CFD-PBM simulation of turbulent drop break-up in a high-pressure static mixer

This work investigates the simulation of dilute, low-viscosity emulsions in a pilot-scale ACIP2 Sonolator using Computational Fluid Dynamics (CFD) and Population Balance Methods (PBM). Comparisons between the simulations and the experimental work of Ryan [1] show excellent agreement of the pressure drop (ΔP) and reasonable agreement of the Sauter mean diameter (d32). The effect of increasing oil viscosity in the d32 − ΔP correlation is also correctly captured. The numerical and the theoretical d32 − ΔP correlations are found to differ strongly with the experimental findings. The assumption of droplet break-up in the turbulent inertial regime (inherent to both theory and to current-state breakage frequency models) is found not to apply in the regions of intense break-up.