Numerical simulation study of mixing efficiency in a T‐tube mixer and analysis of its competitive mechanism with yield

Abstract In this study, a numerical simulation model was developed to investigate the regulation mechanism of liquid–liquid homogeneous mixing efficiency in a T‐shaped tube mixer (TTM) using computational fluid dynamics (CFD). By systematically analyzing the effects of geometric parameters (length‐to‐diameter ratio L / D ) and flow conditions (Reynolds number Re and flow rate ratio R v ) through simulations, key findings revealed that increasing length‐to‐diameter ratio, decreasing Reynolds number and elevating flow rate ratio significantly enhance mixing efficiency. The mixing index improved from 0.45 to 0.85 as length‐to‐diameter ratio increased from 5 to 60 (at pipe diameter = 5 mm, Reynolds number = 6000) while mixing index decreased from 0.625 to 0.575 when Reynolds number rose from 2000 to 6000 (at length‐to‐diameter ratio = 10). An empirical formula for mixing efficiency was derived through data fitting. In addition, a competitive mechanism between mixing efficiency and yield was found, which is important for guiding the mixing efficiency regulation of liquid–liquid homogeneous reaction in continuous flow reactors. In addition, three structural optimizations were carried out for TTM. After comparing mixing index and pressure drop, TTM‐3SBS was ultimately selected. Compared with the TTM, the mixing index of TTM‐3SBS has increased by 102.2%, and the pressure drop is lower than that of other structures. The results provide a theoretical basis for optimizing the reactor design and improving the chemical reaction efficiency.