Discrete element method (DEM) simulations of particle mixing process in an intensive mixer were conducted to study the influence of structural and process parameters on the mixing performance and power consumption. The DEM model was verified by comparing the impeller torque obtained from simulation with that from experiment. Impeller and vessel torque

coordination number (

CN

) and mixing index (Relative standard deviation) were adopted to qualify the particle dynamics and mixing performance with different parameters. A method based on cubic polynomial fitting was proposed to determine the critical mixing time and critical specific input work during the mixing process. It is found that the mixing performance and energy efficiency increases with the decrease of impeller offset. The mixing performance is improved slightly with the increase of blade number and the impeller with 3 blades has the highest energy efficiency due to its low input torque. Results indicate that the energy efficiency and the mixing performance increase with the decrease of filling level when the height of granular bed is higher than th

at of blade.