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Liquid-liquid dispersion is prevalent in the chemical industries to create a larger interface between the phases that can intensify the chemical processes, such as liquid extractions and heterogeneous reactions. Oscillatory baffled columns (OBCs) have emerged as alternatives to conventional commercial columns in which external components apply an oscillating flow. A computational fluid dynamics (CFD) approach coupled with the factorial design of the experiment method was employed to study the effect of main geometrical and operational factors, including free baffle area (known asamplitude, and frequency along with their interactions on minimum droplet diameter (), maximum droplet diameter (), and Sauter mean diameter (). The ANOVA p-values showed that the interaction between frequency and all the other main factors was insignificant for all responses. In addition,did not have a significant impact on thein the system, and amplitude had the most substantial impact on all the responses (i.e.,and) among all the factors. It was found that the higher amplitude, higher frequency, and smallerresulted in smallerwhich can provide higher interfacial area, higher mass transfer, and higher reaction rate for the processes such as suspension polymerization and liquid-liquid extractions. In addition, the largerprovided a narrower range of droplets (which is of significance for polymerization processes. Mathematical models were also developed forandusing regression analysis with a reasonable level of accuracy. For the first time, semi-theoretical models were proposed forandin an OBC by combining the models existing in the literature forandand a quasi-steady-state model for energy dissipation rate in an OBC. The proposed models can be used to predict the parameters mentioned above by having geometrical and operational parameters, which help design suitable OBCs for a desired liquid-liquid dispersion system. A visual assessment of theand the dispersed phase volume fraction was also accomplished, showing larger droplets tended to be closer to the wall. Besides, a very uniform dispersed phase volume fraction throughout the OBC indicated the suitability of the column for such processes.

Liquid–liquid dispersion system in a moving baffle OBC: a numerical and theoretical study