Finite‐element simulation of mixing: 2. Three‐dimensional flow through a kenics mixer

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Abstract
Numerical tools for the analysis of complex 3‐D mixing devices were developed. Calculations are based on the finite‐element method. The flow calculation is combined with that of pathlines for a fairly large number of material points; along these pathlines, relevant kinematic variables, which are then subjected to a statistical treatment, are evaluated. These numerical techniques are applied to the analysis of a Kenics mixer. It is assumed that the geometry is periodic in the axial direction, that is, that the mixer contains an infinite number of blades; the finite‐element analysis may then be completed on a single wavelength of the geometry. To test the accuracy of the three‐dimensional calculation, a Kenics device was mounted in order to mix clays of different colors, and photographs of experimental cross‐sections were compared with numerical results showing concentration maps. A statistical treatment was performed on some 8,000 material points crossing the entry section to evaluate mixing quality.