• Higher Reynolds numbers and dispersed phase volume fractions increase energy dissipation, reducing Sauter mean diameter (SMD) and shifting droplet size distribution (DSD) toward smaller sizes.
• Smaller aspect ratios, greater blade twist and assembly angles amplify shear rate, leading to smaller droplet sizes and narrower DSDs, with aspect ratio having the most significant impact.
• Mixing elements with different spin enhance shear and stretching efficiency, reducing SMD by 3.7–5.8 times in the smaller size range with a significantly narrower distribution compared to same spin.
• Optimized structural parameters for Kenics static mixers include an aspect ratio of 1–1.5, blade twist angle of 180°, assembly angle of 90°, and interlaced assembly of adjacent elements with different spin, balancing pressure drop and efficiency.