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Mixer Tank CFD Simulation

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In this project, a tank mixer is modeled and the effect of its rotating impeller on the mixing procedure is investigated.


This ANSYS Fluent project includes CFD simulation files and a training movie.

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In industry, mixing is an operation that involves the manipulation of heterogeneous materials with the intent to make them more homogeneous. Industrial Mixer is a machine that blends, homogenizes, and mixes different materials into a single substance. Mixers combine virtually any solid or liquid that is necessary to form the final product. Mixing is performed to allow heat and/or mass transfer to occur between one or more components or phases.

Modern industrial processing almost always involves some form of mixing as it is needed during the manufacturing or processing period. Their powerful motors and blades allow mixers to work with a variety of materials. These machines are widely used across many industries including pharmaceutical, chemical, agriculture, food, and beverage, etc.

Project Description

In this project, a tank mixer is modeled and the effect of its rotating impeller on the mixing procedure is investigated. The simulation is done using the VOF model for the three phases of air, water, and salt. The k-epsilon model is applied for solving the turbulent flow inside the tank. MRF model is also used to model the rotation of the impeller.

Mixer Geometry & Mesh

The geometry of this project includes a tank, a mixer consisting of a rod, and an impeller. The geometry is designed in ANSYS Design Modeler® and meshed by ANSYS Meshing®. The mesh type used for this geometry is unstructured and the total element number is 152641.

mixer mixer


Mixer CFD simulation

The assumptions considered in this project are:

  • Simulation is done using a pressure-based solver.
  • The present simulation and its results are considered to be steady and do not change as a function time.
  • The effect of gravity has been taken into account and is equal to -9.81 m/s2 in the Y direction.

The applied settings are recapitulated in the following table.

Viscous modelk-epsilon
k-epsilon modelstandard
near-wall treatmentstandard wall function
Phase 1Air
Phase 2Water
Phase 3Salt
(Mixer)Cell zone conditions
Rotating zone MRF
Rotational velocity10 rpm
(Mixer)Boundary conditions
InletsMass-flow inlet
Gauge total pressure0 Pa
Salt inletDirection specification methodNormal to boundary
Mass flow rate0.6 Kg/s
Gauge total pressure0 Pa
Water inletDirection specification methodNormal to boundary
Mass flow rate0.6 Kg/s
OutletsPressure outlet
Gauge pressure0 Pa
Backflow direction specification methodNormal to boundary
wall motionstationary wall
(Mixer)Solution Methods
Pressure-velocity couplingCoupled
Spatial discretizationpressurePRESTO!
Spatial discretization


Volume fractionCompressive
momentumsecond-order upwind
turbulent kinetic energysecond-order upwind
turbulent dissipation ratesecond-order upwind
Initialization method Standard
gauge pressure0 Pa
velocity (x,y,z)0 m/s-1
Turbulent kinetic energy1 m2/s2
Turbulent dissipation rate1 m2/s3


The contours of mixture density, mixture velocity, phase ID, and volume fractions of water, air, and salt are obtained.


All files, including Geometry, Mesh, Case & Data, are available in Simulation File. By the way, Training File presents how to solve the problem and extract all desired results.


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