Comparison of flow characteristics in a bench-scale system with commercial-scale pipelines: Use of computational fluid dynamics (CFD).

The challenges for scale-up are often encountered in cleaning operations during the interpretation of data from clean-in-place (CIP) research. The objective of this investigation was to design and characterize flow characteristics in a bench-scale system in a manner that evaluates scale-up to a commercial-scale CIP operation. A bench-scale temperature-controlled vessel was designed for evaluation of in-place cleaning, and for development of scale-up parameters. The wall shear stress was selected as the parameter for the comparison, as it is the significant parameter associated with deposit removal. Using the traditional prediction models, the wall shear stress of bench-scale ranged 0.015 to 4.99 Pa with impeller speeds from 50 to 900 rpm. For the commercial-scale with 0.022 m of inside diameter, prediction ranged from 1.43 to 7.90 Pa with the mean fluid velocity from 0.72 to 1.67 m/s. Computational fluid dynamics (CFD) was used to predict wall shear stress on the surfaces within the bench-scale and commercial-scale systems. The predicted wall shear stress values ranged from 0.016 to 2.42 Pa for surfaces within the bench-scale system, and from 1.33 to 7.20 Pa for the commercial-scale system. The differences between two calculation methods are attributed to the averaging the magnitude over the whole area and the overestimation of friction coefficients employed in the traditional prediction. The results confirm that CFD provided more reliable wall shear stress estimates for surfaces of interest. The wall shear stress estimates for a bench-scale compare favorably to estimates for a commercial-scale pie section in a CIP system. PRACTICAL APPLICATION: The current investigation demonstrates that the computational fluid dynamics (CFD) simulation provides accurate estimates for the scale-up parameters. Both academic and industrial researchers will benefit from the proposed methodologies to compare the flow properties of the bench-scale and commercial-scale CIP operation that facilitate the practical implementation of the systems.