Direct numerical simulations of liquid-liquid dispersions in a SMX mixer under different inlet conditions

The internal dynamics of static mixers handling liquid-liquid flows have been comprehensively explored over the past decade. Although the effect of the inlet configuration is often overlooked, a few studies have suggested a relationship between the phases' initial set-up and the performance of the mixer in terms of the droplet size distribution (DSD). Accordingly, different dispersed phase morphologies at the inlet of a SMX static mixer have been tested and their effect on the overall dispersion performance of the mixer has been evaluated based on the DSD and growth of interfacial area. In particular, three representative scenarios are considered: (1) Isolated cases, where one and three individual droplets are injected, mimicking a controlled syringe injection; (2) Numerous variable-sized droplets, simulating a pre-mixed/dispersed inlet; and (3) Jet inlet, emulating a standard phase injection from a gear pump. In addition, this study provides novel insight into the underlying physics dictating droplet deformation and breakage in SMX mixers for industrially-relevant scenarios. This can be achieved thanks to the massively-parallel high-fidelity three-dimensional direct numerical simulations computed with a robust hybrid front-tracking/level-set algorithm, which provides a wealth of information on intricate interfacial dynamics; this information cannot be obtained via experimental or volume-averaged modelling techniques implemented in past studies.