MIXING TANK

Introduction

Mixing is important in the preparation of solid, liquid, and gases in the production process of various
industries. In designing the equipment to be used, the nature of the chemicals involved should be known
and assessed so that the nature of materials to be used and the degree of mixing could be identified. In
mixing liquid and solid operations, batch processes are the most commonly used.

A mixer will be designed that will be used in a process in biodiesel production. The plant is a small scale
plant due to the limited amount of raw material supplied per day. The equipment will be used to mix two
raw materials which are vital in biodiesel production. Ethanol and calcium oxide derived from calcined
duck eggshells are mixed before they are subjected into a transesterification process reactor. The mixing
occurs through the bulk flow of the liquid and by the motion of the eddies created by it. Impellers that are
used at high reynold’s numbers are propeller and pitched-bladed turbine which are essentially axial flow
devices and are suitable for bulk fluid mixing.

Design Calculation

F1= 41.10 kg calcined F3= 750.77 kg

duck eggshells/batch base catalyst
F2= 709.67 kg slurry/batch
ethanol/batch

Mass Balance

Assumptions:

1. There is no loss of material during mixing

2. The pressure drop associated with the mixing of streams is small, and the pressure drop
can be assumed to be equal to zero with little error (Turton, Bailie, Whiting, Shaeiwitz,
& Bhattacharyya, 2012).

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
 Mass flow rate of the base catalyst slurry

𝑚3 = 𝑚1 + 𝑚2

𝑚3 = 41.10 𝑘𝑔 + 709.67 𝑘𝑔

𝑚3 = 750.77 𝑘𝑔/𝑏𝑎𝑡𝑐ℎ

Energy Balance

Assumptions:

1. The equipment will follow the geometric proportion for a “standard” agitation system.
2. Assuming the calcined duck eggshells has been efficiently converted to CaO.
3. Both components enter with the same pressure and temperature.

Two streams of different properties will enter the system. In order to obtain its Reynold’s number, the
viscosity and density of the mixture should be determined first.

The density can be determined by using E. Shashi Menon’s Method:

100
𝜌𝑚 =
𝐶𝑤 100 − 𝐶𝑤
+
𝜌𝑠 𝜌𝐿

Where:

ρm = density of mixture, kg/m3

Cw = solid concentration, % wt

ρs = density of solid particles, kg/m3

ρL = density of liquid, kg/m3

the density of calcined duck eggshells, ρs is 3340 kg/m3 while the density of ethanol, ρL is 789 kg/m3. The
solid concentration can be calculated by dividing the mass of solid particles present in the overall mass
that comes in the system.

41.10 𝑘𝑔
𝐶𝑤 = 𝑥100 = 5.47%
750.77 𝑘𝑔

Having the value of solid concentration, the density of the slurry mixture can be obtained.
100
𝜌𝑚 = = 823.40 𝑘𝑔/𝑚3
5.47 100 − 5.47
3340 + 789

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
The concentration of solids by volume, Cv in % weight and the concentration of solids by weight, Cw have
a relationship to the solid density and the mixture density.
𝜌𝑚
𝐶𝑣 = 𝐶𝑤 𝑥 ( )
𝜌𝑠
823.40
𝐶𝑣 = 5.47 𝑥 ( )
3340
𝐶𝑣 = 1.35 %

The term volume fraction, Φ represent the ratio of the volume of solid to the volume of liquid.
𝐶𝑣
Φ=
100
1.35
Φ=
100
Φ = 0.0135

The viscosity of a dilute suspension of solids in a liquid can be determined from the volume fraction and
viscosity of the liquid.

𝜇𝑚 = 𝜇𝐿 𝑥 (1 + 2.5Φ)

Where:

µm = viscosity of slurry mixture, cP

µL = viscosity of liquid in slurry mixture, cP

the viscosity of ethanol, µL is 1.095 cP

𝜇𝑚 = 1.095 𝑥 [1 + 2.5(0.0135)]

𝜇𝑚 = 1.132 𝑐𝑃

Mechanical Design of the Mixing Tank

Since the system is a batch liquid-solids system, it is important to identify what kind of impeller, and type
of agitation is needed. In doing so, the dimensions and power required can also be obtained.

𝑚𝑎𝑠𝑠 𝑚𝑖𝑥𝑡𝑢𝑟𝑒
𝑉𝑚𝑖𝑥𝑡𝑢𝑟𝑒 =
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑚𝑖𝑥𝑡𝑢𝑟𝑒

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
 750.77 𝑘𝑔
𝑉𝑚𝑖𝑥𝑡𝑢𝑟𝑒 =
823.40 𝑘𝑔/𝑚3

𝑉𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = 0.912 𝑚3

Table 1 Geometric Proportions for a "Standard" Agitation System

For a “standard” agitation system, the ratio of the fluid height to the tank diameter is equal to 1.
𝜋 2
𝑉𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = 𝐷 𝐻
4 𝑡
𝜋 3
𝑉𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = 𝐷 = 0.912𝑚3
4 𝑡
𝐷𝑡 = 𝐻 = 1.05 𝑚

The ratio of the impeller diameter to the tank diameter is 0.4

𝐷𝑎 = 0.4 𝐷𝑡 = 0.4 (1.05 𝑚) = 0.42 𝑚

Impeller to bottom of the tank clearance,

1 1
𝐶 = 𝐷𝑡 = (1.05 𝑚) = 0.35 𝑚
3 3

Baffle width,
1 1
𝐽= 𝐷𝑡 = (1.05 𝑚) = 0.0875 𝑚
12 12

0.45
0.1 0.2 𝑔(𝜌𝑝 − 𝜌𝐿 )
𝑆𝑣𝐿 𝐷𝑃 [ 𝜌𝐿 ] 𝑋 0.13
𝑁𝑗𝑠 =
𝐷𝑎0.85

Where:

Njs = stirring speed required for suspension of solids

S = Zwietering factor

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
 vL = liquid kinematic viscosity

Dp = diameter of the solid particles, m

Da = impeller diameter, m

g = acceleration due to gravity, m2/s

ρs = ρp = density of particle in mixture, kg/m3

ρL = density of liquid in mixture, kg/m3

X = weight percent of particles in the suspension

Basing on table 2 for values of the geometric parameter S, the corresponding zwietering factor of a propeller
impeller is equal to 6.6

Table 2 Values of the Geometric Parameter S for Flat-bottom tanks

0.45
9.8(3340 − 789)
(6.6)(2.02𝑥10−6 )0.1 (0.00007)0.2 [ 789 ] (5.47)0.13
𝑁𝑗𝑠 =
(0.42)0.85

𝑁𝑗𝑠 = 3.24 𝑟𝑝𝑠

The minimum speed of the impeller to achieve a just suspension is equal to 3.34 revolution per seconds or
194 revolutions per minute. This minimum speed will suspend the calcined duck eggshells in the fluid
system, which is the ethanol.

Solving the Reynold’s Number will help determine the power required to drive the impeller.

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
 𝐷𝑎2 𝑁𝜌
𝑁𝑅𝑒 =
𝜇

Where:

NRe = Reynold’s number

Da = impeller diameter

N = impeller speed

ρ= density of mixture

µ = viscosity of mixture

(0.42)2 (3.24)(823.40)
𝑁𝑅𝑒 = = 415727
(0.001132)

The Reynold’s number calculated indicates that the flow inside the system is turbulent. Turbulent flow
shows that vigorous mixing is happening within the system. Thus, the strong axial flow of liquid will not
allow any solids in settling at the bottom of the tank. Using curve 2, for propeller agitators, at a Reynolds
number of 415727 a corresponding Np of 4 is obtained.

𝑃
𝑁𝑃 =
𝜌𝑁 3 𝐷𝑎5
𝑃
4=
(823.40)(3.24)3 (0.42)5

𝑃(1000)
4=
(823.40)(3.24)3 (0.42)5

𝑷 = 𝟏. 𝟒𝟔 𝒌𝑾

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
 Table 3 Power requirement for baffled agitated tanks

For applications such as slurry suspension, the power calculated has classified what kind of agitation is
needed.

Materials of Construction

Vessel: Ethanol is the most abundant chemical that will enter the system. Ethanol is non-corrosive chemical
so the material for construction to be used can be carbon steel. This is popularly used with organic chemicals
and neutral or basic aqueous solutions. It cost less and can be easily fabricated due to its availability. There
was no data on what material is suitable for a slurry having Calcium oxide. Since the solid content present
in the slurry is 5.47% of the total mass entering, the component considered in designing the vessel will be
in accordance to ethanol.

Shaft and Impeller: There design of the shaft should be able to withstand the torque and bending moment
of the impeller. A strong material should be used for it to handle such forces. Stainless steel type 302 has a
composition of 17% Cr, 8% Ni, and 0.15% C where its general purpose is similar to austenitic type with
good corrosion resistance and mechanical process.

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
Specification Sheet

Equipment No.
Mixer Data Sheet Descript. (Func.)
Sheet No.
1
Operating Data
2
No. of Machines 1 3
Rate of Charging 750.77 kg/batch 4
Mixing Time 15 mins 5
Type of Mixing Turbulent 6
5.47% Solids 3.2
Solids Content 7
S.G.
1.095 cP Liquid 0.79
Liquid Viscosity 8
S.G.
Mixture Viscosity 1.132 cP 9
10
Vessel Data
11
Depth of Vessel 1.26 m 12
Depth of Mixture 1.05 m 13
Diameter 1.05 m 14
Capacity 0.912 m3 15
Working 25OC
16
Temperature
17
Technical Data
18
Type of Mixer Propeller 19
Rotational Speed 194 rpm 20
Motor Power Supply 1.46 kW 21
Max Torque 22
Method of Support 23
24
Materials of Construction
25
Shaft Stainless Steel 26
Support 27
Vessel Carbon steel 28
Impeller Stainless Steel 29

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.
References
Couper, J., Penney, W., Fair, J., & Walas, S. (2012). Chemical Process Equipment Selection and Design.
Butterworth Heinemann.

Hall, S. (2012). Branan's Rules of Thumb for Chemical Engineers. Butterworth Heinemann.

Peter, M., Timmerhaus, K., & West, R. (2003). Plant Design and Economics for Chemical Engineers.
Elizabeth A. Jones.

Sinnott, R. (2003). Coulson and Richardson's Chemical Engineering Chemical Engineering Design.
Butterworth Heinemann.

Towler, G., & Sinnot , R. (2008). Chemical Engineering Design Principles, Practice and Economics of
Plant and Process Design. Butterworth-Heinemann.

Turton, R., Bailie, R., Whiting, W., Shaeiwitz, J., & Bhattacharyya, D. (2012). Analysis, Synthesis, and
Design of Chemical Process. New Jersey: Prentice Hall.

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Design Report No. 2 Designing Process Vessels and Piping System Rodrigo, Jessa Maye H.