Mixers

Multiphase mixing processes in stirred vessels where hydrodynamics, turbulence, and phase interaction govern efficiency, separation performance, and scale-up in chemical and process industries

Technical capabilities in MPflow

MPflow provides advanced CFD tools for simulating mixing processes in mechanically agitated systems, including complex multiphase interactions and turbulence-driven transport.

  • Dedicated solvers for rotating machinery and impeller-driven flows
  • Support for multiphase systems (liquid–liquid, gas–liquid) and phase separation
  • Accurate modelling of turbulence, recirculation zones, and vortex structures
  • Capability to simulate baffles, impeller geometries, and vessel internals
  • Fully compatible with OpenFOAM libraries for flexible workflows
  • Prediction of mixing time, phase distribution, and separation efficiency

Our CFD approach

We use high-fidelity CFD to resolve the complex hydrodynamics governing mixing and separation in industrial vessels.

  • Detailed resolution of flow patterns, circulation loops, and dead zones
  • Quantification of turbulence intensity and energy dissipation rates
  • Analysis of baffle configurations and impeller design impact
  • Prediction of phase distribution and separation characteristics
  • Simulation across operating conditions (rotation speed, inlet velocity, fluid properties)

Physics-based ML acceleration

Physics-aware machine learning enhances CFD by accelerating predictions and enabling rapid exploration of mixer configurations.

  • ML models trained on CFD-generated hydrodynamic fields and experimental data
  • Fast prediction of flow structures, mixing efficiency, and phase separation
  • On-the-fly deployment for turbulence modelling and source-term approximation
  • Rapid evaluation of design variations (impeller type, baffle number, geometry)
  • Generalisation across operating conditions and fluid systems

Why ML-CFD matters for Mixers

  • Up to 7000× faster predictions → rapid evaluation of mixer configurations and operating conditions
  • 4–7× acceleration with ML-enhanced turbulence modelling, supporting all standard RANS and LES models
  • <7% deviation from CFD in flow patterns, mixing time, and phase distribution in full 3D systems
  • Instant design exploration across impeller types, baffle configurations, and vessel geometries
  • Optimises mixing efficiency and separation performance
  • Reduces experimental effort and scale-up costs in industrial process design