Micromixing efficiency in a rotating foam stirrer reactor with various reactor configurations and liquid viscosities

Abstract BACKGROUND The rotating foam stirrer reactor (RFSR) has shown its high mass transfer efficiency. Nevertheless, its micromixing efficiency, which is one of the significant parameters, still needs more comprehensive study for its better application and optimization. This work therefore employed the iodide–iodate reaction system to analyze the micromixing efficiency in an RFSR, and the effects of reactor configuration and liquid viscosity on micromixing efficiency were investigated. RESULTS The results show that high micromixing efficiency can be achieved when the feed location is at the outer edge of the rotor. Solid foam with low pores per linear inch (ppi) and equipping baffles on the reactor wall can also considerably improve the micromixing efficiency. The results further reveal that the micromixing efficiency decreased with increasing liquid viscosity. Micromixing times in an RFSR with various configurations, estimated based on the incorporation model, ranged from 2.1 × 10 −4 to 2.0 × 10 −2 s. The minimum value is smaller than that of many conventional reactors and is competitive with that of some novel reactors. In addition, a correlation to predict the micromixing time based on the average energy dissipation rate was developed, which agreed well with experimental values. CONCLUSION This study indicates that the RFSR has excellent micromixing efficiency and also provides fundamental information for optimization of the RFSR and its application in process industries. © 2019 Society of Chemical Industry