-Overview

-CFD Simulation Approach

-Research aspects

-What is included in the simulation package 

-Package Costing

-Add Ons

In a Chemical Mixer CFD (Computational Fluid Dynamics) Simulation, the flow behavior of fluids (liquids, gases, or multiphase systems) inside a mixer is analyzed. This helps to understand how the substances interact with each other, how well they mix, and how different design or operational parameters influence the process. 

Such chemical mixers are used in Pharmaceutical Industry, Food & Beverage, Fertilizers, Oil and Gas and Biotechnology industries.

Common Challenges in Chemical Mixer CFD

• High computational cost: CFD simulations, especially with complex turbulence and multiphase flows, can be computationally expensive.
• Mesh Refinement: Achieving an adequate mesh resolution, especially near moving parts (like the impeller) or walls, is essential to accurately capture flow patterns and mixing behavior.
• Modelling multiphase Systems: Handling systems with multiple phases (e.g., gas-liquid or liquid-liquid) often requires complex models and accurate interfacial interaction models.
• Chemical reactions: For reactive mixing, accurate kinetic models need to be incorporated, adding another layer of complexity.

- Water and air fluids are studying the mixing pattern due to the impeller blades

- Multiphase simulation with Mixture model

- Surface tension effects considered

- Gravity effects included 

- Mesh refinement in local regions near the impeller blades to capture the mixing 

- Processing of results using contours,streamlines,residence time distribution & fluid mixing animations

Key Objectives of a CFD Simulation for Chemical Mixing are as below:

1. Flow distribution: Ensuring uniform flow and optimal distribution of fluids across the mixer.

2. Mixing efficiency: Evaluating how well different components (such as reactants, solvents, or catalysts) are mixed in the system.

3. Residence Time Distribution (RTD): Understanding how long fluids spend in different regions of the mixer and whether the flow is ideal or there are regions of stagnation.

4. Design optimization: Identifying key design parameters (e.g., impeller speed, baffle configuration, and mixer geometry) to improve mixing efficiency and process throughput.

- 3D cleaned CAD model of the mixing tank assembly with mixer blades as shown in images

- Ansys Fluent Mesh file of the mixer tank

- Step by step procedure for simulation setup and result processing of a baseline case

- Online technical support for any help related to using this package and conducting the simulations

The package includes the files of a baseline case of the provided CAD model. User can easily change any parameters in the geometry and/or operating conditions to run the simulations for any desired conditions. Assistance will be provided to carry out such simulations.

Add Ons: 

Below are few additional services that can be combined with the above package

1. Online training on Geometry preparation, Meshing, Solving & result processing – INR 6000 + GST (18%) 

2. Case and data files – INR 3,000 + GST (18%)

Contact Us for purchasing this CFD package.