Enhancing liquid-solid mass transfer and achieving uniform particle dispersion using an in-line toothed high shear mixer

• HSMs is suitable for enhancing liquid-solid mass transfer, with the highest k LS reaching 15.63 × 10 −4 m/s. • Revealing the effect of operational conditions and structural parameters on k LS in HSM. • The spatial distribution of k LS in HSM was calculated and plotted via CFD simulation. • A dimensionless correlation of k LS was successfully developed and validated. The high shear mixer (HSM) is suitable for intensifying the liquid–solid mass transfer process, with a maximum mass transfer coefficient k LS of 15.63 × 10 −4 m/s. Furthermore, the particle motion and dispersion within HSM were captured, and their mechanistic influence was elucidated, which is essential for understanding the intrinsic correlation between particle dispersion behavior and mass transfer efficiency. The results indicate increasing the rotor speed significantly enhance the mass transfer. Increasing the rotor speed improves particle dispersion uniformity, and the subsequently enhanced mechanical effects of HSM facilitate the deformation and elongation of large particles. Both effects contribute to enhancing mass transfer of large particles. The effects of rotor and stator slotting ratio on k LS were also revealed. Based on the power-law correlation established in this study between k LS and the turbulent energy dissipation rate ( ε ), the spatial distribution of k LS was accurately predicted through CFD simulations, thereby providing an auxiliary tool for understanding the liquid–solid mass transfer in mixing systems. HSMs are anticipated to emerge as promising devices for intensifying liquid–solid heterogeneous processes, owing to their exceptional interphase mass transfer efficiency and capability to attain rapid yet homogeneous particle dispersion. Finally, key factors were systematically analyzed and identified, leading to the establishment of Sh LS dimensionless correlation that effectively guides HSM selection and application.