In response to the accelerating demands of industrial development

the scale-up of stirred reactors has become increasingly prevalent. Multi-shaft stirred reactors have emerged as a promising solution; however

a critical challenge remains in achieving efficient mixing while simultaneously minimizing energy consumption. Here

a novel approach based on differential rotation speeds to optimize mixing performance was proposed. Results demonstrate that a carefully configured rotation speed difference significantly enhances mixing efficiency

reducing mixing time by 17.89% and power consumption by 12.07%. This strategy not only amplifies flow field instability but also minimizes instability discrepancies

promoting a more uniform distribution of vortices across various scales. Furthermore

under this approach

the bottom impeller has the strongest impact on mixing

while the middle and lower impellers synergistically strengthen the weaker mixing regions and facilitate the redistribution of energy in the flow field. This method promotes efficient energy transfer from large-scale to small-scale vortices

ultimately improving overall mixing performance. This work offers a promising avenue for the optimal design and operation of multi-shaft stirred reactors

advancing both efficiency and energy sustainability.