Can we live Danckwerts' dream? Mixing Analysis in a Baffled Stirred Tank Reactor Based on 4D-Particle Tracking Experiments

Abstract

We present an experimental investigation of mixing dynamics within a laboratory-scale 3-liter stirred tank reactor (STR) equipped with two Rushton turbines and three baffles. Using time-resolved, four-dimensional particle tracking velocimetry, we successfully capture trajectories of up to 40,000 tracer particles in the full reactor volume despite obstructions by stirrer and baffles, providing unprecedented time-resolved flow and mixing information. From these Lagrangian data, we analyze velocities, accelerations, and spatial dispersion, revealing anisotropic mixing. By utilizing novel network-based analysis methods on the experimental particle trajectories, we identify coherent fluid compartments that exhibit strong internal mixing but weak exchange with neighboring compartments. We uncover five distinct compartments acting as transport barriers, which have a high impact on substrate distribution in chemical and biochemical processes. Our approach thus realizes and extends early thought experiments from Danckwerts and Levenspiel by providing detailed insight into the behavior of single fluid parcels and Lagrangian mixing withing chemical and biochemical reactors, offering a valuable approach for evaluation and optimization of chemical and biochemical processes. The trajectory data are made freely available to serve as an experimental reference for further research.