Separation of liquid–liquid dispersion in a batch settler: CFD-PBM simulations incorporating interfacial coalescence

Several commercially important chemical processes involve liquid–liquid phase separation. In the present work, we have developed a multi-fluid Eulerian CFD model using OpenFOAM that incorporates binary and interfacial coalescence processes. We simulated separation of kerosene dispersed in water in a batch settler and validated the predictions using the measurements of time-evolution of coalescing and settling interfaces, local dispersed-phase volume fraction (α_O) and drop size distribution (DSD). Simulations are performed to understand the contributions of binary and interfacial coalescence processes to the phase separation process. While the time-evolution of coalescing and settling fronts can be predicted reasonably well using the two-fluid model with empirically-corrected drag models, local α_O and DSD could not be predicted. We have shown that the comprehensive multi-fluid Eulerian model, which incorporates binary and interfacial coalescence, predicts the time-evolution of the coalescing and settling fronts, local α_O and the DSD in an excellent agreement with the measurements.