Fundamental approach to the design and optimization of static mixers

Mixing in the Kenics static mixer is optimized using computational analysis and theoretical concepts. A total of 54 cases were examined to consider the effect of mixer geometry and inertia on flow and mixing performance. The effect of varying the standard geometry is discussed for a broad range of Reynolds numbers. While only the twist angle affects performance at low flow rates (Re≅1), both the element aspect ratio and the twist angle are shown to be important at high flow rates (Re⩽1,000). The energetic mixing efficiency decreases with increasing flow rate. Finally, a quality‐driven design method is developed based on stretching calculations, and is illustrated for the standard mixer design.