Comparison through a CFD approach of static mixers in an emulsification process

Emulsions, characterized by droplet dispersions of immiscible liquids in a continuous phase, are often found in many diverse fields of the chemical industry. The energy needed to break these droplets can be sourced from mechanical agitators in stirred tanks, active mixers like pulse-flow mixers, and ultrasonic mixers. However, static mixers serve as a convenient alternative due to their typically lower maintenance costs and increased resistance to failures. Static mixers are available in diverse shapes and dimensions, with two widely used types being the Kenics Static Mixers and the Sulzer Static Mixers. While these two static mixers have been extensively studied in the literature in terms of pressure drop and mixing efficiency, to the best of the authors’ knowledge there is no study comparing the two in emulsification processes. This work aims to compare the performance of these static mixers in the production of emulsions by employing a Computational Fluid Dynamics approach. Results showed that the Sulzer Static Mixers allow to obtain higher values of turbulent energy dissipation, which in turn leads to smaller droplet diameters.