Optimization of mixing in agitated reactors: A CFD-based approach for energy efficiency and dispersion in biphasic systems
Abstract
A Computational Fluid Dynamics (CFD) study was conducted to simulate the hydrodynamic behavior of a Norstone-type high-shear impeller operating in a stirred unbaffled tank containing a biphasic system (glycerin-hexane). A transient, multiphase Eulerian-Eulerian approach was implemented in ANSYS Fluent under laminar flow conditions. The model captured the formation of four distinct recirculation loops and identified zones of high-energy dissipation at the impeller blades, which are critical for the dispersion of the secondary phase. Experimental validation was conducted using temperature sensors (Max6675 thermocouples) connected to an Arduino Uno; good agreement between simulated and measured temperatures was observed. This work provides a validated CFD framework and fundamental insight into the flow dynamics, establishing a solid foundation for optimizing impeller geometry and operating conditions to achieve greater mixing homogeneity and energy efficiency in industrial biphasic systems.