The complex fluid flow in a large-scale tank stirred with multiple Ekato Intermig impellers used in the seed precipitation process was numerically analyzed by the computational fluid dynamics method. The flow field, liquid-solid mixing, and power consumption were simulated by adopting the Eulerian granular multiphase model and standard k-epsilon turbulence model. A steady multiple reference frame approach was used to represent impeller rotation. The simulated results showed that the five-stage multiple Intermig impeller coupled with sloped baffles could generate circulation loops in axial, which is good for solid uniform mixing. The fluid is overmixed under the current industrial condition. Compared with the current process conditions, a three-stage impeller with L/D of 1.25 not only could meet the industrial requirements, but also more than 20% power could be saved. The results have important implications for reliable design and optimal performance for industry.
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