thermal uniformity in liquids is achieved much more

efficiently than composition uniformity and explains

inpart the difference between VisiMix and the

thermal tracer method. Pr << Sc (c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 39

rm2technologies LLC

Characterization of lab impellers key to use of models: VisiMix flat turbine impeller width adjusted to match Power number of the lab agitator Experimental values for HP60,

T=10 cm;

standard gassing impeller

D=4.7mm, W=10mm;

fluid at 140oC, VL=1.089 liters,

surface tension=26 dyne/cm,

viscosity=0.25 cP, density=930

gm/liter.

VisiMix estimate

w/ impeller

power matched

to experiment

(blade width =

4.4 mm power

number Np=1.7)

VisiMix estimate

w/ true impeller

blade width =10

mm power

number Np=3.5

super-

ficial

velocity

agitator

power

H2

mass

transfe

r coeff.,

kLa

agitator

power

H2

mass

transfe

r coeff.,

kLa

agitator

power

H2

mass

transfe

r coeff.,

kLa

rpm cm/s W/kg 1/s W/kg 1/s W/kg 1/s

800 0.16 0.8 0.15 0.9 0.029 1.8 0.066

1000 0.23 1.6 0.23 1.7 0.074 3.5 0.18

1200 0.31 2.7 0.33 2.9 0.16 6.0 0.40

1400 0.49 4.6 0.42 4.6 0.33 9.6 0.87

VisiMix model of HP60 w/

single baffle; gassing impeller is

modeled as a flat blade turbine

With Np=1.7.

(c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 40

rm2technologies LLC

Summary of differences in model approximations for VisiMix at 1400 rpm

Blade width, mm 4.4 (flat blade turbine

adjusted to match

measured power)

10 (actual width of

impeller)

kLa, s-1 0.33 (exp. = 0.42) 0.87

vortex depth, cm 2.1 (exp. vortex ~2.5

cm)

3.6

average energy dissipation,

W/kg

4.6 9.5

gas hold-up 3.5% 5.5%

Sauter mean bubble, mm 1.8 1.4

circulation rate, liters/s 1.7 2.4

micro-mixing time, s 0.14 0.088

circulation time, s 0.64 0.46

measured kLa =0.42 s-1

@4.6 W/kg

(c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 41

rm2technologies LLC

What about the scale-up of mass transfer? plant & lab raw materials & catalyst are from same lots numbers

mixing in lab reactor measured and kLa > 0.4 s-1; mass transfer is

very fast compared to reaction so that CH2,bulk lab = CH2,sat lab

lab reactor pressure was adjusted to match plant rate profile

– RC1 programmed to match exact temperature profiles of plant

– when plant = 800 psig and lab = 700 psig the rates are equivalent

plant RC1 HP60

volume 3300 gal 1.0 liter

agitation 84 rpm 1400 rpm

Impeller

diameter

type

40 inch

2x flat

turbines

1.8 inch

gassing

pressure 800 psig 700 psig

kLa from scale-

down

0.052 s-1

kLa from VisiMix 0.062 s-1

lab saturated Hplant saturated H

plant

plantbulk Hlab saturated Hlabbulk H

22

222

CC

rateak

CCC

L

HP60

plant

(c) Reinaldo Machado; rm2technologies LLC 2011

ppt00 42

rm2technologies LLC

So what have I/we learned?

VisiMix predictions and lab reactors mixing measurements

agree well when reactor geometries match and physical

properties are known.

If lab reactor geometries do not match the catalogue of

available geometries in VisiMix, geometric approximations

must be made.

– For power and heat transfer, errors appear to be insignificant.

– For solid suspension, phase dispersion and circulation

more detailed mixing data for the lab reactor is necessary to adjust the approximations.

validations may be necessary.

The limitations of lab mixing characterization methods such

as thermal tracing must be considered when using them for

scale-up or matching more detailed VisiMix models.

(c) Reinaldo Machado; rm2technologies LLC 2011

43 ו"תשע/אייר/ה"כ

44 ו"תשע/אייר/ה"כ

45 ו"תשע/אייר/ה"כ

46 ו"תשע/אייר/ה"כ

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Design - Example

Design Example

CRYSTALLIZER. SCALING-UP • The process rate and particle size distribution in crystallization and

precipitation processes are dependent on chemical composition and physico-chemical properties of the system.

• In the same time they can be substantially dependent also on some phenomena that are functions of mixing conditions – for example, on primary and secondary nucleation, attrition and breakage of crystals, distribution of solid phase and liquid-solid mass transfer.

• The following example is related to a particular case when the crystallization is controlled mainly by these parameters, and scaling-up conditions include reproduction of these phenomena.

• The corresponding parameters selected from the list of VisiMix outputs and used below for crystallization scale-up are presented in the Table.

This example is based essentially on the article ‘Optimizing Crystallizer Scaleup’ by Wayne J. Genk , Chem. Engng. Progress, June 2003, pp. 36-44

For calculation of the Mass transfer coefficient, it is necessary to enter a number of additional initial data, including the Diffusivity of the solute. In our case the problem consists not in prediction, but in reproduction of the same value of the Mass transfer coefficient.

Reactor Configurations

Pilot Production Design

Results

56 ו"תשע/אייר/ה"כ

De Dietrich - Example

http://www.ddpsinc.com/MixingSimulations.htm

De Dietrich - Example

http://www.ddpsinc.com/Visimix.htm

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QbD - Example

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65

Methodology (J.M. Berty, CEP, 1979)

LABORATORY

(R&D)

PILOT

(Pilot)

Demo – Simulation (Visimix, Dynochem,CFD)

PLANT

(Production)

BENCH SCALE (RC1,Mini Pilot)

LABORATORY

(R&D)

PILOT

(Mini Pilot)

PLANT

(Pilot,Production)

BENCH SCALE (RC1, HEL)

Scale

Down

Final

Design Build

16יוני 02

QbD

67 ו"תשע/אייר/ה"כ

Lab and Prod Calculations

Moshe Bentolila, Roberto Novoa, and Wayne Genck, Michal Hasson, Efrat Manoff, "Computer Aided Process Engineering at Chemagis" , PHARMACEUTICAL ENGINEERING July/August 2011. 30-38

Non ideal stirring – non homogeneity • Before performance of scale up experiments

VisiMix simulation was used to check suspension at different Mini Pilot Reactors:

Reactor 7603 7605 7605 7607

Volume, L 10 25 25 50

RPM 500 (Max) 400 500 (Max) 150 (Max)

Main Characteristic

Liquid – Solid Mixing

Solid suspension quality

Complete suspension is questionable.

Partial settling of solid phase may

occur.

Complete suspension is

expected.

Complete suspension is

expected.

Complete suspension is questionable.

Partial settling of solid phase may

occur. Max. degree of non uniformity of solid

distribution

AXIAL, % 22.3 10.3 29.1 132

RADIAL, % 65.7 34.3 76.3 90.8

Not all Mini Pilot reactor are capable of full suspension of POCA.

Process parameters vs. constraints

Case Target Function Yield EOR [hr] Stirrer [rpm] TEMP [0C]

A

High demand to the product and the

reactor.

Yield →max, EOR≤8

98.1 8 546 26

B

The price of the product equals 10 times

the value of reactor availability.

(10∙yield-EOR)→max

98.4 8.3 623 25

C

High demand of the product with low

availability of reactors. One hour of

available reactor equals 10 times yield.

(1∙yield-10∙EOR)→max

95.2 1.5 483 39

D

High availability of reactors, High cost of

impurity purification.

(10∙yield-10∙IMAM-1∙EOR)→max

98.9 14.4 637 20

Bentolila, M., Kennet, R., “Scale-up Optimization Using Simulation Experiments,” presented at the American Institute of Chemical Engineers (AIChE), Palm Springs California, 11-16 June 2006.

Methodology

In the three years since the commencement of this process, their engineers achieved a high level of proficiency in the use of the simulation models in order to analyze the results as a function of the process operational parameters. After three years of working with this integrated plan – they have summarized their knowledge and experiences up to this point, as follows: 1. VisiMix products, when integrated in the validation process (up until they

achieved a stable process and confirmed the production) – helped to reduce the number of lost production batches (each batch valued in millions of dollars) - from 100 to just under 10 batches – (review slide 25)

2. VisiMix program used in conjunction with another simulation tool - as

reported in this presentation - contributed to the improvement of the teamwork style and professionalism. Net results were observed throughout the implementation of the new solution in better project development: EOR (end of reaction) time reductions, projects development time and cost reduction, and in addition - increasing the expertise and qualification level of the professional staff.

The presentation can be review on the Visimix Website in the References - Users Publications page. (Scale up optimization using simulation experiments-Chemagis

presentation) 02 16יוני

Methodology

16יוני 02

# produced lots needed until till a stable process is achieved

Productivity - Example

• Production Example

74

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76 ו"תשע/אייר/ה"כ

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Safety - Example

SECOND ORDER EXOTHERMAL REACTION IN A BATCH REACTOR

• This example shows how to simulate 2nd order exothermal reaction carried out in a stirred batch reactor.

• VisiMix performs simulation of exothermal reaction based on the analysis of the equipment and process parameters, and helps avoid runaway reaction that may take place when the energy generated by the reaction is greater than the energy removed from the reactor.

Process Safety Example

Problem description:

A second order irreversible reaction is carried out in a stirred batch reactor. This

reaction is run according to the stoichiometry

A + B C

The equation for the reaction rate is:

r = k CA CB

where

r is reaction rate, moles of A/(Lsec);

k is reaction rate constant, L/(molesec); CA is concentration of reactant A, mole/L; CB is concentration of reactant B, mole/L.

The reaction rate constant is a function of the system temperature and is given by

k = k0 e -E/RT

where

k0 is Arrhenius constant, L/(molesec);

E is energy of activation, kJ/mole;

R is gas law constant, J/(moleK); T is absolute temperature, K.

Results

Before Cooling Operation After Cooling Operation

VisiMix Products

VisiMix software:

• Based on advanced scientific knowledge and practical

expertise

• User-friendly and easy to operate

• Requires easily accessible initial data

The latest VisiMix products are:

• VisiMix 2K8 Turbulent

• VisiMix 2K8 Laminar

• VisiMix 2K8 Different Impellers

• VisiXcel- Data Base

• Pipe Line

• Rotor Stator Disperser – RSD

Introduction

NEW!

VisiMix Products

• VisiMix 2K8 Turbulent – for low-viscosity liquids and

multiphase systems.

The program provides process parameters necessary for

analysis, scaling-up and optimization of mixing tanks and

reactors with all types of impellers

VisiMix Software Products

Calculations of:

Blending

Suspension

Dissolution

Emulsification

Gas dispersion

Heat transfer

Chemical reactions

Mechanical stability of shafts

VisiMix Products

• VisiMix 2K8 Laminar - for highly viscous media

VisiMix Software Products

• pastes

• creams

• shampoos

• liquid soaps

• gels

• ointments

• paints:

• coatings

• slurries

• polymer solutions

Newtonian and non-Newtonian

Macro-scale blending

Micromixing in high-shear areas

Heat transfer

VisiMix Products

• VisiMix 2K8 Different Impellers – for combined mixing

devices

VisiMix Software Products

The program handles mixing devices consisting of any 2 – 5

impellers.

Different distances between impellers

Used in combination with VisiMix Turbulent.

Provides parameters of hydrodynamics, turbulence and heat

transfer.

VisiMix Products

•VisiMix VisiXcel – Data Base (DB) – automatic conversion tool:

Visimix Output to Excel Spreadsheet

•Integrates VisiMix report parameters in standard Excel worksheets

•Analysis VisiMix results in Excel

•Builds a Database of mixing tanks and reactors.

•Builds a Database of projects - for processes

•Makes correlation between plant equipment nomenclature to VisiMix

database of mixing tanks and reactors in VisiMix Project Database.

•Easy access to design data of the mixing tanks, to process

parameters and to corresponding results of VisiMix modelling.

•Results of VisiMix mathematical modelling in the VisiMix VisiXcel-DB

and arrange the data according to the reactor nomenclature.

• Easy access to recalculation of the VisiMix modelling from the

Database of the reactors & the projects

VisiMix Software Products

•VisiMix Pipe-Line

• Calculates hydraulic resistance of simple pipelines for liquid

viscosity and non-Newtonian products.

• Chemical engineers benefit from a quick and user friendly method

for charging times and the bottle-necks in the line.

• Includes : - Pipes - Riffled hoses – Elbows – Valves - And more

• Also comes with a database containing rheological constants for

the typical commercial non-Newtonian products - pastes, creams,

shampoos, paints, etc. (see Help Section for details)

• The first and only tool calculating flow resistance for liquids that

correspond to Carreau rheological model. (See Help Section for

details)

VisiMix Software Products

VisiMix Products

VisiMix Products

VisiMix Software Products

• VisiMix RSD (Rotor Stator Disperser)

The revolutionary new VisiMix RSD - Rotor Stator Disperser software is the first product of its kind that provides support for mixing devices for media subjected to high sheer stress: Based on 3 years dedicated research in a lab with dedicated equipment Works with all types of media - both high and low viscosity liquids, Newtonian and Non-Newtonian. Input geometrical data and process parameters and obtain fast and reliable results with one click VisiMix RSD enables you to quickly calculate · Shear rates and stresses in internal spaces · Pumping capacities

· Power consumption and torque

NEW!

VisiMix Orientation

The VisiMix Demonstration Tools:

VisiMix Demonstration Tools

VisiMix Turbulent – Examples & User Guide

VisiMix Laminar - Examples & User Guide

VisiMix Different Impellers – Examples & User Guide

VisiMix RSD– Examples & User Guide

VisiMix Turbulent SV – Trial & Education

VisiMix Review of Mathematical Models

Selected Verification Examples

The Comparison between Published Experimental Data and

VisiMix Calculations

http://www.visimix.com

Millions Saved By Using VisiMix! A Real Return On Investment (ROI).

VisiMix LTD, is pleased to provide you with some very important new information on VisiMix Savings, which we have compiled for publication. These documents, show savings of millions of dollars per year. Please click the links directly below to view the following savings examples: Mixing Calculations in Development (Saved - $1,000,000) Productivity Improvement In API Company (Saved - $1,600,000) RSD Application in a Chemical Reaction Process (Saved - $250,000) Control Morphology and P.S. in Energetic Material Processes (Saved - $900,000) Troubleshooting for Crystallization Processes (Saved $2,000,000) Troubleshooting in Life Science Industry (Saved €900,000) Three Phase System – Solid-Liquid-Liquid (Saved €1,200,000) Improve Dissolution of Organic Solid (Saved €1,200,000) Physical Properties of the Final Product (Solid) – Ensuring Regulatory Compliance of $20,000,000 Sales We also invite you to view some highlights from our very successful International Conference in Boston that took place in July 2011, which united users and future users of the VisiMix Software to share some insights into the various uses and benefits of the software.

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Conclusion Using VisiMix Products support you can

understand better your processes

Reduce dramatically your Scaling up processes and Scaling down

Save a huge amount of Time & Money ($1,000,000 +)

The VisiMix Products are friendly and easy to use with very quick results.

The VisiMix results are based on a systematic and seriously experimental checking – and found very reliable.

VisiMix Projects Parameters and Data Base allows you to share and transfer the data with colleagues in the company.

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If You Are Interested In Learning More

• India:

– Please call Dinesh Malviya at +91 9321024445

– e-mail Dinesh at dmalviya@helindia.com

• Mexico:

– Please call Ing. Vicente Cortes at +52 5555273838

– e-mail Ing. Cortez at cortes_v@mix-cor.com.mx

• Colombia

― Please call Leonardo Rodriguez +57 315 305 950

― e-mail lrodriguez@colfloequipos.com

If You Are Interested In Learning More

• VisiMix

– Spain and South America

• Aura Portman +972 547449423

• e-mail aurap@visimix.com

– Rest of the World

• Marcie Forrest +972-2-587-0123

• e-mail marcie@visimix.com

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Thank you for your attention