(6ja) Innovating Multiphase Contactor Design with Advanced Experimental and Simulation Tools

Research Interests:

Multiphase flows are encountered in most of the chemical, biological and energy generation processes. By using state-of-the-art experimental techniques in conjunction with high performance computer modeling enables process innovation to increase profit while reducing the environmental impact of the process. For example, optimization of flow pattern has resulted into reduction of the two phase contactor volume at least 10 folds for same throughput. My philosophy is to use combined CFD/experimental approach to rigorously validate the CFD model with subsequent use of CFD to achieve design objective. Main advantage of such approach is savings in terms of cost of new device development without compromising the reliability of the design. I have applied such approach to a wide range of equipment size from micro-fluidized bed to large scale methane fermentation reactor.

Successful Proposals: 

• High performance computing: 2000000 SU (processor hours) granted on LSU HPC (Supermike II and SuperMIC), 2000000 SU granted on LONI clusters (QueenBee 2).
• University of Newcastle postdoctoral fellowship, Australia. 3 year award, AUD $87878 per annum.
• Faculty strategic pilot grant (AUD $14600), ‘Flotation in fluidized bed with turbulence tuning particles’ (Mayur Sathe).
• Startup grant (AUD $10000), ‘Aeration of High Solids Concentration Wastewater Streams’, (Geoffrey Evans, Elham Doroodchi, Mayur Sathe).

Postdoctoral Project:  “Advanced velocimetry in turbulent two and three phase flow.”

Under supervision of Geoffrey Evans (Chemical Engineering, University of Newcastle, Australia).

PhD Dissertation:  “Development of Experimental Techniques and CFD Simulations of Multiphase Dispersions.” Under supervision of J. B. Joshi (Institute of Chemical Technology, Mumbai, India) & B. D. Kulkarni (National chemical laboratory, Pune, India)

Research Experience:

My research work is balance of experimental and numerical study of multiphase systems. Multiphase flows are unique since the medium is discontinuous yet fluid. I probed multiphase dispersions with advanced experimental techniques like Particle Image velocimetry, Laser Doppler Anemometry, Hot film anemometry and Phase Doppler Particle analyzer. I customized these instruments using in-house electronics and software to adapt them for measurements considered beyond the range of these instruments. The experimental program was parallel to CFD simulations, providing better insight into transport phenomena in multiphase equipment. So far, I have worked on all combinations of gas, liquid and solid phases. As Research scientist, my current principle project at LSU is design of a novel bioreactor for fermentation of stray methane to liquid products (ARPAE-REMOTE program). The project budget is $4000000. I am involved with CFD modeling and coming up with innovative designs to exceed the ARPA-E targets. I am also involved with experimental studies which are primarily located at City College, New York. As IT consultant at CCT, LSU I am involved with use of supercomputing resources for applications relevant to chemical industry. I am a part of EPIC (Enabling Process Innovation through Computation) consortium. Under the aegis of EPIC, I have worked to use CFD tools like Ansys FLUENT and OpenFOAM to solve problems of industrial as well as fundamental interest.

 Teaching Experience:

I am currently mentoring 7 PhD students at University of Newcastle as PhD co-supervisor. I am mentoring 4 PhD students at Louisiana state university. I have taught “Green Engineering” (UG course, with Geoffrey Evans) and “Advanced Particle Processing II” (PG course).

Future Direction:

As a faculty I would like to continue using experiments and simulation for process intensification in chemical as well as in other industries.  In particular I would like to optimize the turbulence generation in multiphase contactors. The turbulent motion of fluid enhances transport processes. It also enhances viscous dissipation of energy. To maximize ‘bang for the buck’ the energy must be provided at right length scale, right intensity and at right location. While micro reactors offered a solution which met such criteria, they are not economical at industrial scale. I would like to design decimeter scale devices which facilitate mass, heat and momentum transport via carefully tuned turbulence. I would like to demonstrate the use of homogeneous, tunable turbulence to achieve unsurpassed energy efficiency for multiphase process. To achieve this, I would work to make a balanced experimental and computational research group. I would collaborate with people in Petroleum engineering, Bioengineering, mineral engineering and mechanical engineering to make the working prototypes of multiphase contactors for industries including chemical, biological, petroleum, energy, water processing and agriculture. 

Selected Publications: (total number-29)

1. 1.         Sathe, M. J., Thaker, I. H., Strand, T. E. and Joshi, J. B., 2010. Advanced PIV/LIF and Shadowgraphy System to Visualize Flow Structure in Two-Phase Bubbly Flows. Chemical Engineering Science, 65 (8), 2431-2442.
2. 2.         Sathe, M. J., Deshmukh, S. S., Joshi, J. B. and Koganti, S. B., 2010. Computational fluid dynamics simulation and experimental investigation: Study of two-phase liquid-liquid flow in a vertical Taylor-couette contactor. Industrial and Engineering Chemistry Research, 49 (1), 14-28.
3. 3.         Sathe, M. J., Mathpati, C. S., Deshpande, S.S., Khan, Z., Ekambara, K. and Joshi, J. B., 2011. Investigation of flow structures and transport phenomena in bubble columns using particle image velocimetry and miniature pressure sensors. Chemical Engineering Science, 66 (14), 3087-3107.
4. 4.         Sathe, M., Joshi, J., Evans, G., 2013. Characterization of turbulence in rectangular bubble column. Chemical Engineering Science, 100, 52-68.
5. 5.         Deshmukh, S. S., Sathe, M. J., Joshi, J. B. and Koganti, S. B., 2009. Residence Time Distribution and Flow Patterns in the Single Phase, Annular Region of Annular Centrifugal Extractor. Industrial and Engineering Chemistry Research, 48 (1), 37–46.
6. 6.         Tabib, M. V., Sathe, M. J., Deshpande, S. S. and Joshi, J. B., 2009. A Hybridized Snapshot Proper Orthogonal Decomposition-Discrete Wavelet Transform Technique for the Analysis of Flow Structures and Their Time Evolution. Chemical Engineering Science, 64 (21), 4319-4340.
7. 7.         Mitra, S., Sathe, M.J., Doroodchi, E., Utikar, R., Shah, M.K., Pareek, V., Joshi, J.B., Evans, G.M., 2013. Droplet impact dynamics on a spherical particle. Chemical Engineering Science, 100, 105-119.
8. 8.         Doroodchi, E., Sathe, M., Evans, G., Moghtaderi, B. 2013. Liquid-liquid mixing using micro-fluidised beds. Chemical Engineering Research and Design, 91(11), 2235-2242.
9. 9.         Hoque, M. M., Sathe, M. J., Mitra, S., Joshi, J. B., Evans, G. M., 2015. Comparison of specific energy dissipation rate calculation methodologies utilising 2D PIV velocity measurement. Chemical Engineering Science, 137, 752-767.