Mixers impellers, types

The pumping number is a function of impeller type, the impeller/tank diameter ratio (D/T), and mixing Reynolds number Re = pND /p.. Figure 3 shows the relationship (2) for a 45° pitched blade turbine (PBT). The total flow in a mixing tank is the sum of the impeller flow and flow entrained by the hquid jet. The entrainment depends on the mixer geometry and impeller diameter. For large-size impellers, enhancement of total flow by entrainment is lower (Fig. 4) compared with small impellers. 

When comparing flow (or pumping) per power, we determine that it is dependent on the impeller type, speed, diameter, and geometry of the installation. The mixer is not fully specified until torque, x, and lateral loads (fluid force, F) are included in the analysis [29]. 

Because the most common impeller type is the turbine, most scale-up published studies have been devoted to that unit. Almost all scale-up situations require duplication of process results from the initial scale to the second scaled unit. Therefore, this is the objective of the outline to follow, from Reference [32]. The dynamic response is used as a reference for agitation/mixer behavior for a defined set of process results. For turbulent mixing, kinematic similarity occurs with geometric similarity, meaning fixed ratios exist between corresponding velocities. 

The power put into a fluid mixer produces pumping Q and a velocity head H. In fact all the power P which is proportional to QH appears as heat in the fluid and must be dissipated through the mechanism of viscous shear. The pumping capacity of the impeller has been measured for a wide variety of impellers. Correlations are available to predict, in a general way, the pumping capacity of the many impeller types in many types of configurations. The impeller pumping capacity is proportional to the impeller speed N and the cube of the impeller diameter D,... 

First ask yourself if there is any role for fluid shear stresses in determining and obtaining the desired process result. About half of the time the answer will likely be no. That is the percentage of mixing processes where fluid shear stresses either have no effect or seem to have no effect on the process result. In these cases, mixer design can be based on pumping capacity, blend time, velocities and other matters of that nature. Impeller type location and other geometric variables are major factors in these types of processes. 

After the precise formulation of the liquid product constituents has been prepared, the constituents are manually added to a liquid mixer. This type of mixer is simpler in design than dry product mixers and more closely resembles a large drum with impeller blades. 

Figure 6.1 is an example of a rotational mixer. This type of setup is used to determine the optimum doses of chemicals. Varying amounts of chemicals are put into each of the six containers. The paddles inside each of the containers are then rotated at a predetermined speed by means of the motor sitting on top of the unit. This rotation agitates the water and mixes the chemicals with it. The paddles used in this setup are, in general, called impellers. A variety of impellers are used in practice. 

The slurry concentrate of the drug is agitated gently with an impeller-type mixer. 

Mass-Transfer Models Because the mass-transfer coefficient and interfacial area for mass transfer of solute are complex functions of fluid properties and the operational and geometric variables of a stirred-tank extractor or mixer, the approach to design normally involves scale-up of miniplant data. The mass-transfer coefficient and interfacial area are influenced by numerous factors that are difficult to precisely quantify. These include drop coalescence and breakage rates as well as complex flow patterns that exist within the vessel (a function of impeller type, vessel geometry, and power input). Nevertheless, it is instructive to review available mass-transfer coefficient and interfacial area models for the insights they can offer. 

Many types of multishaft mixers do not require planetary motion. Instead the mixers rely on an anchor-style impeller to move and shear material near the tank wall, while another mixer provides a different type of mixing. The second or third mixer shafts may have a pitched-blade turbine, hydrofoil impeller, high-shear blade, rotor-stator mixer, or other type of mixer. The combination of multiple impeller types adds to the flexibility of the total mixer. Many batch processes involve different types of mixing over a range of viscosities. Some mixer types provide the top-to-bottom motion that is missing from the anchor impeller alone. 

There are many ways to obtain mixing in a vessel. This chapter focuses on the turbulent impeller type of mixers, as they are frequently applied in the chemical process industries. 

To complete the current picture, when composite materials are used, the airfoil can be shaped in any way that is desirable. The A6000 (Fig. 9e) illustrates that particular impeller type. The use of proplets on the end of the blades increases flow about 10% over not having them. An impeller which is able to operate effectively in both the turbulent and transitional Reynolds numbers is the A410 (Fig. 9f) which has a very marked increase in twist angle ofthe blade. This gives it a more effective performance in the higher viscosity fluids encountered in mixers up to about 3 kW. 

This section describes mixer geometry impellers (types listed in Figure 9.3), the number required, their characteristics, importance of location, vessel shape, and effects of baffles. An example is given to show a basic calculation of mixer power and flow. 

The simple concept of an average mixer shear rate has been widely used in laboratory and industrial work and in most applications it has been assumed that the shear rate constant, k, is only a function of impeller type. Research is continuing on the possible influence of flow behaviour index and elastic properties, and also on procedures necessary to describe power consumption for dilatant fluids. It should be noted that in all aspects of power prediction and data analysis, power law models (equation 8.12) should only be used with caution. Apparent variability of k, may be due to inappropriate use of power law equations when calculations are made it should be ascertained that the average shear rates of interest (y = k N) lie within the range of the power law viscometric data. 

Figure 22-1 outlines the steps in a typical sizing procedure. The customer usually specifies a particular process requirement, a tank diameter, and a volume. The process requirement may be solids suspension, blending, mass transfer, or combinations of the above. The mixer supplier uses this preliminary information to calculate process sizing and impeller type. From these calculations, the supplier selects a specific power requirement and impeller diameter, which in turn lead to the selection of the operating speed. 

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