Numerical study of oil–water emulsion formation in stirred vessels: effect of impeller speed

The mixing of immiscible oil and water by a pitched blade turbine in cylindrical vessel is studied numerically. Three-dimensional simulations combined with hybrid front-tracking/level-set method are employed to capture the complex flow interfacial dynamics. A large eddy simulation approach, Lilly–Smagorinsky model, simulate turbulent two-phase dynamics at Reynolds numbers $Re=1802{-}18\ 026$ . numerical predictions validated against previous experimental work involving single-drop breakup stirred vessel. For small $Re$ , interface deformed but does not reach impeller hub, assuming instead shape Newton's Bucket. As rotating speed increases, deforming attaches hub which leads formation long ligaments that subsequently break up into droplets. largest studied, system becomes extremely wherein creation ligaments, their coalescence drops occur simultaneously. outcomes presented terms spatio-temporal evolution vortical structures. results drop size analysis number drops, distribution, also as parametric function