Power Consumption and Rubber Phase Evolution in an Intermeshing Mixer: A Three-Dimensional Non-Newtonian Volume-of-Fluid Computational Fluid Dynamics Analysis

This study investigates the influence of key operating parameters of fill factor, rotor speed, and rotor wear on the power consumption of an isothermal intermeshing internal mixer. A three-dimensional computational fluid dynamics (CFD) model incorporating dynamic remeshing was developed using the finite volume method to solve the continuity and momentum equations for non-Newtonian rubber flow. The dynamic remeshing approach enabled accurate tracking of the moving rotor geometry and maintained mesh quality under varying operating conditions. The model integrates the actual mixer geometry and rheological properties of the rubber, and was validated against plant-scale power consumption data, showing good agreement. Simulations were performed across a range of operating conditions to quantify the effects of each parameter. Results indicate that increasing the fill factor from 50% to 82% raises normalized power from 14–19 kW/% to 17–22 kW/%, with higher levels producing extensive shear stress coverage to the rotor barrels but at the cost of potential clogging and reduced energy efficiency. Increasing rotor speed from 35 to 60 rpm increases normalized power from 20–22 kW/rpm to 22–23 kW/rpm, as higher rotor speeds intensify the local shear stress and strain rate fields near the rotor tips, thereby increasing power consumption. Rotor wear was found to significantly influence power consumption, with increasing wear leading to a progressive reduction in energy demand. The results indicate that worn rotor conditions reduce mechanical energy transfer due to diminished rotor–material interaction and increased clearances, resulting in lower shear stress generation within the mixing chamber. These findings identify operational windows that minimize energy costs while maintaining effective wall shear stress, offering practical guidance for optimizing mixer performance.