The present study summarizes the design of the Rushton turbine and simulates the three-dimensional turbulent flow around the impeller blades of Rushton turbine in a stirred baffled vessel. The 3-dimensional flow around the impeller interacts with the baffles as the impeller rotates. This generates extremely complex flow physics within the vessel being stirred. The simulations are carried out using the Multiple Reference Frame (MRF) approach. The 3-dimensional model of the Rushton turbine and vessel is modelled as per the literature of Ranade et al. using SolidWorks package. The Rushton turbine with impellers is discretized into smaller finite volume domains using ICEM CFD pre-processing tool. Hexahedral grids are generated through the turbine and the impellers. The hexahedral cells generated are used to capture the boundary layer phenomenon more accurately compared to the tetrahedral cells for the same cell count. The flow physics involves both stationary and rotating domains and proper interface is provided between these domains so that the flux transfer is more uniform. A finite volume CFD code ANSYS CFX 12.1 is used to capture the 3-dimensional flow fields by solving the continuity, momentum and energy equations using RANS algorithm. A second order upwind scheme is employed for better accuracy. Shear Stress Transport (SST) k-ω turbulence model is used to capture the fluctuating quantities generated due to the turbulence created. SST k-ω has a blending function which ranges from 0 to 1 and can act both s as Standard k-ω and Standard k-ε turbulence models. The flow field near the walls is captured using Standard k-ω models and the flow physics at the free stream region is captured using Standard k-ε model. The numerically predicted results are compared with the experimental data available in the literature. Upon validation, the baffled vessel is varied for different rotational speeds and numerically analysis is carried out. The radial velocity contours and streamlines along with the turbulent kinetic energy are presented at the mid plane of the turbine rotational speeds. The effect of baffles is studied with respect to the flow optimization thereby increasing the reliability and life time of the Rushton turbine. © 2006-2014 Asian Research Publishing Network (ARPN).