Robust, scalable correlations for pressure loss across corrugated (SMV-style) static mixers at high Reynolds (Re) numbers are currently lacking. To address this, results from an experimental and computational fluid dynamics (CFD) based study involving a single SMV mixing element for Re in the range of 8,000 – 250,000 is reported. The investigated scenarios encompassed three different pipe diameters and variations in the wall roughness. The equivalent sand grain roughness was first estimated from measurements in an empty pipe and provided as an input to the CFD model. The agreement between the CFD predictions and measurements ascertained the validity of the roughness estimate. When the mixing element was absent, roughness contributed about 70–90% of the pressure losses in the rough stainless steel pipes and up to 7% of the losses in the smooth PVC pipe. A capillary model based semi-analytical correlation was developed to generalize the pressure loss characteristics when the mixing element was present. The proposed correlation captured both current and historical pressure loss measurements with an improved accuracy over currently available correlations. Even with the mixing element present, about 60% of the pressure losses were attributed to the inclusion of wall roughness.

目前缺乏针对高雷诺数 ( Re ) 的波纹（SMV 型）静态混合器的压力损失的稳健、可扩展的相关性。为了解决这个问题，基于实验和计算流体动力学 (CFD) 的研究的结果涉及用于Re的单个 SMV 混合元件报告的范围为 8,000 – 250,000。研究的场景包括三种不同的管道直径和壁面粗糙度的变化。等效砂粒粗糙度首先根据空管中的测量结果进行估计，并作为 CFD 模型的输入提供。CFD 预测和测量之间的一致性确定了粗糙度估计的有效性。当混合元件不存在时，粗糙度对粗糙不锈钢管的压力损失贡献了大约 70-90%，在光滑的 PVC 管中贡献了高达 7% 的压力损失。开发了基于半分析相关性的毛细管模型来概括存在混合元件时的压力损失特性。所提出的相关性以比当前可用的相关性更高的精度捕获当前和历史压力损失测量值。即使存在混合元件，约 60% 的压力损失归因于壁粗糙度。