Comparing flows of FENE-P, sPTT, and Giesekus model fluids in a helical static mixer

Helical static mixers are used widely for mixing of non-Newtonian fluid flows in the laminar regime. We study flows of three viscoelastic constitutive models (sPTT, FENE-P, and Giesekus) in the helical static mixer using computational fluid dynamics. These three models have similarities in steady viscometric flows in that they all exhibit shear thinning and their planar extensional viscosities can be matched, but their responses can differ in complex geometries. We observe flow distribution asymmetries at the element intersections for all three models, which hinders the mixing performance of the device. These have previously been observed with the constant shear viscosity FENE-CR model. The asymmetry behaves similarly between the sPTT and Giesekus models, however the FENE-P model behaves in a distinct manner; beyond a critical degree of elasticity, the asymmetry sharply changes direction. This was also observed previously with the FENE-CR model. These results suggest that shear thinning and second-normal stress differences (present in the Giesekus model) do not significantly influence mixing performance in the range of conditions studied. We show that increasing the aspect (length/diameter) ratio of the mixer elements mitigates the poor mixing caused by elasticity. Overall, this study provides insight into the behaviour of these well-used constitutive models in complex, industrially-relevant flows. •We compare sPTT/FENE-P/Giesekus model flows in a helical static mixer with CFD.•All three models have similar material functions in steady and homogeneous flows.•FENE-P response in the mixer is highly distinct from the sPTT/Giesekus responses.•Lengthening the mixer elements helps to improve mixing performance.•Viscoelastic lip vortices are observed on the underside of the mixer elements.