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Volume 112
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Synergistic structural optimization of stirred tanks based on CFD-DEM simulation for improved solid–liquid suspension
Mingyu Chen a, Yunhai Huang b, Xin Huang a c d *, Mingpu Yuan a, Ting Wang a c d, Na Wang a c d, Hongxun Hao a c d *
a National Engineering Research Center of Industrial Crystallization Technology, School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, China
b China Nuclear Power Engineering Co., Ltd, Beijing, 100840, China
c Collaborative Innovation Center of Chemical Science and Engineering (Tianjin), Tianjin, 300072, China
d State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, China
10.1016/j.partic.2026.03.003
Volume 112, May 2026, 222-234
Received 2 December 2025, Revised 24 February 2026, Accepted 2 March 2026, Available online 18 March 2026, Version of Record 26 March 2026.
E-mail: x_huang@tju.edu.cn; hongxunhao@tju.edu.cn
Highlights

• A CFD–DEM–VOF model was used for solid–liquid mixing in stirred tanks.

• Tank bottom, baffle, and impeller inlet were jointly optimized for better suspension.

• Profiled bottom improved axial flow and minimized dead zones.

• The optimized design achieved uniform particle distribution and high turbulence.


Abstract

Efficient solid-liquid suspension in stirred tanks is critical for mass and heat transfer in various industrial applications. However, insufficient suspension uniformity remains a common challenge, leading to reduced process efficiency and increased energy consumption. This study investigates the mixing performance of a novel channel-type impeller in stirred tanks with different structural configurations through CFD-DEM coupled simulations. Multiple geometries were examined, including the bottom shapes and baffle forms for tank and the size of suction inlet for impeller. The simulation results revealed that the profiled bottom played a crucial role in facilitating the smooth conveyance of fluid to the impeller and eliminating dead zones. Besides, the introduced baffles significantly restructured the flow, suppressing free-surface vortices. Meanwhile, the enlarged suction inlet of impeller could further increase axial flow supply. Finally, a synergistic optimization strategy, including profiled bottom flow guidance, baffle vortex suppression, and enlarged-inlet enhancement was proposed. The optimal design (PCTBE) could lead to near-uniform particle suspension and highest turbulent kinetic energy coverage. This combined strategy significantly enhances suspension uniformity and circulation efficiency, offering practical guidance for improved stirred-tank design and operation.

Graphical abstract
Keywords
Stirred tank; Impeller design; Computational fluid dynamics; Discrete element method
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