Abstract: A chaotic mixing rotor was proposed, on which three-dimensional non-Newtonian isothermal flow field simulation was performed by means of Polyflow software to characterize the mixing performance in a two-rotor continuous mixer. The mixing process experienced by the material was statistically analyzed by particle tracking analysis (PTA) method. The influences of rotor structure and processing parameters on the mixing performance was also been discussed. Additional mixing experiments were conducted to evaluate and characterize the mixing performance of different rotor structures. It was found that the distributive mixing capability of high-chaos rotor was better than that of classical rotors, while the dispersive mixing capabilities of the two kinds of rotors were the same. The mechanical property of blends prepared by chaotic rotors was better than prepared by classic rotors. Both dispersive and distributive mixing capability would be promoted when the rotor speed increased. Besides, appropriate feed speed was also a key factor to achieve a good mixing performance. Key words：two-rotor continuous mixer; chaotic rotor; numerical simulation; mixing performance.

Key words: two-rotor continuous mixer, chaotic rotor, numerical simulation, mixing performance