The Impact of Stator Geometric Design on the Power Consumption in Continuous High-Shear Mixers

Although continuous high-shear mixers are extensively employed in mixing, emulsification, and fragmentation processes across various industries, the design and implementation of their stators predominantly rely on empirical experience. Information regarding the power consumption of mixers with diverse designs remains relatively scarce. This study investigates the influence of stator geometry on the power consumption and flow rate of continuous high-shear mixers. Systematic experiments were conducted using nine stators with varying slot widths, slot areas, and slot angles. The results indicate that both slot width and slot area significantly affect mixer performance, while the influence of slot angle is more complex. Under controlled conditions, increasing slot width resulted in higher flow rates and lower power consumption, whereas enlarging the slot area led to increases in both flow rate and power consumption. Furthermore, alterations in slot angle displayed inconsistent effects on mixer performance. The research findings provide valuable practical guidance and a new perspective for the design of emulsification equipment in the food processing industry, aiming to reduce energy consumption and enhance mixing efficiency.