During the scale-up study of a batch reactor, MELAMIN engineers needed to simulate the behavior of their design before proceeding with changes. The transport and mixing phenomena inside the reactor were simulated by SIMTEC, to examine the effectiveness of three different impeller configurations. The employed geometry included the rotating impeller with its shaft, the four baffles and the heat exchange spiral pipes. The injection of the tracer liquid and its subsequent mixing were simulated with the Multiple Reference Frame (MRF) method.

Valuable information was obtained for each configuration, regarding the reactor’s mixing capability, the required mixing time and the required rotation torque. Moreover, some strong local recirculating vortices were highlighted for several reactor configurations, which could cause severe mixing problems. The results indicated the best impeller design and provided the appropriate time for complete mixing. This enabled the company engineers to achieve a cheaper and safer decision process.