Flow pattern assessment and design optimisation for an industrial solvent extraction settler through in situ measurements and CFD modelling

Since the flow pattern was considered to be poor, further numerical modelling was undertaken to investigate design improvements. Variations to several design parameters were assessed, mainly focussing on modification to the internal picket fences. Single-phase simulations were used as a fast screening tool, then the most promising modified designs were further assessed by two-phase simulations. Through quantitative assessment of the flow patterns obtained for proposed design modifications, the study has led to the identification of a design which substantially improves the flow pattern, which is expected to reduce entrainment losses and improve process economics.