CFD-PBE Simulation of Flow Dynamics and Mass Transfer in Two-Stage Countercurrent Mixer-Settler

Flow condition and mass transfer behavior of liquid–liquid extraction in a two-stage countercurrent extractor are investigated experimentally and numerically. CFD-PBE simulation is adopted to analyze the impact of operating parameters, including impeller speed, residence time, and organic-aqueous ratio of feed flow on volume fraction and droplet size of dispersed phase and volumetric mass transfer coefficient. Droplet size distribution is calculated by considering breakage and coalescence of dispersed phase. The allocation of dispersed phase between stages is found to be determined by impeller speed. Meanwhile, the allocation of dispersed phase between mixers and settlers is governed by residence time and organic-aqueous ratio of feed flow. Turbulence intensity, volume fraction, and droplet size distribution are revealed to be dominating parameters that affect the spatial nonuniform distribution of volumetric mass transfer coefficient. The mass transfer rate can be improved by increasing impeller speed in two stages. Higher residence time and organic-aqueous ratio of feed flow, however, have opposite effects on mass transfer rate in stage-1 and stage-2.