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<p>Mixing equipment is critical in the chemical and energy industries, directly affecting mixing time, reducing power, and specific mixing energy per unit volume. This study applied computational fluid dynamics to examine flow and mixing in a dual-impeller reactor with fluids of varying viscosities. Four impeller combinations were evaluated based on flow patterns, tracer dispersion, mixing time, and single-exponential decay model. Under low-viscosity conditions, RT-DBOT (Rushton Turbine with Disk-Blade Open Turbine) reduces the mixing time by only 3.9% relative to PBT-RT (Pitched-Blade Turbine with Rushton Turbine), whereas PBT-RT lowers the specific mixing energy <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\({W}_{r}\)</EquationSource> </InlineEquation> by 7.1% and the power by 11.3% compared with RT-DBOT, indicating a more favorable energy-performance trade-off. Under medium-to-high viscosity, BCBDT-RT (Backward-Curved Blade Disk Turbine with Rushton Turbine) achieves a mixing time about 6% shorter than PBT-BCBDT (Pitched-Blade Turbine with Backward-Curved Blade Disk Turbine) and reduces <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\({W}_{r}\)</EquationSource> </InlineEquation> by 1.6%, indicating a more favorable time and energy balance. Based on mixing time and specific mixing energy, PBT-RT is the optimal configuration for low-viscosity fluids, whereas BCBDT-RT is the optimal configuration for medium-to-high-viscosity fluids. Meanwhile, the exponential decay model validated the simulation results and clarified inter-impeller synergy, providing practical guidance for energy and efficient mixing across fluids with different viscosities.</p>

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Evaluation of mixing effects in dual impeller reactors through computational fluid dynamics and an exponential decay model

  • 期刊论文

  • 发表日期：

    2026年4月18日

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  • Wenbo Shi,
  • Hui Sun,
  • Jianwei Zhang,
  • Jianxin Xu,
  • Hua Wang

摘要

Mixing equipment is critical in the chemical and energy industries, directly affecting mixing time, reducing power, and specific mixing energy per unit volume. This study applied computational fluid dynamics to examine flow and mixing in a dual-impeller reactor with fluids of varying viscosities. Four impeller combinations were evaluated based on flow patterns, tracer dispersion, mixing time, and single-exponential decay model. Under low-viscosity conditions, RT-DBOT (Rushton Turbine with Disk-Blade Open Turbine) reduces the mixing time by only 3.9% relative to PBT-RT (Pitched-Blade Turbine with Rushton Turbine), whereas PBT-RT lowers the specific mixing energy \({W}_{r}\) by 7.1% and the power by 11.3% compared with RT-DBOT, indicating a more favorable energy-performance trade-off. Under medium-to-high viscosity, BCBDT-RT (Backward-Curved Blade Disk Turbine with Rushton Turbine) achieves a mixing time about 6% shorter than PBT-BCBDT (Pitched-Blade Turbine with Backward-Curved Blade Disk Turbine) and reduces \({W}_{r}\) by 1.6%, indicating a more favorable time and energy balance. Based on mixing time and specific mixing energy, PBT-RT is the optimal configuration for low-viscosity fluids, whereas BCBDT-RT is the optimal configuration for medium-to-high-viscosity fluids. Meanwhile, the exponential decay model validated the simulation results and clarified inter-impeller synergy, providing practical guidance for energy and efficient mixing across fluids with different viscosities.