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Effect of structural parameters on the flow field and power consumption of

in-line high shear mixer

Article  in  Journal of the Indian Chemical Society · April 2021

DOI: 10.1016/j.jics.2021.100042

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 Journal of the Indian Chemical Society 98 (2021) 100042

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Effect of structural parameters on the flow field and power consumption of

in-line high shear mixer
Cholu Kwon a, *, Undek Song a, Unsong Pak b, Chungmyong Kim c, Kyong-Chol Kim d
a
Institute of Mechanical Engineering State Academy of Sciences, Pyongyang, Democratic People’s Republic of Korea
b
Pyongyang Transportation University, Pyongyang, Democratic People’s Republic of Korea
c
School of Metallurgy, Pyongyang University of Mechanical Engineering, Pyongyang, Democratic People’s Republic of Korea
d
Faculty of Applied Chemical Engineering, Kim Chaek University of Technology, Pyongyang, Democratic People’s Republic of Korea

A R T I C L E I N F O A B S T R A C T

Keywords: The effects of three structural parameters on flow field and power consumption of in-line high shear mixer (HSM)
ANN were investigated by large eddy simulation (LES). In addition, an artificial neural network (ANN) is used to
CFD predict the relationship between the structural parameters and the power consumption, and the effect of
LES
dimensionless structural parameters on the power number constant Poz and k1 is studied. The results show that
High shear mixer
Flow field
the stator tooth thickness and the tooth tip-base distance have a slight effect on the flow field, and the shear gap
Power consumption width is a key parameter affecting the flow field. As the stator teeth thickness, the tooth tip-base distance and the
shearing gap width increases, the power number Po decreases. There is a linear relationship between the constant
k1 and the dimensionless structural parameters. With the increase of the dimensionless parameter Ts/Ds-o of the
stator tooth thickness, the dimensionless parameter St/H of the tooth tip-base distance, and the dimensionless
parameter Sg/DR-o of the shear gap width, the constant k1 decreases. With the increase of the parameter St/H, Sg/
DR-o and Ts/Ds-o, the constant Poz first increases and then decreases. There is a linear relationship between the
constant Poz and the parameter Ts/h. With the increase of the parameter Ts/h, the constant Poz increases.

1. Introduction is inversely proportional to Reynolds number in laminar region [10].

As an energy intensive process intensification equipment, HSM has
the characteristics of narrow stator rotor clearance, high linear velocity at
rotor end, high shear rate in stator-rotor gap and high local energy
dissipation rate near shear head. Therefore, they are widely used in
various industrial processes, such as emulsification, dissolution, disper-
sion, crystallization, crushing, reaction, etc. [1–7].
In recent years, some researches have been reviewed, focusing on the
design, development and different applications of HSM [7–9]. Through
experiments and numerical simulation methods, various studies have
been made on the flow characteristics and power consumption of the
HSM. In most of the experimental studies, flow visualization using laser
doppler velocimetry (LDA) and particle image velocimetry (PIV) tech-
niques was used to study the effects of process parameters and geomet-
rical parameters.
Padron (2001) studied the flow characteristics and power consump-
tion of different components of the batch HSM, and found that the power
number is independent of the Reynolds number in turbulent region, and
Doucet et al. (2005) also reached a similar conclusion [11]. Kowalski
et al. (2011) measured the power consumption of the in-line Silverson
150/250 HSMs by torque method and calorimetric method, the results
were shown that the torque method was more accurate than the calo-
rimetry method for measuring power consumption [12]. Based on the
research of Kowalski et al. (2011), the same method was used to study the
power consumption of different stator structures in the in-line HSM Sil-
verson by Cook et al. (2012) [13]. Through a large amount of data, the
author proved that the power consumption characteristics are similar to
the power consumption of the batch HSMs studied by Padron (2001)
[10]. In addition, it is found that the stator structure has a significant
effect on the power consumption of the in-line HSMs. Sch€ onstedt et al.
(2015) proposed a new model to improve the power consumption
characteristics of in-line HSMs [14]. Li et al. (2019) studied the effect of
structural parameters and operating parameters of HSMs on the mixing
performance. ANN was used to correlate the micro mixing time with the
structural parameters [15]. Mortensen et al. (2018a, 2017) used PIV
measurements to analysis the effect of stator slot design on local

* Corresponding author.
E-mail address: kwoncholu1985@163.com (C. Kwon).

https://doi.org/10.1016/j.jics.2021.100042
Received 14 January 2021; Received in revised form 9 April 2021; Accepted 12 April 2021
0019-4522/© 2021 Indian Chemical Society. Published by Elsevier B.V. All rights reserved.
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

turbulent stress. Espinoza et al. (2020) performed the flow and turbu- and shear gap have an important influence on the flow field pattern and
lence characteristics in the Silverson 150/250 HSMs by 2-D PIV mea- power consumption [47,48]. Wu et al. (2014) studied the shear rate
surements [16–18]. distribution of multistage stator rotor reactor under laminar and turbu-
Due to the high shear rate, the flow in the in-line HSMs is very lent regimes by CFD simulation method, and further improved the cor-
complex, which makes it more difficult to understand the flow and relations of Kp and Ks on axial shear width and radial gap based on the
mixing characteristics on an industrial scale. Computational fluid dy- research by Kroezen et al. (1988) [49,50]. Zhang et al. (2017) used CFD
namics (CFD) is a popular tool to analyze the flow field in mixer, and it methods to simulate the flow of viscous fluid in the in-line HSMs under
€
takes less time [19,20]. Ozcan-Taşkin et al. (2011) studied the flow field turbulent and laminar regimes, and studied the effect of structural pa-
of three different in-line Silverson HSMs by the standard K
ε turbulence rameters on its flow characteristics. Based on the experimental data, the
model, as a result, it was shown that the predicted values are consistent correlations of Kp and Ks with the tip-to-base distance and the shear gap
with the experimental values [21]. Utomo (2008) used LDA and CFD to were summarized [33].
study the flow pattern and turbulent energy dissipation rate of Silverson Although a general model of the flow field and power consumption of
HSMs in detail [22]. Utomo and Pacek (2009) used the LDA and CFD the HSMs varying with operating parameters has been obtained, there is
simulation to study the effect of stator geometry (decomposition head, still a lack of research on how key structural parameters affect its flow
slot head and square hole head) on the flow field and turbulent energy field and power consumption. In this paper, LES model is used to study
dissipation rate of a batch Silverson HSMs [23]. As a result, it was proved the influence of three structural parameters (tooth-to-base distance,
that the standard K
ε turbulence model can predict the flow field in the stator tooth thickness and shear gap width) on the flow field and power
mixer to a certain extent. consumption of in-line HSMs in turbulent flow. In addition, ANN is used
Minnick et al. (2018) simulated the flow characteristics of HSMs to establish a model between the studied parameters and the power
under different back pressure conditions by the Realizable K
ε turbu- consumption, which better predict the power consumption characteris-
lence model. Studies have found that under the same geometry and rotor tics of the HSMs, and the effect of dimensionless structural parameters on
tip speed, batch and in-line HSMs have different emulsification efficiency the power number constant Poz and k1 is studied. As the results, it is
[24]. Vikash et al. (2017) predicted the flow and mixing characteristics in show that the flow field and power consumption of the in-line HSMs are
a batch HSMs by using RANS K
ε turbulence model. As a result, the K
respectively related to the tooth-to-base distance, stator tooth thickness
ε turbulence model underestimates the turbulence energy [25]. Mor- and shear gap width. These results provide a theoretical basis for the
tensen et al. (2018) compared the value predicted by the K–ε turbulence application and design of the in-line HSMs.
model with the PIV measurement, and they found that the RANS model
underestimated the turbulent energy dissipation rate [26]. 2. Simulation
Murthy et al. (2008) used the various turbulence models (standard
model, large eddy simulations (LES) and Reynolds-stress transport model 2.1. The geometry of the in-line HSMs with ultrafine teeth
(RSTM)) to simulate the flow characteristics of a baffled stirred vessel
with the various impeller [27]. Yeoh et al. (2004) used the LES and RANS As discussed by Zhang et al. (2017) and Xu et al. (2014), a pilot scale
methods to perform the flow characteristics of a mixing vessel with a in-line HSM (FLUKO, FDX1/60) with the ultrafine tooth structure is used
Rushton impeller [28]. Xu et al. (2014) studied the flow field charac- [29,33]. The rotor is two rows straight teeth, with 52 teeth per row, and
teristics of in-line HSM in turbulent flow by using CFD method, and the tooth slots width is 1 mm. The stator is two rows, 15 backward in-
compared with the LDA test. As a result, it was proved that the LES model clined tooth structure, with 30 teeth per row, the tooth slots width is 2
can predict the internal flow of the HSMs more accurately than the mm. All HSM chambers have the same structural design and dimensions
standard K
ε turbulence model [29]. The results shown that the LES (with the inner diameter of the chamber is 90 mm, the axial length of the
can well predict the flow characteristics. Vikash and Kumar (2019) used chamber is 60 mm, the diameter of Inlet tube is 25 mm, the diameter of
LES to characterize flow and turbulence characteristics of batch HSMs outlet tube is 20 mm).
[30]. It was found that LES provided accurate turbulent information as
compared to RANS. The LES model has been used to perform the flow
characteristics and power consumption of HSM in many studies [28,29,
31–34].
Generally, Multiple reference-frame (MRF) and sliding-mesh (SM)
were used to investigate the rotor motion. The simulation method is
selected according to the calculation time and operation conditions. SM
is a more accurate method to simulate rotor motion. However, the
calculation cost is higher than MRF [9,35,36]. In addition, many studies
used SM method to investigate unsteady state equations [25,29,30,
36–38]. Further, MRF has been adopted in many studies to simulate rotor
motion [31–33,39–42]. Shekhar (2003) simulated the fluid pattern and
power consumption of the anchor stirrer reactor under high viscosity
fluid, and found the relationship between the power consumption con-
stant Kp and the shear constant Ks with respect to the clearance ratio c= T
[43], the results are consistent with the experimental results by Ayazi
et al. (1989) [44]. Thakur et al. (2004) measured the power consumption
of horizontal fan type stirred tank by experimental means, and studied
the relationship between Kp on the blade length and the shear gap width,
and the relationship between Ks and the shear gap width [45]. Vial et al.
(2003) studied the hydrodynamic characteristics of the stator-rotor
reactor by using CFD method, and obtained the correlations of Kp and
Ks on rotor length and shear gap width in laminar flow state [46].
Mardaru et al. (2012) and Souidi et al. (2012) studied the flow field and
power consumption of the cross-blade near-wall stirred tank by the Fig. 1. Main structure of the in-line HSM for CFD simulation. a) the in-line
simulation and experimental method, they reported that the blade angle HSM; c) rotor head; d) stator head; b) and e) Assembled stator and rotor head.

2
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

Fig. 1 shows the main structure of the in-line HSM for CFD simulation,
and Table 1 shows the main dimensions of the in-line HSMs. When
exploring the effect of structural parameters on the flow field and power
consumption of HSM, the diameter of stator and rotor varies with the
stator teeth thickness and shear gap width, and the diameter of inner ring
rotor is taken as the benchmark.
2.2. Simulation method
All CFD simulation calculations are simulated by ANSYS Fluent 18.0
software. In the process of simulation calculation, the laminar model and
the LES model is used to predict the flow of the in-line HSMs. The mul-
tiple reference frame (MRF) method is used to simulate the relative
motion of the stator and rotor. In the simulation, the velocity inlet,
pressure outlet, non-slip wall and SIMPLE algorithm are used to solve the
discretization equation. The calculation domain of the in-line HSM in-
cludes the rotor domain and the stator domain.
In this paper, in order to realize the grid independence, the enhanced
near wall function and the standard k-ε model were adopted for the
initial calculation. Based on its converged velocity gradient, the mesh
was adapted, until a good quality mesh was obtained. Then, four refined
mesh (mesh 2, mesh 3, mesh 4) were gained. Table.SI1 lists the power
number of in-line HSM2 for water (23–25  C, ρ ¼ 998.2 kg/m3, μ ¼ 1
mPa) with four refined mesh at N ¼ 1000r/min, Q ¼ 500 L/h. It is
indicated that the mesh3 can satisfy the requirement of LES model. In the
LES model, the average y þ values are 1.04–1.51, and the number of
refined meshes reaches 3.14 million to 3.82 million. Firstly, the laminar
model and LES model is used to simulate HSM2, and compared with the
power consumption model parameters reported in literature and the
simulated power consumption results. Then, the flow field and power
consumption of other HSMs in Table 1 are simulated by LES model with
the validated model.
For the simulation of HSM2, water (pure water 23–25  C, ρ ¼ 998.2
kg/m3, μ ¼ 1 mPa s) and Emkarox/water solutions (Emkarox) in Carrier
et al. (2013) was used as the working fluid [51]. Its viscosity ranges from
0.21 Pa s to 1.2 Pa s. Other HSMs only considered the case where water
(pure water 23–25  C, ρ ¼ 998:2 kg/m3, μ ¼ 1 mPa s) is used as the
working fluid. In this paper, the LES with the standard Smagorinsky-Lilly
sub-grid scale model, the bounded central differencing scheme and sec-
ond order implicit transient formulations were employed to solve the
momentum equation. In all simulations, the time step size was set to T=
600, and the rotor was rotated by 0:6 for each iteration step and other
settings are default. For large eddy simulation, the convergence criterion
is defined as the absolute residual of all equation scales less than 1 
10
4 . The maximum number of iterations within each iteration step are
set at 20 without further adjustment. After the calculation converges,
there is almost no difference between the velocity components and tur-
bulent dissipation rate of each rotation period, so only the data in one
rotation period is collected [29,52].
3. Data processing
For in-line HSM, the power consumption is very complex, which is
related to rotor speed and flow rate. In the past decade, some experi-
mental studies have used many different HSMs designs and found sup-
port for the three factors model describing power consumption [7,12,33,
52–56]. Kowalski power consumption model for HSM is [56]:
Ps ¼ Pf þ PL ¼ PT þ PF þ PL ¼ Poz ρN 3 D5 þ k1 QρN 2 D2 þ PL (1)
Where Ps is the total energy (w), PT is the power required to overcome
the fluid resistance during the rotor rotation(w), PF is the energy required
for the fluid to flow through the mixer(W), PL is the energy loss (w), Pf is
the net power (w), ρ is the density of the working fluid (kg/m3), N is the
rotational speed (rps).
This formula can be described by power number Po.
Pf
Po ¼ (2)
ρN 3 D5
Q
Po ¼ Poz þ k1 ¼ Poz þ k1 Fl (3)
ρND3
Where Po is the power number, Poz is the power number at zero flow rate,
k1 is proportionality constant, Fl is the flow number. In this study, the
linear velocity of rotor, Reynolds number Re and flow number Fl are all
calculated based on the outer diameter of the outer row rotor.
4. Results and discussion
4.1. Simulation and verification
The net power of the in-line HSMs can be calculated from torque and
speed.
Pf ¼ 2π NMn (4)
Where Pf is the net power, Mn is the torque. Taking HSM2 as an example,
the power consumption is simulated in detail at turbulent fluid and
laminar flow. Fig. 2 shows the correlation between Po and Fl of HSM2
calculated by CFD at operating speed (500–4000 rpm) and flow rate
(500–2000 L/hr) with water as the working fluid. Fig. 3 shows the cor-
relation between Po and Re of HSM2 at operating speed (60–240 rpm)
and flow rate (500 L/hr) with Emkarox/water solutions (Emkarox) as the
working fluid. It can be seen that the linear relationship between the
power number Po and the flow number Fl is more obvious. When the
Reynolds number Re less than 1000, Po is inversely proportional to Re.
When the Re is more than 1  105, the power number is gradually getting
approached the constant.
Fig. 4 shows the comparison between the CFD simulation values with

Table 1
In-line high shear mixers of different structures investigated in CFD simulation.
Item Sg (mm) St (mm) Ts (mm) h (mm) H (mm) DR-o (mm) DR-i (mm) DS-o (mm) DS-i (mm)

HSM1 0.5 1 2 11 12 58 47 63 52
HSM2 0.5 1 2.75 11 12 59.5 47 66 53.5
HSM3 0.5 1 3.5 11 12 61 47 69 55
HSM4 0.5 3 2 11 14 58 47 63 52
HSM5 0.5 3 2.75 11 14 59.5 47 66 53.5
HSM6 0.5 3 3.5 11 14 61 47 69 55
HSM7 2 1 2 11 12 64 47 72 55
HSM8 2 1 2.75 11 12 65.5 47 75 56.5
HSM9 2 1 3.5 11 12 67 47 78 58
HSM10 2 3 2 11 14 64 47 72 55
HSM11 2 3 2.75 11 14 65.5 47 75 56.5
HSM12 2 3 3.5 11 14 67 47 78 58

Note: DR
o - outer rotor diameter, DR
i - inner rotor diameter, DS
o - outer stator diameter, DS
i - inner stator diameter, Sg - shear gap width, St tooth tip-base distance, TS -
tooth thickness, h- height of teeth, H ¼ ðh þSt Þ shear height.

3
C. Kwon et al.
Fig. 2. The relationship between the power number Po and the flow number Fl
of in-line HSM2 with the working fluid of water, operating speed (500–4000
rpm), flow rate (500–2000 L/hr).
Fig. 3. The relationship between the power number Po and the Reynolds
number Re of in-line HSM2 with working fluid of Emkarox/water solutions
(Emkarox), operating speed (60–240 rpm), flow rate (500 L/hr).
the experimental results of Xu et al. (2014) and Zhang et al. (2017) [29,
33]. It can be seen that the error between the calculated values and the
experimental values are within 10%, which indicates that the simulation
values is in good agreement with the experimental values. The power
consumption parameters obtained by Xu et al. (2014) and Zhang et al.
(2017) was Poz ¼ 0:147, k1 ¼ 14:49 and Kp ¼ 1724:2. The parameter
predicted by LES model are Poz ¼ 0:148, k1 ¼ 13:54, and Kp ¼
1619:76. Table 2 shows the comparison between the predicted values
and the experimental values reported in the literature. Experimental re-
sults and predicted values are very similar. It is show that the CFD
simulation can be used the characteristics of fluid dynamics and power
consumption of the HSMs. It is shown that the CFD simulation can be
used the characteristics of fluid dynamics and power consumption of the
HSMs.
4.2. The effect of structural parameters on the flow field
4.2.1. Velocity field
Fig. 5 shows the velocity vector diagram of the Newtonian fluid (pure
water 23e25 C, ρ ¼ 998:2 kg/m3, μ ¼ 1 mPa s) under the turbulent state
(N ¼ 1000 rpm, Q ¼ 500 L/h) of the HSMs. For brevity, the display range
4
Journal of the Indian Chemical Society 98 (2021) 100042
Fig. 4. Comparisons of the estimated Po using the CFD simulation with the
experimental data for HSM2. (a); Comparison with results of Xu et al. (2014)
[29], water as the working fluid, operating speed (500–4000 rpm), flow rate
(500–2000 L/hr). (b); Comparison with results of Zhang et al. (2017) [33],
Emkarox/water solutions (Emkarox) as working fluid, operating speed (60–240
rpm), flow rate (500 L/hr).
of the speed vector diagram is limited to the plane z ¼ 6 mm, r ¼ 15e45
mm, and θ ¼
90e0o. It can be seen from the velocity vector diagram
that the in-line HSM turbulent flow is very complicated, which is man-
ifested by the self-circulating flow in the stator teeth gaps.
The flow ejected from the outermost stator teeth gaps forms eddy
current, and the fluid near the eddy current is drawn into the shear gap
again. These phenomena are similar to the flow field characteristics of
the HSM in the literature [12,17,18,22,31,32].
From Fig. 5(a), (b) and (c), it can be found that as the stator teeth
thickness increases, the eddy current in the outer row stator tooth gap
increases, while the jet flow from the stator tooth gap decreases, the less
fluid is entrained into the shear gap. Fig. 5(d), (e) and (f), Compared with
Fig. 5(a), (b) and (c), it can be found that as the tooth-to-base spacing
increases, the eddy current of the outer row stator tooth gap increases,
while the jet flow from the stator tooth gap decreases, the turbulence
intensity and eddy current intensity around the outer row stator is
reduced. Fig. 5(g), (h) and (i), Compared with Fig. 5(a), (b) and (c), it is
show that as the tooth tip-base distance increases, the velocity in the
shear gap decreases significantly, and the turbulence intensity decreases
obviously. As tooth tip-base distance and shear gap width increases
simultaneously, the internal turbulence intensity of the HSMs decreases.
However, as the thickness of the stator teeth increases, the jet flow from
the outer row stator gap increases slightly, as shown in Fig. 5(J), (k) and
C. Kwon et al.
Table 2
A comparison of power characteristics of some in-line HSMs.
HSMs
Rotor Stator Manufacturer Dr (mm)
Teeth (2 row) Teeth Fluko 60
Teeth (2 row) Teeth Fluko 60
Teeth (2 row) Teeth Fluko 60
Teeth (2 row) Teeth Fluko 60
Teeth (2 row) Teeth Fluko 60
(l). However, as the thickness of the stator teeth increases, the jet flow
from the outer row stator gap increases slightly.
4.2.2. The strain rate distribution
Fig. 6 shows the strain rate distribution cloud diagrams of various in-
line HSM with water as the working fluid. For brevity, the display range
of the strain rate distribution cloud diagram is limited to the plane z ¼ 6
mm, r ¼ 15e45 mm, and θ ¼
90e0o. From Fig. 6(a), (b) and (c), it is
known that as the stator tooth thickness increases, the shear rate area of
larger value changes slightly. Fig. 6(d), (e), and (f) shows that as the tooth
tip-base distance increases, the change of the shear rate area with larger
values decreases slightly. Fig. 6(g), (h) and (i) shows that of the shear gap
width increases, the value of the shear rate decreases significantly, and
the shear rate region with larger values is less obvious. Fig. 6(g), (h) and
(i), Compared with Fig. 6(j), (k) and (l), it is shown that as tooth tip-base
distance and shear gap width increases simultaneously, the change of the
value of the shear rate decreases slightly. Therefore, the stator tooth
thickness and the tooth tip-base distance have a slight influence on the
shear rate distribution, and the shear gap width is a key parameter that
affects the shear rate distribution.
4.2.3. The histogram of shear rate distribution
Fig. 7 shows the histogram of the shear rate distribution of the in-line
HSM in turbulent flow, with a span of 0–4  104 s-1, divided into 100
groups. Fig. 7 shows the histogram of shear rate distribution of HSMs.
The calculation domain examined is the calculation domain of shear head
height (H ¼ 12–14 mm), which is very important for high shear mixing
performance. From Fig. 7(a), (b) and (c), as the stator teeth thickness
increases, the distribution of the low shear rate in the HSM is high, which
means that its shear capacity is reduced. Fig. 7(d), (e) and (f) Compared
with Fig. 7(a), (b) and (c), as the tooth tip-base distance increases, the
overall shear rate distribution of the HSM increases slightly. Fig. 7(g), (h)
and (i) Compared with Fig. 7(a), (b) and (c), as the shear gap width in-
creases, the shear rate distribution become more concentrated, and the
distribution of the low shear rate in the HSM is higher. Fig. 7(j), (k) and
(l), Compared with Fig. 7(g), (h) and (i), it is show that as tooth tip-base
distance and shear gap width increases simultaneously, the distribution
of the low shear rate in the HSM is high slightly. This shows that the
stator teeth thickness and the tooth tip-base distance has a slight effect on
the shear rate distribution, but the shear gap width has an important
effect on the shear stress of the in-line HSM.
4.3. The effect of structure parameters on power consumption
Generally, the relationship curve between the power standard ðPo ¼
Pf =ρN 3 D5 ) and the Reynolds standard ðRe ¼ ρND2 =μÞ of the mixer
measured under the condition of Newtonian working fluid is called the
power curve. Fig. 8 and Fig. 9 shows the correlation between the power
number Po and the flow number Fl, and the correlation between the
power number Po and the Reynolds number Re of various HSM calculated
by CFD at operating speed (500–4000 rpm) and flow rate (500–2000 L/
hr) with water as the working fluid.
From Fig. 8(a), (b) and (c), it can be seen that the linear relationship
between power number Po and flow number Fl is more obvious. As the
stator tooth thickness, the tooth tip-base distance and the shear gap
5
Journal of the Indian Chemical Society 98 (2021) 100042
Power Characteristics Method References
PoZ K1 Kp
0.147 14.49 EXP [32]
0.139 14.03 CFD [32]
1724.2 EXP [31]
1613.2 CFD [31]
0.148 13.54 1619.8 CFD In this article
increases, the power number Po and the constant k1 decreases.
From Fig. 9, at low Reynolds number Re, the power number Po de-
creases exponentially with the increase of Reynolds number Re. When the
Reynolds number is more than 1  105 , the power number gradually
approaches a constant, which is very similar to that in literature [14,23,
29,33]. It can be seen that the power curve of HSM changes with the
change of tooth tip-base distance, stator tooth thickness and shear gap
width. Figs. 8 and 9 shows that the structural parameters (tooth tip-base
distance, stator tooth thickness and shear gap width) have a significant
effect on the constant Poz and k1 has obvious effect.
5. Artificial neural network model
Due to the complex structure of the HSM, it is difficult to determine
the functional relationship between the power consumption of the HSM
and various structural parameters under the different working condi-
tions. ANN has the characteristics of fast processing, simple calculation,
and need not to assume the exact relationship between input and output
variables, so it is an effective method to estimate complex processes [58].
Many artificial neural network models have been used to estimate
complex nonlinear problems [15,59–62]. In order to further explore the
effect of structural parameters on power consumption, BP neural network
(BPNN) is used to predict the effect of structural parameters (tooth
tip-base distance, stator tooth thickness and shear gap width) on the
power number Po, the effect of dimensionless structural parameters on
the constant Poz and k1 is studied. In this paper, BP neural network
(BPNN) is used to establish a prediction model of HSM power con-
sumption. In this paper, BP model include: one hidden layer, input layer
and output layer, in which Fl, Re, Ts=h,St =H, Sg =DR
o and TS =DS
o are
used for input data, the HSM power number is used for output data.
Where, Ts=h and St =H are the stator tooth thickness in the axial direction
and the tip-to-base clearance in the axial direction, TS =DS
o and Sg =DR
o
are the stator tooth thickness in radial direction and the tip-to-base
clearance in radial direction.
The number of neurons in the hidden layer of BP neural network is
calculated by Eq. (5) [63,64].
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ph ¼ ni þ mo þ β (5)
Where ph is the neuron number of the hidden layer, ni is the neuron
number of input layer, mo is the neuron number of output layer, β is an
integer between 1–10. In order to define the number of neurons in hidden
layer, BP neural network is trained at the different value of β, and optimal
value of β is defined as 10. Calculation result is shown that Table 3. In this
paper, the number of neurons in the input layer as 5, the number of
neurons in the output layer as 1. According to Eq. (5), the number of
neurons in the hidden layer is determined as 12.
The output model of hidden layer neuron and output layer neuron can
be calculated with Eq. (6) and Eq. (7).
X 
qj ¼ f Iwij  Xi
dj (6)
Where Iw is the weight matrix between input layer and hidden layer, d is
the threshold matrix, X is the vector of input variables, f ð Þ is the neuron
transfer function in the hidden layer. Logsig and Tansig function is
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

Fig. 5. Velocity vector diagram of the in-line high shear mixers on the plane z ¼ 6 mm.
(a) HSM1; (b) HSM2; (c) HSM2; (d) HSM4; (e)HSM5; (f) HSM6; (g) HSM7; (h)HSM8; (i) HSM9; (j) HSM10; (k)HSM11; (l) HSM12.

widely for the transfer function in hidden layer. In this paper, Logsig Using ANSYS FLUENT software, 180 samples data were obtained.
function is used for the transfer function. Among them, 80% samples are used as neural network training samples,
X  and 20% samples are used as neural network test samples. Table SI3 of
Gk ¼ F HWjk  qj
dk (7) the Supporting Information shows 180 data obtained by using LES
model. In order to improve the stability of the neural network, the
Where Hw is the weight matrix between the hidden layer and output simulated data are normalized before training.
layer, Fð Þ is the neuron transfer function in the output layer. Purelin The results shows that the average training error of BP neural network
function is widely using in the transfer function. is stable from 50 iterations. After 394 iterations, the training value rea-
ches the best value, and the training mean square error is 3.6656e-07.

6
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

Fig. 6. Shear rate cloud diagram of the in-line high shear mixers on the plane z ¼ 6 mm.
(a) HSM1; (b) HSM2; (c) HSM2; (d) HSM4; (e)HSM5; (f) HSM6; (g) HSM7; (h)HSM8; (i) HSM9; (j) HSM10; (k)HSM11; (l) HSM12.

Pk  Pn    

The fitting result of neural network is good. Fig. SI1 and Fig. SI2 of the wi;j i¼1 wi;j  wj;m 
PWi ¼ P nj¼1
Pk       
o (8)
Supporting Information shows the training results of BP neural network n wi;j  Pn wi;j   wj;m 
i¼1 j¼1 i¼1
and the neural network test results.
In ANN model, the effect of input parameters on output can be
determined by sensitivity analysis of network weight. According to Eq. Where k and n are the number of neurons in the input and hidden layers
(8), weights of input parameters are obtained. respectively, i, j and m correspond to the input and hidden layers
respectively, and PWi is the weight to study the effect of parameters on
the power consumption of HSM. Table SI4 of the supporting information
shows the ANN parameters weight for predicting the power consumption

7
C. Kwon et al.
Fig. 7. Histogram of shear rate distribution of in-line high shear mixer. (The horizontal axis represents strain rate (1000
1s
1), the vertical axis represents frac-
tion.).(a) HSM1; (b) HSM2; (c) HSM2; (d) HSM4; (e)HSM5; (f) HSM6; (g) HSM7; (h)HSM8; (i) HSM9; (j) HSM10; (k)HSM11; (l) HSM12.
of HSM. Fig. 10 shows the weights of the parameters studied.
The results show that the weight of TS =DS
o is 34.8%, and that of Sg =
DR
o is 32.58%, which indicates that the two dimensionless parameters
have the greatest influence on the power consumption of HSMs. The
weight of Reynolds number Re is 1.54%, which has little effect on the
power consumption of HSM. The order of effect is TS = DS
o (weight
34.8%), Sg =DR
o (weight 32.58%), St =H (weight 13.76%), flow criterion
Fl(weight 13.31%), Ts=h (weight 4.01%), Reynolds number Re(weight
1.54%).
In order to study the effect of dimensionless structural parameters on
the constant Poz and k1 , Fig. 11 and Fig. 12 shows 3D relationship dia-
grams between the dimensionless structural parameters and the power
number constants predicted by the ANN model. From Fig. 11, it can be
seen that there is a linear relationship between constant k1 and dimen-
sionless structural parameters, with the increase of dimensionless struc-
tural parameters Ts=h, St =H, Sg =DR
o and TS =DS
o , k1 decreases.
From Fig. 12(a) and (b), it can be seen that the constant Poz have a
linear relationship with the parameter Ts=h, Poz increases with the in-
crease of the parameter Ts=h.
Fig. 12 (a), (c) and (d) shows that Poz first increase and then decreases
with the increase of the parameter St =H. while Fig. 12 (b) and (e) shows
that Poz first increases and then decreases with the increase of the
parameter Sg =DR
o . Fig. 12(d) and (e) shows that Poz increase slightly
with the increase of the parameter TS =DS
o .
In order to verify the correlation, the calculation results of the
established ANN model are compared with the experimental results of Xu
et al. (2014) [22] and CFD simulation values. Fig. 13 shows that the
8
Journal of the Indian Chemical Society 98 (2021) 100042
calculated values are in good agreement with the experimental values,
and the error between the calculated values and the experimental values
is within 10%. Therefore, it is verified that the established ANN model
can be used to calculate the power consumption of Newtonian fluid in
turbulent state, and it has a wide range of applications in the design and
application of in-line HSMS.
6. Conclusions
In this paper, CFD simulation method is used to study the effect of
structural parameters on the turbulent flow field and power consumption
characteristics of in-line HSM with water as working fluid. In addition, an
artificial neural network (ANN) was used to establish a model between
the studied parameters and power consumption, and the relationship
between the structural parameters of the HSM and the power consump-
tion was predicted.
The results show that as the stator teeth thickness and the tooth tip-
base distance increases, the eddy currents in the stator tooth slot in-
creases, while the jets ejected from the stator tooth gaps decreases. As the
shear gap width increases, the velocity in the shear gap width is obvi-
ously reduced, and the turbulence intensity is weakened. The stator teeth
thickness and the tooth tip-base distance have a slight effect on the shear
rate distribution, while the shear gap width has a significant effect on the
shear rate distribution.
As the stator teeth thickness increases, the tooth tip-base distance and
the shear gap width increases, the power number Po decreases, but there
is no significant change in the power number Po when the Reynolds
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

Fig. 9. The relationship curve between power number Po and Reynolds number
Re of various in-line HSMs with water as working fluid, operating speed
(500–4000 rpm) and flow rate (500–2000 L/hr).

Table 3
The influence of the training with different adjusting integer.
β Mean squared error Mean relative error Correlation coefficient
(MSE) (MRE) (R2)

1 2.2067% 3.66E-5 0.99944

2 2.9148% 2.12E-5 0.99968
3 1.3713% 1.75E-5 0.99974
4 1.1585% 1.58E-5 0.99978
5 1.2081% 1.46E-5 0.99978
6 1.2048% 1.38E-5 0.99979
7 1.0147% 1.42E-5 0.99982
8 1.0039% 1.33E-5 0.99984
9 0.9206% 1.28E-5 0.99984
10 0.9135% 1.25E-5 0.99986

Fig. 8. The relationship curve between power number Po and flow number Fl of
various in-line HSMs with water as working fluid, operating speed (500–4000
rpm) and flow rate (500–2000 L/hr). (a) stator tooth thickness Ts¼2(mm); (b)
Ts¼2.75(mm); (c) Ts¼3.5(mm).

number Re is greater than 1  105.

ANN prediction results show that the dimensionless parameter Ts/DS-
o (34.8%) of the stator tooth thickness and the dimensionless parameter
Sg/DR-o (32.58%) of the shear gap width have the greatest effect on the
power consumption of the HSM. However, the Reynolds number Re
(1.3%) has little effect on the power consumption of HSMs in turbulent
regime (Re > 10⁵).
Fig. 10. Weights of the investigated parameters on the power number.
The dimensionless structural parameters Ts=h, St =H, Sg =DR
o and TS =
DS
o have obvious effects on the power number constant Poz and k1 .
There is a linear relationship between the constant k1 and the dimen-
sionless structural parameters, with the increase of the dimensionless

9
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

Fig. 11. 3D diagrams of the constants k1 versus the dimensionless structure
parameters predicted by the ANN model. (a) Ts=h and St = H; (b) Ts= h and Sg =
DR
o ; (c) St =H and Sg =DR
o ; (d) St =H and TS =DS
o ; (e) Sg = DR
o and TS = DS
o .
Fig. 12. 3D diagrams of the constants Poz versus the dimensionless structure
parameters predicted by the ANN model. (a) Ts=h and St =H; (b) Ts=h and
Sg =DR
o ; (c) St =H and Sg =DR
o ; (d) St =H and TS =DS
o ; (e) Sg =DR
o and TS =DS
o .

10
C. Kwon et al. Journal of the Indian Chemical Society 98 (2021) 100042

ni Neuron number of input layer

p Neuron number of the hidden layer
PF Flow rate power term, W
Pf Net delivered power to fluid, W
pℎ Neuron number of the hidden layer
PL Losses power term, W
Po Power number, dimensionless
Poz Power number at zero flow rate, dimensionless
Ps Shaft power, W
PT Tank power term, W
Pwj Weight of the investigated parameters
Q Volumetric flow rate, m3/s
Sg Shear gap width, mm
St Tip-base distance, mm
T The period of revolution, s
TS Tooth thickness, mm
X Vector of input variables

Greek Symbols
ρ Density, kg/m3
μ Viscosity of fluids, Pa s
Fig. 13. Comparison of calculated Po using the established ANN model with the β Constant, dimensionless
experimental data.

Abbreviations
structural parameters, the constant k1 decreases. There is a linear rela- ANN Artificial neural network
tionship between the constant Poz and the parameter Ts= h, and Poz in- CFD Computational fluid dynamics
creases with the increase of the parameter Ts=h. With the increase of the HSM High shear mixer
parameters St =H, Sg =DR
o and TS =DS
o , Poz first increases and then de- LDA Laser doppler velocimetry
creases. These results provide a theoretical basis for the design and LES Large eddy simulation
amplification of HSM. MRF Multiple reference frame
MRE Mean relative error
Declaration of competing interest MSE Mean squared error
PIV Particle image velocimetry
The authors declare that they have no known competing financial RANS Reynolds-Averaged Navier–Stokes
interests or personal relationships that could have appeared to influence R2 Correlation coefficient
the work reported in this paper.
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