Slug-Induced Stabilization of Taylor Vortex Flow in a Continuous Taylor–Couette Reactor

Transitioning from batch to continuous processing is a key strategy in process intensification. This study investigates gas–liquid slug flow in a high-precision horizontal Taylor–Couette reactor to enhance hydrodynamic stability and mixing performance. Experiments were conducted with varying gap widths and fluid viscosities. In low-viscosity systems, slug coalescence occurred at larger gaps, whereas high-viscosity fluids maintained stable slug structures. PIV measurements revealed that each liquid slug contained two to four steady Taylor vortex cells with asymmetric circulation. A calm inward flow region near the gas–liquid interface acted as a barrier to axial dispersion. Turbulent kinetic energy analysis showed localized peaks near vortex outflow boundaries, while fluctuations were strongly suppressed near interfaces. Unlike single-phase flow, which transitioned to wavy vortex flow at high rotation rates, slug flow maintained stable laminar Taylor vortex flow over an expanded operating range. These results demonstrate that gas slugs function as hydrodynamic barriers that suppress wave propagation, enabling intensified radial mixing while preserving axial confinement. The findings provide design insights for high-performance continuous reactors.