(550a) You Can Observe a Lot Just by Watching: Industrial Problem Solving Via Physical Modeling and Flow Visualization

Physical modeling and flow visualization experiments are used extensively in The Dow Chemical Company to solve manufacturing problems.

A single industrial flow problem can cover a multitude of length and time scales that require consideration. Process intensification has led to complicated geometries and a variety of multiphase and reacting flow problems, and hence the experimental techniques must enable the study of more and more complex systems. At the same time, the rapid timelines required in solving industrial flow problems often require the use of grossly simplified experiments that nevertheless give crucial insight for problem-solvers.

Industrial flows cover many geometries, from stirred tanks to inline mixing devices to reaction injection molding (RIM) devices to flow atomizers to name a few. In some cases, careful geometric scale-down to the lab or pilot scale is necessary for visualization, while in other cases geometric similarity is unnecessary. In still other cases, only full scale testing can be trusted. Performing the appropriate experiment is a crucial element of success.

This presentation uses real examples to illustrate how flow visualization techniques such as laser diagnostics and video imaging methodologies have been used effectively for value creation at Dow.