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<p>Within continuously and eccentrically stirred tanks, the correct prediction of fluid mixing behavior is strongly dependent on the resolution of highly complex, multi-scale hydrodynamic features. To address this challenge, this study adopts a high-fidelity computational fluid dynamics (CFD) framework, integrating the volume of fluid (VOF) method, a delayed detached-eddy simulation (DDES) turbulence model, the <i>Q</i>-criterion for vortex identification, and thermodynamic entropy production theory to analyze the multiphase flow of a urea-water mixture. A comparative performance evaluation between flat-blade and propeller impellers reveals that the flat-blade configuration yields superior mixing efficiency, as evidenced by lower mixing times and distinct torque profiles. Mechanistically, the flat-blade impeller generates more intense and persistent trailing vortices that enhance localized fluid entrainment and promote global macro-circulation. Furthermore, multi-scale modal analysis via proper orthogonal decomposition (POD) demonstrates that macromixing performance is predominantly governed by dominant, large-scale coherent flow structures. Ultimately, these insights clarify the interdependence between transient flow topology and mixing kinetics, offering actionable design criteria for optimizing high-performance, continuous eccentric agitation systems.</p>

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Influence of flow characteristics on mixing performance in continuous-operation eccentrically-stirred tank

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • San-xia Zhang,
  • Chun Xiang,
  • Jin Li,
  • Yi Sun,
  • Jun-hao Zhang,
  • Jun-hao Zhou,
  • Zhen-hua Duan,
  • Jing Ma

摘要

Within continuously and eccentrically stirred tanks, the correct prediction of fluid mixing behavior is strongly dependent on the resolution of highly complex, multi-scale hydrodynamic features. To address this challenge, this study adopts a high-fidelity computational fluid dynamics (CFD) framework, integrating the volume of fluid (VOF) method, a delayed detached-eddy simulation (DDES) turbulence model, the Q-criterion for vortex identification, and thermodynamic entropy production theory to analyze the multiphase flow of a urea-water mixture. A comparative performance evaluation between flat-blade and propeller impellers reveals that the flat-blade configuration yields superior mixing efficiency, as evidenced by lower mixing times and distinct torque profiles. Mechanistically, the flat-blade impeller generates more intense and persistent trailing vortices that enhance localized fluid entrainment and promote global macro-circulation. Furthermore, multi-scale modal analysis via proper orthogonal decomposition (POD) demonstrates that macromixing performance is predominantly governed by dominant, large-scale coherent flow structures. Ultimately, these insights clarify the interdependence between transient flow topology and mixing kinetics, offering actionable design criteria for optimizing high-performance, continuous eccentric agitation systems.