DTB-Inspired Crystallizer Flow Optimization via Vortex Regulation: Li2CO3 Quality &Mixing Efficiency

Using CFD simulations and experiments, six adjustable parameters were evaluated. Sensitivity analysis shows rotational speed has the highest energy sensitivity (324%), while agitator and draft tube heights are critical for flow efficiency (>158% sensitivity).

Under optimized conditions, mixing time drops to 8.8 s, specific mixing energy to 4.55 kJ·m⁻³, saving 79.6% energy versus conventional operation. Crystallization tests confirm the optimized flow eliminates dead zones, yielding Li2CO3 with ≥98.18% purity, <1.4% spatial purity variation, uniform morphology, and narrow size distribution (Span < 1.0). This work provides a lab-scale basis for industrial DTB optimization, though scale‑up validation is required.