Many processing applications call for the addition of small quantities of chemicals to working fluid. Hence, fluid mixing plays a critical role in the success or failure of these processes. An optimal combination of turbulent dispersion down to eddies of the Kolmogoroff scale and molecular diffusion would yield fast mixing on a molecular scale which in turn favors the desired reactions. Helical static mixers can be used for those applications. The range of practical flow Reynolds numbers for these mixers in industry is usually from very small (Re ∼ 0) to moderate values (Re ∼ 5000). In this study, a helical static mixer is investigated numerically using Lagrangian methods to characterize mixer performance under turbulent flow regime conditions. A numerical simulation of turbulent flows in helical static mixers is employed. The model solves the three-dimensional, Reynolds-averaged Navier-Stokes equations, closed with the Spalart-Allmaras turbulence model, using a second-order-accurate finite-volume numerical method. Numerical simulations are carried out for a six-element mixer, and the computed results are analyzed to elucidate the complex, three-dimensional features of the flow. Using a variety of predictive tools, mixing results are obtained and the performance of static mixer under turbulent flow condition is studied.

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