Assessment of the Influence of Various Degrees of Conicity in Pharmaceutical Reactors on Mixing and Homogenization Processes, Heat Transfer, and Emptying

Abstract

Purpose

The purpose of this research is to assess the impact of conical geometry in pharmaceutical reactors. The study aims to evaluate how different degrees of bottom conicity in reactors influence critical aspects such as component mixing and homogenization, heat transfer, and the emptying/dosing of the internal fluid.

Methods

Reactors with varying degrees of bottom conicity were designed, and computational fluid dynamics (CFD) simulations were conducted alongside a central composite design (CCD) to assess the interactions between design factors and variables in the mixing and homogenization process. Additionally, CFD simulations were performed to analyze the heat transfer within the internal fluid, generated by an external electric heater, as well as the emptying of the fluid over time, driven by a conical helical screw paddle.

Results

The results indicate that reactor conicity significantly influences mixing efficiency, homogenization, and heat transfer. Reactors with intermediate/high conicity (25º, 40º, and 60º) demonstrated more effective homogenization over time, whereas those with low conicity (5º and 10º) achieved faster initial thermal distribution. The reactor with intermediate conicity (25º) stood out for its balance between operational efficiency and ergonomics, making it an optimal choice for pharmaceutical applications.

Conclusions

This study highlights the importance of reactor geometry in process optimization, emphasizing that conicity plays a crucial role in operational efficiency and overall reactor performance. The findings underscore the need for further research to refine these systems and enhance efficiency in pharmaceutical applications. Future validation efforts will focus on experimental comparisons based on the optimized system identified in this study.

Graphical Abstract