Numerical investigation of mixing performance in a curved‐sheet typed static mixer with symmetrical folded blades

Abstract BACKGROUND Mixing is one of the most important unit operations in process industries. Owing to the low energy consumption and high continuity, static mixers are widely used in chemical and biochemical industries. The structure of static mixers determines the flow pattern within the device, which directly influences the mixing performance. Therefore, optimizing the geometry of mixing elements is critical for enhancing mixing efficiency. This study proposes a novel curved‐sheet typed static mixer with symmetrical folded blades (CSFB) and investigates its mixing performance using computational fluid dynamics (CFD). RESULTS The CSFB static mixer with six mixing elements achieved a mixedness of 99.5% at an inlet Reynolds number (Re in ) of 2500. Its distributive and dispersive mixing performance outperformed the Kenics, LPD and Komax static mixers. The CSFB static mixer achieved complete homogeneity within a shorter distance than the other static mixers. Additionally, the flow resistance of the CSFB mixer was lower than that of a high‐mixing performance CBF static mixer with asymmetrically arranged blades. CONCLUSION The multiblade structure of the CSFB mixing element enhanced radial flow and promoted the rapid mixing of fluids. The perforated blades reduced pressure drop by minimizing the collision between the fluid and blades. Compared with the previously reported high‐mixing performance CBF static mixer with asymmetric blades, the CSFB static mixer achieved complete mixing at a lower pressure drop. © 2025 Society of Chemical Industry (SCI).