Rob
Ansys Employee

OK. You don't need to model the baffles with a thickness in most cases, similarly the blades. Dead regions are probably inside those solids, and unless you need to see heat transfer they can be voids. 

You also have a fairly large jump in cell size between the rotating & stationary zones. Shafts can be moving walls, so no need for a cell zone around it. 

Check the overlap on the non-conforms, I suspect you've got a gap forming and that could explain the weird contours.  Read this  https://ansyshelp.ansys.com/account/secured?returnurl=/Views/Secured/corp/v222/en/flu_ug/flu_ug_sec_grid_nonconform.html   and look at the text (TUI) command in 6.6.4