The effective management of sludge and residuals which are by-products of many process industries such as minerals processing, water & wastewater treatment, pulp and paper, petrochemical etc. is very important from an environmental and economic perspective. Many conventional and emerging phase separation (solid-liquid) techniques have been documented in scientific literature. Over the past decade, several empirical and analytical studies of fluid flow and turbulent aggregation processes in many flow units with different energy dissipation and mass transfer rates have been conducted. On the basis of the identified research problem, an innovative design concept was developed that aims to address the problem of throughput constraints and high operating cost in the technical application of classical Taylor-Couette devices. A working hypothesis adopted in this study is based on the premise that the performance of any pre-treatment device is a function of the physicochemical, process engineering or operating conditions and stirrer-vessel system.