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Quantifying Mixing using Magnetic Resonance Imaging

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Published on: January 25, 2012

Power Consumption and Rubber Phase Evolution in an Intermeshing Mixer: A Three-Dimensional Non-Newtonian

Fareed Konadu Osman¹, Dandan Hou², Lei Han¹

¹School of Energy Science and Engineering, Harbin Institute of Technology, Harbin 150001, China.

|May 27, 2026

Summary

Optimizing internal mixer power consumption involves managing fill factor and rotor speed, as higher levels increase energy use. Rotor wear, however, progressively reduces power demand, offering insights for energy efficiency.

Keywords:

dynamic remeshing intermeshing rotor mixer non-Newtonian flow power consumption rubber mixing

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Area of Science:

Materials Science
Chemical Engineering
Computational Fluid Dynamics

Background:

Internal mixers are crucial for rubber processing.
Understanding operating parameter effects on energy consumption is vital for efficiency.

Purpose of the Study:

To investigate the impact of fill factor, rotor speed, and rotor wear on isothermal internal mixer power consumption.
To develop and validate a computational fluid dynamics (CFD) model for simulating non-Newtonian rubber flow in mixers.

Main Methods:

Developed a 3D CFD model using the finite volume method with dynamic remeshing.
Incorporated actual mixer geometry and rubber rheological properties.
Validated the model against plant-scale power consumption data.

Main Results:

Increased fill factor (50-82%) raised normalized power (14-19 kW/% to 17-22 kW/%) but risked clogging.
Increased rotor speed (35-60 rpm) raised normalized power (20-22 kW/rpm to 22-23 kW/rpm).
Rotor wear significantly reduced power consumption due to decreased rotor-material interaction.

Conclusions:

Operational windows exist to minimize energy costs while maintaining effective shear stress.
Findings provide practical guidance for optimizing internal mixer performance and energy efficiency.