Mixing Equipment

Daniel Ribeiro
 Outline

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Mixing equipment

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Mechanically agitated mixing tanks

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Components of agitated mixing tanks

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Flow patterns within agitated mixing tanks
 Various Mixing Duties

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Blending of miscible liquids
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Contacting of immiscible liquids
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Emulsification processes
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Suspending coarse solids in low-viscosity
liquids
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Dispersing fine solids in high-viscosity liquids
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Dispersing gas in liquids
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Contacting gas/liquid/solid in catalytic
chemical reactions
 Mixing Equipment

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Mechanically agitated mixing tanks
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Jet mixers
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In-line static mixers
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In-line dynamic mixers
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Dispersion mills
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Valve homogenizers
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Ultrasonic homogenizers
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Extruders
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etc.
In-line Static Mixer
Thermal Mixer
 Mechanically-agitated tanks

Shaft

Impeller
Baffles
 Tanks

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Generally, round is preferable to square or
rectangular.
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Often vertically mounted cylindrical tanks.
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Typically, fluid level is equal to about one tank
diameter (1:1) when running full.
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If the height-to-diameter ratio exceeds 1.25:1,
multiple impellers will likely be needed.
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Tall narrow tanks (2:1~4:1) are used to maximize
heat transfer through the tank and residence
times for sparged gases.
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Tank diameter can range from 0.1 m, for small
batch units, to 10 m or more, for large industrial
units.
 Tanks

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The base of the tank may be flat, dished or
conical, depending on factors such as
operating pressure, ease of emptying and
solids suspension.
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ASME torispherical bottom is the most common dish type
for process vessels
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2:1 ellipsodial bottom is often used for higher pressure
applications (above 2 Mpa)
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Hemispherical bottom is often used for very high pressure
applications (above 10 Mpa)
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Conical bottom is often used where crystallization in the
reactor is intended (allow the precipitating solids to flow
freely to the bottom outlet)
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Flat bottom is typically used for unpressurized storage
and transfer applications.
 Tanks

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Tank size and shape is much more important
in solids suspension application than in
blending.
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The ASME dished-bottom tanks are the best to
suspend solids because the bottom’s shape aids in
directing flow from the impeller.
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Steep, cone-bottom tanks should be avoided
because solids that settle in the heel of the cone are
extremely difficult to suspend.
 Baffles

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Baffles are energy-inefficient drag producers
that are typically flat-stock metal beams or
plates attached perpendicular to the side
walls of the tank.
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Generally speaking, for fluids with viscosities
less than 1 kg/ms, 3 or 4 baffles (equal to the
number of impeller blades) are required to
prevent tangential flow pattern.
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Baffles are generally not required with high-
viscosity liquids where tangential flow pattern
is not a problem.
 Baffles

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Baffles usually run the height of the tank wall
and have a width about 1/12~1/10 of the tank
diameter with an offset of 1/3 baffle width.
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A fully baffled tank usually has four baffles
that essentially inhibit the natural tangential
flow pattern.
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Swirl is more pronounced with a partially
baffled tank, i.e., fewer baffles, baffles of
smaller width, baffles set at an angle or
mounted with an offset.
 Draft Tubes

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A draft tube is a cylindrical housing around the
impeller. Its diameter is slightly larger than
that of the impeller.
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Usually, draft tubes are used with axial
impellers to direct suction and discharge
streams.
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Its top to bottom circulation pattern is of
particular value in deep tanks for suspension
of solids and for dispersion of gases.
 Impellers

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Propellers, turbines, paddles, anchors, helical
ribbons and helical screws are usually
mounted on a central vertical shaft inside a
vertical cylindrical tank. Their range of
application depends to a great extent upon
liquid viscosity.
– Propeller (< 2 kg/ms)
– Turbine (< 50 kg/ms)
Viscosity
– Paddle (< 1000 kg/ms) increase
– Anchor
– Helical ribbon
Speed
– Helical screw increase
 Impellers

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Angled blade turbines are used to promote
vertical mixing.
• Retreating-curve blade turbines are used to
promote radial mixing and to reduce fluid
drag.
• Propellers are used to promote vertical mixing.
• Helical screws and anchors promote mixing at
the vessel wall and vertical circulation of the
process fluid.
 Impellers

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Impellers are categorized by their ability to
dissipate energy.
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Flow impellers
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Shear impellers
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Pressure impellers

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Each impeller has a primary function, such as
developing flow. The components of its other
functions (shear and pressure) also need to be
considered in their design.
 Flow Impellers

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These impellers provide good mixing and top-
to-bottom motion throughout the tank.
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The majority of processing requirements are
flow-controlled applications in which the flow
generated has a direct result on the outcome
of the process.
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For example, blending of two miscible liquids
requires high bulk fluid flow to ensure good
mixing while generating very little shear that
could emulsify the two components of the
mix.
 Shear Impellers

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These impellers produce a high level of
energy in a small area.
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Relatively little flow while imparting extremely
high amounts of localized shear to break down
and disperse the solids uniformly in the liquid.
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For example, pigment dispersions, solids
make-down to gas dispersions and
emulsification.
 Pressure Impellers

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These impellers push against a static head
while producing the flow necessary to
complete the process.
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Most notably used in minerals processing
circulators, such as CIP tanks, alumina
precipitators, phosphoric acid isothermal
reactor, fermentations and bio-oxidations.
 Impeller Flow Patterns

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Flow patterns in an agitated tank generally fall
into three categories:
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Axial
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Radial
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Tangential (to a much less extent)
 Axial Flow

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Axial flow discharge coincides with the impeller
shaft’s axis.
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When the impeller operates in a down-pumping
model, the flow impinges on the tank’s bottom and
spread out in all direction towards the walls. The
flow rises along the walls up to the liquid surface
and is pulled back to the impeller.
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85% of the mixer market is focused on flow-
controlled applications, considerable attention is
paid to designing axial flow impellers, which are
the best impellers for producing flow.
 Axial Flow

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Because axial flow impellers produce only one
loop, fluids mix faster and blend time is
reduced, compared to radial flow impellers.
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And because the fluid does not take sharp
turns near the impeller, power consumption of
axial flow impellers is less than that of radial
flow impellers at the same speed and the
same diameter.
 Axial Flow

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Axial flow impeller
applications:
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Solid-liquid suspensions
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Solid-liquid catalytic reactions
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Dissolving solids
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Blending
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Neutralization
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pH control
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Temperature and concentration
uniformity
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Oil storage tanks

– ...
 Radial Flow

• Radial flow discharge is parallel to the impeller

radius toward the tank wall.
• If a radial impeller is not positioned close to
the surface or to the tank bottom, the flow is
split into two streams upon impinging on the
tank wall. Each flow loop continues along the
wall and then return to the impeller.
 Radial Flow

• Radial flow impeller is beneficial for high-shear

applications:
– Gas-liquid dispersions and absorption
– Liquid-liquid dispersions
– Emulsifications and extractions
– Wetting of polymers
– Reducing particle sizes
– Increasing heat transfer with internal coils
– ...
 Tangential Flow

A tangential flow pattern is the naturally

induced swirling or vortexing flow that fluids
assume in an unbaffled tank.
Tangential flow patterns offer very little mixing
because of small velocity gradients.
Beneficial in certain applications:
Heat transfer
Drawing down of solids, liquids and gases from the liquid
surface
Typical impellers used are anchors, paddles,
pitched blade turbines and backswept curved
bladed turbines.
 Mixing Tips

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Impellers should most often be center
mounted.
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The impeller should be located 1/2 to 2D
(diameter) off bottom, depending on a variety
of factors, including the solid suspension level
and the viscosity.
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If gross vortexing is excessive, mount the
impeller off-center as much as half the tank
radius.
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If must use a square or rectangular tank
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Center mount impeller.
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Combine a lower prop with an upper impeller to
assist drawdown.
 Summary

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Various mixing equipment

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Agitated mixing tank

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Components of agitated mixing tanks

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Flow patterns