CFD Simulation of a High Shear Mixer for Industrial AdBlue® Production

The increasing global demand for cleaner transportation has intensified the importance of efficient AdBlue® (AUS32) production, a key chemical in selective catalytic reduction (SCR) systems that reduces nitrogen oxides (NOx) emissions from diesel engines. This work presents a computational fluid dynamics (CFD) simulation study of the urea–water mixing process within a high shear mixer (HSM), aiming to enhance the sustainability of AdBlue® manufacturing. The model evaluates the hydrodynamic characteristics critical to optimising the dissolution of urea pellets in deionised water, which conventionally requires significant preheating. Experimental validation was conducted by comparing pressure drop simulation results with operational data from an active industrial facility in the United Kingdom. Therefore, this study validates the CFD model against an industrial two-stage Rotor–stator under real operating conditions. The computational framework combines a refined mesh with the k-ω SST turbulent model to resolve flow structures and capture near-wall effects and shear stress transport in complex flow domains. The results reveal opportunities for process optimisation, particularly in reducing thermal energy input without compromising solubility, thus offering a more sustainable pathway for AdBlue® production. The main contribution of this work is to close existing gaps in industrial practice and propose and computationally validate strategies to improve the numerical design of HSM for solid dissolution.