Industrial Process Simulation Software

VisiMix as a Mixing Simulation Software

VisiMix is a

mixing simulation software that helps with various industrial applications, including R&D, design, production, and Quality by Design (QbD). The software’s main purpose is to model and analyze mixing conditions to optimize chemical processes. It provides solutions for a range of challenges, such as:

• Improved Productivity: In one case, installing two baffles in a reactor reduced the reaction time from 25-50 hours to just 9 hours, resulting in an annual savings of $1,600,000.

• Controlling Morphology and Particle Size: VisiMix was used to modify equipment design and operating parameters to achieve the desired particle size and morphology in a continuous crystallization process, leading to savings of $900,000.

• Troubleshooting Crystallization Processes: The software was used to analyze the radial distribution of solids in a reactor to solve the issue of increased impurity during scale-up, which resulted in a savings of $2,000,000.

• Resolving Dissolution Issues: VisiMix calculations of shear rate and circulation flow rate helped prevent the formation of lumps and enabled fast dissolution of an organic solid, which generated savings of 1,200,000 Euro.

• Three-Phase Systems: For a solid-liquid-liquid system, VisiMix determined that the RPM had to be increased from 55 to 100 to effectively mix the two liquid phases, which led to annual savings of at least 1,200,000 Euros.

The software also provides a visual representation of mixing, showing that the “Actual Reactor” performance can differ significantly from an ideal “Reactor with Perfect Macromixing”.

VisiMix offers solutions for

scale-up and scale-down and provides a customized Proof of Concept (POC) for specific mixing challenges. They also invite users to download a free trial to model their own processes and avoid costly mistakes

• Query successful

VisiMix is a fluid dynamics software designed to help process engineers quickly and accurately simulate mixing conditions. Unlike other tools that use complex numerical methods, VisiMix is based on integral semi-empirical equations of momentum balance. This approach allows it to calculate mixing parameters in just a few seconds, which helps engineers make quick, data-driven decisions.

Key Features and Advantages

• Speed and Ease of Use: VisiMix can calculate mixing parameters in a matter of seconds, whereas other tools can take hours or even days. It features an intuitive, visually appealing interface that simplifies data entry and result interpretation. Other tools often require advanced expertise in computer-aided design (CAD). VisiMix also runs on a simple PC or laptop, while other software may require high-computing devices or cloud services, which adds to the cost.

• Validated Models: The software’s calculated parameters have been experimentally validated and are aligned with Quality by Design (QbD) principles. VisiMix simulates real-world mixing conditions with proven accuracy for various systems, including liquid-liquid, gas-liquid, and solid-liquid mixtures. The results are validated against plant data, and the coefficients are already built into the software. In contrast, other tools often produce model-dependent and unvalidated outputs, making them less reliable for critical decisions and requiring significant time for revalidation.

• Comprehensive Analysis: VisiMix provides a deep analysis for each operation, covering macro- and micro-mixing, turbulent shear, solid suspension, and gas-liquid distribution. It also offers 2D and 3D visualizations. The software can also quickly capture transient phenomena, such as the effects of feed position, impeller type, and baffle configuration, without complex calculations. Other tools may be limited to simple flow visuals and fail to accurately capture real-world mixing behavior, especially during scale-up.

• Direct Scaling: VisiMix allows users to select and reproduce key mixing parameters directly across different scales, which other tools typically lack.

• Return on Investment (ROI) & Support: The software is designed to provide a fast and measurable ROI, often delivering at least a 20x return by reducing scale-up failures. VisiMix offers unlimited application support with responses usually provided within four hours.