Good solid-liquid mixing homogeneity and liquid level stability are necessary conditions for the preparation of high-quality composite materials. In this study, two rotor-stator agitators were utilized, including the cross-structure rotor-stator (CSRS) agitator and the half-cross structure rotor-stator (HCSRS) agitator. The performances of the two types of rotor-stator agitators and the conventional A200 (an axial-flow agitator) and Rushton (a radial-flow agitator) in the solid-liquid mixing operations were compared through CFD modeling, including the homogeneity, power consumption and liquid level stability. The Eulerian–Eulerian multi-fluid model coupling with the RNG k–ε turbulence model were used to simulate the granular flow and the turbulence effects. When the optimum solid-liquid mixing homogeneity was achieved in both conventional agitators, further increasing stirring speed would worsen the homogeneity significantly, while the two rotor-stator agitators still achieving good mixing homogeneity at the stirring speed of 600 rpm. The CSRS agitator attained the minimum standard deviation of particle concentration σ of 0.15, which was 42% smaller than that achieved by the A200 agitators. Moreover, the average liquid level velocity corresponding to the minimum σ obtained by the CSRS agitator was 0.31 m/s, which was less than half of those of the other three mixers.

The viscous fingering phenomenon often occurs when a low-viscosity fluid displaces a high-viscosity fluid in a homogeneous porous media, which is an undesirable displacement process in many engineering applications. The influence of wetting gradient on this process has been studied over a wide range of capillary numbers (7.5 × 10⁻⁶ to 1.8 × 10⁻⁴), viscosity ratios (0.0025 to 0.04), and porosities (0.48 to 0.68), employing the lattice Boltzmann method. Our results demonstrate that the flow front stability can be improved by the gradual increase in wettability of the porous media. When the capillary number is less than 3.5 × 10⁻⁵, the viscous fingering can be successfully suppressed and the transition from unstable to stable displacement can be achieved by the wetting gradient. Moreover, under the conditions of high viscosity ratio (M > 0.01) and large porosity (Φ > 0.58), wetting gradient improves the stability of the flow front more significantly.