(350e) Use of Computational Fluid Dynamics (CFD) Modelling to Optimize Continuous Mixer Design

The manufacturing of silicone polymer products involves many mixing steps of viscous fluids. It is a challenge to be able to predict mixing patterns, dead zones, and residence time distribution for different equipment designs. Mixing in silicone polymerization processes is an extremely important step to achieve desired characteristics, such as molecular weight distribution and viscosity. Inefficient mixing leads to unwanted properties; in some cases, significant fouling on the walls of the mixer can have a very negative impact on the mixing efficiency.

In this study, a continuous mixer is developed to mix the crosslinker with silicone polymer before the next step polymerization. The objective is to create a Computational Fluid Dynamics (CFD) model to predict mixing pattern, dead zone and residence time distribution. The developed model is used to design the mixer with reduced fouling of the mixer and accumulation of cured polymer. Proposed designs are validated through experimental studies.