CFD Mixing App
1.0

Supported Ansys versions:

2025 R2,
2025 R1

Required Product:

An integrated application that automates the complete CFD workflow for stirred tank reactors: from geometry setup and meshing to simulation, post-processing, and performance analysis.

((May vary depending on deployment Scope))

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App Description

The CFD Mixing App enables guided end-to-end CFD simulation of stirred tanks and bioreactors. It automates geometry/model creation, mesh generation, CFD solver setup, and runtime monitoring. Automated reporting provides detailed insights into mixing efficiency and flow patterns. Amongst other critical variables, the app also calculates impeller power number, power/volume, and mixing time of different species. This app reduces engineering effort while ensuring consistent, standardized, high-quality simulation results. Additionally, GPUs can be used during the simulation process to achieve significant acceleration in computational speed, while preserving accuracy fundamental to the results.

Key Benefits

Key benefits of the end-to-end CFD Mixing App for stirred tank reactors include both technical and operational advantages:

Reduced time and cost – Automation accelerates geometry creation, meshing, and solver execution, reducing simulation turnaround time and engineering costs.
Enhanced simulation accuracy – Automated workflows eliminate manual setup errors and deliver consistent, high-fidelity insights into flow fields, turbulence, and mixing behavior.
Scalable and repeatable workflows – The app’s reusable templates support scalable deployment ensuring reproducible results and streamlined R&D/Tech Transfer operations.
Improved design efficiency – Engineers can quickly explore impeller geometries, baffle configurations, and operating speeds to identify optimal designs before physical prototyping.
Energy and performance optimization – CFD-driven insights enable energy-efficient mixing and better reactor performance by minimizing dead zones and improving homogeneity.

Use Cases

Capabilities: Fluid flow in tanks, Liquidliquid mixing, vortex prediction, gas sparging, exposure analysis.

Food, beverage, and consumer goods manufacturing: Optimizing ingredient blending uniformity in products like sauces, cosmetics, and personal care formulations.

Bioprocess and fermentation design: Estimation of oxygen mass transfer coefficient (kLa) and shear effects to optimize bioreactor performance for microbial or cell cultures.

Chemical process optimization: Analyzing momentum transfer and blend times to reduce variability and improve final yield uniformity in chemical and petrochemical industries.