The core objectives of this work were to characterize and optimize the continuous-flow mixing of pseudoplastic fluids exhibiting yield stress in stirred reactors. To achieve these objectives, the effects of impeller type (for the seven axial-flow impellers A100, A200, A310, A315, A320, 3AH, and 3AM and the four radial-flow impellers R500, RSB, RT, and Scaba), impeller speed (50–800 rpm), impeller diameter (T/3.2–T/1.6, where T is the tank diameter), impeller off-bottom clearance (H/3.4–H/1.7, where H is the fluid height in the vessel), inlet and outlet locations (for the four configurations top inlet–top outlet, top inlet–bottom outlet, bottom inlet–bottom outlet, and bottom inlet–top outlet), pumping directions for axial-flow impellers (upward and downward pumping), fluid height in the vessel (T/1.06–T/0.83), residence time (257–328 s), and jet velocity (0.317–3.24 m s–1) on the dynamic performance of the mixing vessel were explored. To identify nonideal flows, dynamic tests were conducted using the frequency-modulated random binary input of a brine solution with the feed. The mixing quality in the vessel was substantially improved by increasing the impeller diameter, increasing the residence time, optimizing the impeller off-bottom clearance, decreasing the fluid height, optimizing the jet velocity, and using the up-pumping axial-flow impeller. Applying these findings will lead to improved quality of products and more efficient use of power in continuous-flow mixing of yield-pseudoplastic fluids.
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