Viscoelastic flow instabilities in static mixers: Onset and effect on the mixing efficiency

Elastic instabilities are identified as flow instabilities occurring in the presence of low inertial effects, induced by the combination of strong elastic forces with nonlinearities of the flow. In continuous flow laminar mixing applications, the onset of these instabilities is likely to occur in the window of applied flow rates; therefore, it is important to understand the effects of their onset on the process efficiency. In this work, we investigated experimentally the onset of elastic instabilities in two tubular static mixers with different geometric features, i.e., the Kenics helical mixer and the SMB-R mixer, the latter characterized by a double X-shaped bar geometry. We obtained concentration maps at various mixer lengths by means of planar laser induced fluorescence techniques. To deduce a generalized effect of the fluid elasticity on the mixing patterns, we tested three fluids with different rheological behavior—a Boger fluid and two shear-thinning fluids. For all cases, we observed deviations from the Newtonian benchmark as soon as the Deborah number exceeded unity, even though different transitions occurred as the mean flow rate increased. The effect of the instability on the mixing patterns strongly depended on the different kinematics induced by the two geometries: for the helical mixer, the typical lamellar structure is not recovered and the two liquid streams remain unmixed, while for the SMB-R, the concentration maps are strongly unsteady, showing temporally and spatially chaotic fluctuations of the mass fraction. In both cases, the instabilities worsen the mixing efficiency compared to the Newtonian case.