Numerical Simulation of Low-Pressure Drop Static Mixers for Mixing Enhancement

Static Mixers (SM), also generally known as inline mixers, form a newly developing industry trend. They have no moving parts, hence have lower energy consumption, lower installation cost, and very low maintenance cost, and are thus an attractive alternative to conventional agitators. Modifications were made to the design to reduce pressure drop and increase the mixing intensity across the mixer and increase the application of inline mixers in the industries. Three hybrid geometries (different combinations of Kenics and LPD) of static mixers were constructed and simulated using Computational Fluid Dynamics (CFD) tools. Kenics is an excellent radial mixing device, and Low-Pressure Drop (LPD) is an excellent axial mixing device. The key design parameter to modify LPD was the slope angle of elliptical plates which affects the mixer performance. Different slope angles from 90º to 120º were simulated. Kenics was modified for different aspect ratios, and the edge of Kenics was curved. Pressure drop, thermal, and Discrete Phase Model (DPM) analysis were performed on these three different classifications of hybrid geometries. The most promising geometry to emerge based on the low-pressure drop and good mixing efficiency was the curved edge Kenics. Keen-sighted these results, further analysis was performed on curved edge Kenics after the modification of the blend radius. It was concluded that for a lower Reynold number, the curved edge with a higher blend radius dominates all other mixers. Result validation was done by comparing the trends and sensitivity of process variables with the established results and standards.