Experimental and computational investigation of chaotic advection mixing in laminar rectangular stirred tanks

Abstract

The phenomenon of chaotic advection mixing in laminar stirred tanks, particularly when handling high-viscosity fluids, represents a common and challenging issue in various chemical and biochemical industrial processes. The effectiveness of these mixing processes is often constrained by the stretching, folding, and squeezing of fluid particles. Previous research efforts have predominantly concentrated on the design and/or optimization of impellers and operation modes to increase the stretching and folding of fluid particles. However, the mechanism of triggering chaos through the squeezing of fluid particles remains comparatively less explored. This study endeavors to address the intricate problem of laminar mixing by proposing the utilization of unbaffled rectangular stirred tanks. Via a combined approach of experimental and computational investigations, we illustrate that the implementation of rectangular stirred tanks yields significant improvements in chaotic mixing within laminar flow regimes. This type of tank not only enhances the convective transport of fluids but also distorts or completely eliminates the segregation regions by squeezing. Remarkably, as the tank L/W ratio increases from 1 to 2.5, the observed asymptotic area coverage from a frontal perspective escalates from approximately 55 % to about 85 %. Concurrently, the dimensionless mixing time decreased significantly from 1950 to 350. Of particular note, macroscopic homogeneous mixing is observed in stirred tanks with L/W ratios of 2 and 2.5 at Re = 29, with dimensionless mixing times of 550 and 350, respectively. This work highlights the potential of rectangular stirred tanks as a simple and cost-effective system for laminar mixing applications. Furthermore, it also hints at the broader applicability of the approach in various industrial mixing contexts, such as the suspension of floating granules, entrainment of air, and others.