CFD modeling of emulsions inside static mixers

Emulsification carried out in continuous devices offers a series of advantages over batch emulsion, such as better control of the droplet size distribution, reduced volume equipment, and lower operative costs. This paper investigates through Computational Fluid Dynamics simulations the emulsification process inside Sulzer Static Mixers. An analysis aimed to identify the most appropriate turbulence model, from a practical point of view, was performed, finding that the realizable Kappa – Epsilon model is more suitable than the well-known Kappa - Omega model. Moreover, an operative correlation linking the Sauter diameter to the main operating parameters, in a wide range of fluid properties and operating conditions, was developed.