The influence of feeding conditions on outlet drop sizes, dense-packed zone, and separation efficiency of a liquid-liquid gravity separator was investigated experimentally. A continuously stirred tank was used to adjust the inlet drop size independent of other feeding conditions, such as flow rate and dispersed phase fraction. The inlet drop size, thereby, is one of the key parameters determining separation efficiency. The outlet drop size was, for the first time, studied in detail and showed a strong association with separation efficiency. The dimension and shape of the dense-packed zone in the separator were determined. With rising inlet drop sizes, a morphological transition of the dense-packed zone from full-length to a trapezoidal shape, wedge shape, and eventually to its complete disappearance was observed. The critical outlet drop sizes were determined with four sedimentation models as a function of feeding conditions, and optimal feeding conditions of the separator were identified.
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