In stirred tank reactors, especially without using baffles, the liquid surface can deform, which in stirring technology is referred to a vortex. These vortices can be advantageous for some mixing tasks, such as obtaining emulsions, they can also impair a consistent product quality. Therefore, it is important for the production and process industry, to know whether a vortex occurs or not. Prediction is only possible with an outdated dimensionless baffle index and research on vortex formation with baffles is limited. In this study, two industrially important axial stirring systems—Propeller and Pitched-blade turbine—with different baffle geometries (rectangular, cylindrical, triangular) and numbers are assessed in regard to power input, vortex characteristics (depth, width, volume) and baffle state prediction. Power is recorded using strain gauges, while vortices are evaluated using an optical image evaluation method. The final vortex result is made dimensionless, accessible to the industry to enable improved predictions about the size of the vortices on an industrial scale in order to make the stirred tanks more economical and sustainable. Furthermore, an initial improvement of the baffle index for the investigated stirrers is given, because the original index incorrectly predicts the baffle state in 12.5% of cases.
Lenters et al. (2026) studied this question.