Geometric optimization of Kenics-type static mixers: numerical analysis of thermal and dynamic performance

Static mixers play an important role in industry by facilitating mixing and heat transfer processes. This study investigates the effect of geometry on the thermal and dynamic performance of a Kenics-type static mixer by examining four different configurations. Numerical simulations using Fluent.20 software were used to analyze parameters such as Reynolds number (ranging from 0.1 to 80), pressure drop, shear rate, fluid temperature, and Nusselt number. The results highlight the critical importance of geometry in fluid dynamics, which affects thermal performance. Among the configurations studied, the third case, characterized by three cavities occupying the entire length of the helix, proved to be the most efficient. This research thus provides valuable insights into the dynamic and thermal characteristics of kinetic static mixers, underscoring the critical importance of geometry in optimizing overall performance. What's more, this performance improvement can be observed at different Reynolds numbers, resulting in improved mixing efficiency and reduced pressure losses. This study shows that the third geometric configuration outperforms the other proposed mixers, with a performance improvement of 99%.