Mixing of liquids is a common procedure in several applications and it either stands as an intermediate step or one of the process itself in various industries. The objective of these processes is to deliver well mixed liquid. In general, either batch or continuous type mixers are used depending on the application and need, and mixing itself is propelled by fitted impellers, moving surfaces, baffles, etc. Though it is a simple process, there exists always several challenges like what is the appropriate mixing time, dynamics of mixing, how does the mixing change when impeller speed is reduced or increased, what is the impact of existing baffles, how does the liquid properties such as viscosity, density affect the mixing, etc. are interesting to consider during process development. Once any these factors are missed, it may lead to inadequate product quality, etc. To address these challenges, CFD simulations with exact geometry of mixer can be carried out to predict unforeseen events as listed above. With this physics-based approach, it is possible to establish a reliable and reproducible process. With the advances gained in terms of turbulent flow models, it is possible to predict, thereby utilize and operate the mixer at its upside of its process parameters while not compromising on the quality.

Computational fluid dynamics (CFD) model has been developed to predict the effect of different physical parameters including temperature and density on the mixing characteristics of the system.

Also, it is possible to evaluate complex geometry of impellers and its rotation position (centered vs off-centered) can be predicted accurately.