You are on page 1of 20

PRINCIPLES OF FLUID MIXING

Phone: 616/399-5600
Fax: 616/399-3084

TABLE OF CONTENTS

Types of Mixers … … … … … … … … … … … … … … 8.1

Mixer Terminology … … … … … … … … … … … … … 8.3

D/T and Z/T … … … … … … … … … … … … … … … 8.7

Axial Flow and Radial Flow … … … … … … … … … 8.8

Flow and Shear … … … … … … … … … … … … … … 8.9

Horsepower (Work, Power, Shaft) … … … … … … … 8.10

Reynolds Numbers … … … … … … … … … … … … 8.12

Pumping Capacity or Flow … … … … … … … … … … 8.14

Torque … … … … … … … … … … … … … … … … … 8.15

Shaft Terminology … … … … … … … … … … … … … 8.16

Critical Speed . … … … … … … … … … … … … … … 8.17

Impeller Effect on Critical Speed … … … … … … … … 8.18

Nomenclature… … … … … … … … … … … … … … … 8.19

©Copyright 2003 BRAWN Mixer, Inc. Page 8-i


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084

TYPES OF MIXERS

Many types of mixers are available. Some mixers are designed specifically for one special application,
while others are more versatile with many options such as variable speed, changeable impellers and
shafts, plus a wide range of motor horsepower. This data sheet will clarify some of the designations
commonly used when discussing mixers.

Aerator: A mixer or other device used to dissolve air into water, usually for biological
waste treatment. It may operate at the surface by splashing, or submerged with
a pipe, or with a sparge providing air to the impeller.

Air Mixer: A mixer with a motor which uses compressed air instead of electricity is
sometimes called an air mixer or air-drive mixer, or pneumatic mixer.

Bottom Entry: A mixer whose drive is mounted to the bottom head of a vessel. The mixer shaft
enters through the tank bottom therefore must be equipped with some type of
shaft seal.

Direct Drive: A direct drive has an output shaft, which rotates at the same speed as the motor.
Direct-drive mixers are relatively simple and offer a higher component of shear to
the process.

Disperser: A special purpose high-shear mixer or just the blade or impeller. Typically, a
high-speed device often with sharp edges (some look like circular saw blades
with bent teeth) used to break up powders or particles to dissolve or suspend
them. (See Rotor Stator definition also.)

Flocculator: A relatively slow-RPM mixer, which is used to enhance the contact of particles in
suspension to agglomerate them for easier settling or separation.

Gear Drive: A mixer with an output shaft that has a speed lower than the motor speed
because of a gear reducer between the motor and output shaft. This mixer
transmits higher torque and has higher pumping efficiency per horsepower.

Homogenizer: A very high-speed mixer used to blend immiscible phases of a solution into a
cream or emulsion.

Magnetic Drive
Mixer: One whose shaft and impeller is driven by a magnet. The internal mixer shaft is
driven by a magnetic field. The driven shaft does not penetrate the vessel
affording ‘seal less’ mixing.

Portable Mixers: These mixers are relatively easily moved from tank to tank and mounted to tank
walls with a C-clamp or adjustable plate mount.

__________________________________________________________________________________
©Copyright 2003 BRAWN Mixer, Inc. Page 8-1
PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084

TYPES OF MIXERS
(continued)

Rotor Stator: A type of high shear mixer which utilizes a rotating head/impeller inside a
stationary shroud or cage.

Sanitary Mixers: A mixer whose drive components (motor, gearbox) are made from stainless steel
or other approved materials. These are used in sanitary and washdown
environments, as well as highly corrosive atmospheres.

Side-Entry Mixers: Mixers mounted on a flange through the side of a tank or chest. Often used for
very tall tanks to reduce capital cost.

Static Mixers: These are pipes with specially-designed baffles inside which blend fluids as they
flow through. These mixers do not have any moving parts.

Top-Entry Mixers: Mixers mounted on the rim, on beams, or on a flange entering from the top of the
tank.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-2


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084

MIXER TERMINOLOGY

Axial Flow: Fluid flow directed axially along the mixer shaft from top to bottom (down-
pumping), or from bottom to top (up-pumping) is called axial flow.

Baffles: Structures attached to an inside tank straight side, either directly or on tabs to
direct the fluid flow vertically in the tank preventing swirl and vortexing.

Bending Moment: The product of force times distance. Fluid forces are exerted on a mixer shaft at
each impeller. The force (lbs) times the distance from the impeller to the lowest
shaft bearing (in) is the bending moment (in –lb). For multiple impellers, the shaft
bending moment is the sum of the individual bending moments.

Bulk Fluid Velocity: The primary pumping rate of a mixer divided by the plan, cross sectional area of
the mixed vessel. Example: Ft3/min ÷ Ft2 = Ft/min.

Case Size: Speed reducer size on gear-driven mixers. When torque design limits are
reached, or when a larger diameter shaft is required to meet other design criteria,
the next larger size gear box (case size) must be used. A given case size may
accommodate many various horsepower and input/output speed combinations,
but carries the same torque and shaft size.

Coverage: The distance between the impeller and the liquid surface. Typical optimum
coverage is equal to twice the impeller diameter. Insufficient coverage may
cause vortexing and/or air entrainment.

Critical Speed: A rotational speed (rpm) of a mixer shaft which is operating at the shaft’s natural
vibration frequency (cycles/min). Operating a shaft at critical speed may amplify
vibrations leading to shaft failure by excessive deflection.

D/T: The ratio of impeller diameter (D) to tank diameter (T).

Dry Well Mixer: A vertically-mounted mixer which utilizes a gear drive that has an oil dam called a
“dry well” around the output shaft. The oil dam extends above the oil level of the
gearbox so that the oil cannot run out of the gearbox during operation.

Equivalent Weight: A calculated value representing the combined impeller weight at the shaft end
when several impellers are installed on a shaft.

Entrainment: The result of the drawing force produced by a flowing fluid, which drags
additional fluid (entrained flow) or air (air entrainment) along with the pumped
fluid.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-3


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084
MIXER TERMINOLOGY
(continued)

Flow: One of two components resulting from the action of a mixer impeller (see
“Shear”). The bulk movement of the fluid. Primary impeller pumping rate
measured in gallons per minute is often referred to as flow.

Fluid Force: The forces exerted on a mixer shaft through the impeller as a result of the fluid
motion in the tank. Fluid forces are calculated for each impeller and used to
calculate the shaft bending moment.

Frame Size: Relating to the physical size of a motor. Frame size is dependent on motor HP,
enclosure, speed, power supply voltage and phase. Example: ½ HP, 1800
RPM, 230/460V has a NEMA 56 frame; 3 HP, 1800 RPM, 230/460V has a NEMA
182 frame.

Freeboard: The distance from the liquid surface to the top of a tank. This distance must be
taken into account when sizing a mixer shaft to ensure adequate coverage.

Free Flow/
Plug Flow: The unobstructed flow of a fluid. Mixer characteristics, such as pumping capacity
and power requirement, are based on the assumption that no obstructions or flow
constrictions are present.

HP (Horsepower): A unit for measuring the power of motors, equal to 746 Watts. In mixer
applications, horsepower may be expressed as shaft HP or motor HP.

Impeller: The device responsible for the actual mixing action in a process. The rotating
impeller is responsible for flow and shear imparted to the fluid as it rotates.

MHP (Motor Horsepower): The actual shaft horsepower, divided by motor efficiency, determines the
required motor nameplate horsepower.

Np: Power number. A constant, unique to each type of mixing impeller, used to
calculate power draw. Power number varies with Reynolds number, but may be
treated, as a constant if the Reynolds number is sufficiently high.

NQ: Flow number. A constant, derived empirically for each unique geometric shape
of mixing impeller, used to calculate flow or pumping rate.
Off Bottom: The distance from the impeller to the tank bottom. Typically, the off-bottom is
between one to two times the impeller diameter.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-4


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084
MIXER TERMINOLOGY
(continued)

Prandl Number: A dimensionless number used to estimate the boundary layer film co-efficient in
heat transfer calculations. In fluids, Prandl Numbers cannot be estimated
accurately and therefore must be derived experimentally.

Q: Flow or pumping rate, measured in gallons per minute, which is the actual
discharge rate of a specific size and type of mixing impeller.

Radial Flow: Impellers that draw from above and below the impeller and discharge it toward
the tank wall, perpendicularly from the mixer shaft, are radial flow impellers. This
type of flow is called radial flow.

Reynolds Number: A dimensionless number used to indicate the type of fluid motion being
produced. The value of this number determines the value of the power number,
which affects the HP draw. Reynolds numbers below 1,000 are considered
laminar; above 2,500 is turbulent flow.

Right-Angle Mixer: A mixer with the motor shaft input perpendicular to the gearbox output shaft. The
motor suspends off the side of the gearbox, keeping the required headroom to a
minimum.

Service Factor: Equipment having a service factor of 1.0 for a given level of performance is
designed to operate without excessive wear or failure over its lifetime at that
performance level. For instance, a 1 HP motor rotating at 1725 RPM with a
service factor of 1.0 will operate for many years under a 1 HP load. A gearbox
designed to transmit 1 HP has a service factor of 1.0 when loaded to 1 HP. If,
however, that same gearbox is loaded to only ½ HP, it now has a service factor
of 2.0, indicating that it is capable of heavier duty than the current use and should
have a longer service life.

Shaft Stress: The intensity of the straining force on a mixer shaft that tends to deform its shape
or cause it to fracture. It is usually expressed in PSI. Shaft stress is calculated
from the bending moment. Stress limits are known for various materials under
static loads. For mixer shafts which are subjected to alternating stresses
because of their rotation, a fatigue stress limit must be established which is much
less than the static limit. Mixers should not be designed with a shaft stress
higher than 15,000 PSI.

Shear: One of two components resulting from the action of a mixer impeller (see
“Flow”). Different velocities existing simultaneously (velocity gradient = shear
rate) which produce stresses on the fluid. Shear rate X viscosity = shear stress
in PSI. Shear stress is responsible for small scale fluid intermixing.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-5


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084
MIXER TERMINOLOGY
(continued)

SHP
(Shaft Horsepower): The actual power required to drive the mixer impeller in the specific process fluid
at the rotational speed supplied to the mixer shaft.

Specific Gravity: The ratio of fluid density E.G. (lb/gal) to the density of water (8.33 lb/gal @ 25°C,
1 atm pressure) under current conditions.

T: Tank diameter.

Tip Speed: The peripheral speed of a rotating impeller. Tip speed is something used to
estimate the shear applied to a fluid. Tip Speed = RPM X D X π.

Torque: The twisting force that is created by a motor and/or gearbox to produce rotation
of a mixer shaft.

Velocity Head: For the mixer concepts presented in these data sheets, velocity head and shear
have the same meaning. (See “Shear”).

Viscosity: Internal fluid friction. The property of a fluid that enables it to develop and
maintain an amount of shearing stress dependent upon the velocity of flow and
then to offer continued resistance to flow.

Z: The designation used to signify the liquid level or height in a tank.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-6


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084

D/T and Z/T


TANK DESIGN CONSIDERATIONS

Other than the mixer itself, the mixing tank


design is the single most important factor in
successful process result.

In order for a mixing impeller to perform optimally,


correct location and liquid coverage is essential.
Incorrect position of mixing impeller may hamper
mixing performance and be detrimental to the
performance life of the mixer drive.

D/T is the ratio of impeller diameter to tank


diameter. For most mixing applications, it ranges
from 0.20 to 0.60. A D/T that is too small may
leave areas unmixed. A D/T too large may choke
off the upflow between the impeller and the tank
wall. Mixer sizing for general blending starts with a
D/T of 0.25. The impeller diameter is then adjusted
to fit the most economical drive selection. A
smaller D/T may be offset by high flow created by
turning at higher RPM.

Z/T is the ratio of liquid height to tank diameter.


When this ratio exceeds 1.2, dual impellers should
be used.

Illustration No. 1 Off-bottom distance is normally 1 to 2 impeller


diameters. Coverage is typically 2 to 4 impeller
diameters.

Typical Baffle Arrangements

Four (4) baffles, 90° apart. Baffle width 1/12 the tank diameter;
length is from the liquid level down to 6 inches off bottom.

Three (3) baffles, 120° apart. Baffle width 1/12 the tank diameter;
length is from the liquid level down to 6 inches off bottom.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-7


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084

AXIAL FLOW and RADIAL FLOW

Illustration No. 2 Illustration No. 3

Most ‘open impeller’ mixing applications operate in the turbulent regime (meaning low viscosity).
Applications requiring high flow are generally best performed with axial flow impellers. If high shear is
required, radial flow impellers may be preferred.

Close clearance impellers including those which ‘scrap’ the tank interior work best in laminar
flow (high viscosity) conditions.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-8


PRINCIPLES OF FLUID MIXING
3389 128th Avenue Phone: 616/399-5600
Holland, MI 49424 USA Fax: 616/399-3084

FLOW and SHEAR


Constant Horsepower
In general, a mixer with a small diameter impeller,
Impeller Type turning at a high speed, will result in the fluid seeing
the applied power as mostly shear. This is
Rake/Picket Fence represented by the bottom of the impeller spectrum
Helix Flow Q above. Conversely, a low-speed mixer with a larger
Hydrofoil diameter impeller will discharge a higher volume of
Propeller fluid, resulting in high flow. The required ratio
Axial-Flow of these components is determined according
Turbine to the application requirement.

Homogenizers are relatively small-bladed, very high


Radial-Flow RPM mixers, which produce tremendous amounts
Turbine of shear for dispersing two phases into an emulsion.
Bar Turbine Flocculators, by way of contrast, are typically
Sawtooth slow moving, large diameters, which gently push
Impeller & liquid around a tank to build large particles from
Stator Shear S smaller ones with the aid of chemical addition.
(Velocity Head) An impeller which produces high flow would have
Homogenizer little effect in a process requiring dispersion.
Illustration No. 4 (Impeller Spectrum): The list of Shear in flocculation would have a negative
impellers at the left of our impeller spectrum is a effect.
sampling which illustrates that different impeller shapes
produce different ratios of flow and shear. The importance of understanding this principle
lies mainly in recognizing that equal power does
not mean equal mixing result. The process result
The energy which a mixer transmits to the fluid is always a function of impeller type AND speed
results in two effects - flow and shear (or velocity and diameter.
head) - by the following relationship:
In Section 8.1 we will further discuss how it is
P oc Q x S x S.G. feasible to change the effect of mixing performance
where: P = Power without changing impeller type while maintaining
Q = Flow a constant horse power.
S = Shear (head)
S.G. = Specific Gravity Mixing processes such as blending, dissolving and
solids suspension are 'flow or pumping-controlled'
For a given power level, a mixture can be designed and make up most mixing applications. If high shear
so that either the shear component or the flow is not an essential component in achieving your
component represents most of the power applied. result, you should select a mixer with lower speed,
and larger diameter impellers. This will produce
more flow per utility dollar.

Copyright 2003 BRAWN Mixer, Inc. Page 8-9


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 U.S.A. Fax: 616/399-3084

HORSEPOWER

The power consumed by a rotating impeller in a process fluid is easily measured. The units we
typically express this power in is ‘horsepower’. It is common to relate mixer performance to
horsepower. However, there are problems associated with this tendency.

Horsepower can be calculated for most mixer (turbulent flow) applications as follows:

SHP = Np N3 D5 S.G.
1.53 x 1013

NP = Power Number of impeller


N = Impeller speed (RPM)
D = Impeller diameter (IN)
S.G. = Specific Gravity
1.53 x 1013 = Conversion factor

As can be seen from this formula, changes in RPM or impeller diameter have a major impact on
required horsepower to operate your mixer. When we examine this horsepower effect closely and tie it
together with the formula for pumping capacity(see Pumping Capacity, page 8) we can derive the
following:

QHP = D4/3K

QHP = Flow at constant HP


D = Impeller Diameter (inches)
K = A Constant

What this means is, if horsepower is constant and we increase impeller diameter, (RPM’s must go
down) and hence increase D/T, we receive a disproportional gain in flow.

The following table illustrates this:

2HP Mixers

Model RPM Max AF3 Diameter Q(gpm)

BD200 1725 7.24” 1559


BGM200 350 18.85” 5582
BGM200-233 233 24.05” 7717
3BTO2-68 68 50.4” 20,727

©Copyright 2003 BRAWN Mixer, Inc. Page 8-10


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 U.S.A. Fax: 616/399-3084

HORSEPOWER (Continued)

Viscosity Effect: As described in section 8-12 on Reynolds Number, as viscosity increases, impeller
power number may begin to increase. This becomes important in the HP calculations because as
power number begins to go up so does the horsepower required to drive the mixer. Simply increasing
the input horsepower may be the answer, but one must bear in mind that this change reduces the
service factor of the mixer drive, hence a ‘bigger’ mixer may be required.

Viscosity increase also effects the flow characteristics of fluid as compared to water. A correction factor
may be obtained from a qualified mixer application engineer. However, most viscons fluids should be
checked in the lab to obtain a predictable viscosity profile.

Multiple Impellers: More than one impeller may be required for some processes. This may be due to
tank geometry or fluid characteristics. Regardless of how many impellers are required or why, it is
important to realize the multiple effect on horsepower required.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-11


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

REYNOLDS NUMBERS

Viscosity Effect on Mixing Performance

Reynolds Number is a dimensionless number that can be derived as follows:

Nre = 10.75 N D2 S.G.


Viscosity

visc. = fluid viscosity (cPs)

Power number is constant for each impeller type, as long as the Reynolds number is sufficiently high.
Power number is a function of Reynolds Number.

The Reynolds number is the indicator of the type of mixing fluid regime your mixer will operate in, in the
process fluid. If the Reynolds Number is above 2,000, you are generally operating in the fluid regime
where the power number is constant (turbulent flow). When the Reynolds Number you calculate is less
than 1,000 (laminar flow), then the Power Number increases as the Reynolds Number decreases (see
Illustration No. 5). Consequently, the shaft horsepower you calculate must be based on the corrected
power number. In this case, you will need to obtain an Np (Power Number) vs Nrey (Reynolds
Number) curve from the impeller manufacturer or by experimentation. The Illustration shows how the
Power Number for each impeller varies with changes in Reynolds Number.

The Illustration below shows that, as Reynolds Number drops, we reach a point where the power
number begins to increase sharply. This point depends on the type of impeller in use. Reynolds
Numbers or Nrey between 1000 and 2000 are generally considered “in transition”.

A1
A2

Illustration No 5
©Copyright 2003 BRAWN Mixer, Inc. Page 8-12
PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

POWER NUMBERS

Each impeller of constant geometric design demonstrates a uniform Power Number curve. By knowing
the impeller speed and diameter, the fluid specific gravity, and measuring the shaft horsepower, we can
calculate the impeller Power Number with the following formula:

Np = 1.53 x 1013 SHP


N3 D5 S.G.

SHP = Shaft horsepower (HP)

N = Speed (RPM)

D = Impeller diameter (INCHES)

S.G. = Specific Gravity

Impeller Power Numbers are generally derived in water-like fluids.

Notice that, for very high Reynolds Numbers, (low viscosity) the Np curve is flat. This indicates that the
Power Number is constant. Calculating horsepower with this constant Np can be accomplished using
the equation as shown in the “HORSEPOWER (Work, Power Shaft)” section.

Many open impeller mixing applications are what we commonly refer to as flow controlled applications.
This means that the process result is a direct result of the mixer pumping rate or flow. This concept can
be seen in Illustration 6 on page 8-15.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-13


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

PUMPING CAPACITY OR FLOW

Pumping capacity is the measure of fluid discharged by a rotating impeller. This flow produced directly
by the impeller and through the impeller area is known as primary flow. In addition to primary flow,
liquid is drawn by and pushed by the primary flow to produce “induced flow”. The primary and induced
flow together make up the total flow. Total flow is difficult to calculate, but can be measured in the
laboratory. Total flow is typically several times higher than primary flow. This distinction is very
important when comparing mixer performance and efficiency. Mixers should be compared using
primary pumping capacity. Total flow may be estimated by the mixer manufacturer, but should not be
used for comparison purposes.

For simplicity, pumping capacity calculations assume “free flow” or plug flow where the impeller is not
too close to the tank bottom and flow is not hindered by other constrictions. Water is used as the
standard liquid, with a specific gravity of 1.0 and a viscosity of 1.0 centipoise. The result is generally
referred to as the water pumping capacity, since pumping capacity for the actual conditions can also be
calculated by adjusting the flow number for the fluid characteristics and tank geometry.

The following equation is used to calculate PRIMARY pumping capacity:

Q = Nq N D3
231

Q = Flow in gallons per minute (GPM)


Nq = Flow number for impeller
N = Mixer speed (RPM)
D = Impeller diameter (IN)
231 - Conversion factor

Nq, the flow number, is determined empirically for each impeller type (geometry). It is constant for the
impeller under standard conditions (water, free flow). The impeller manufacturer can supply this
number to you if you are calculating pumping capacity.

Dual Impellers: Depending on how the impellers are spaced, the fluid characteristics, tank geometry
and other variables, multiple impellers will pump somewhat more than one impeller at like speed and
horsepower.

While this pumping capacity is a very useful concept for comparing mixers, caution must be exercised
when using it as a sizing criteria, since the same liquid in one small area of the tank may be pumped
over and over, while other areas do not get mixed. D/T, off-bottom distance, number and location of
impellers must also be correct.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-14


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Tel: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

TORQUE

Torque is the twisting or turning force acting to produce rotation on the mixer shaft.

Torque = HP x 73025
RPM

In flow-controlled mixing processes, torque = mixer flow X a constant, which is, in turn, equal to process
result. Also, higher torque (not necessarily higher HP) = higher mixer cost. Mixer torque per unit
volume may be an important scale-up criteria.

The torque required for any mixing process will effect the size and type of mixer drive and also have a
direct impact on mixer shaft design.

Process Result ∝ Flow

Flow ∝ Torque (K)

Torque ∝ $ (Capital Cost)

Illustration No. 6: Flow Controlled Applications

©Copyright 2003 BRAWN Mixer, Inc. Page 8-15


PRINCIPLES OF FLUID MIXING
Phone: 616/399-5600
Fax: 616/399-3084
SHAFT TERMINOLOGY

©Copyright 2003 BRAWN Mixer, Inc. Page 8-16


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Phone: 616/399-5600
Holland, MI 49424 Fax: 717/399-3084

CRITICAL SPEED

Natural Frequency & Rotational Frequency

A rigid body, like a mixer shaft, vibrates when subjected to outside forces. Like a tuning fork, it has a
predetermined vibrational frequency (harmonic), which remains constant as long as the composition of
the shaft and the shaft-impeller relationship is not altered. This vibrational frequency is called natural
frequency. Unlike a tuning fork however, a mixer shaft must also deal with the forces of rotation.

The rotational frequency is the number of turns or revolutions the shaft makes over a period of time -
seconds, minutes, etc. We typically measure rotational frequency in revolutions per minute (RPM). If
you could adjust the shaft speed so the rotational frequency exactly matched the natural frequency of
the shaft, you would achieve critical speed, represented by Ncr in our equation (Illustration No. 9).
Additional critical speeds actually occur at several multiples of the first critical speed.

Critical Speed Can Be Dangerous

These speeds (vibration and rational) are called “critical” because they are the speeds at which the two
frequencies reinforce one another. This condition has the potential to set up destructive force. The
relationship of shaft length and impeller weight to critical speed is given by the following equation. This
equation calculates the first natural, or vibrational, frequency of the shaft.

d = Shaft diameter (IN)


l = Shaft length (IN)
a = Bearing spacing (IN)
ρ = Density (LB/CU. IN)
We = Weight or equivalent of impeller(s)
E = Modulus of elasticity

Illustration No. 7

Some mixers are designed to operate above first critical speed. When designed this way the shaft
passes through critical speed with nothing more than a slight tremor at start up or shutdown. Generally
speaking, it is good design practice to stay below the first critical speed by 20% or more. The ratio of
operating speed to critical speed (N/Ncr) is called the critical speed ratio. A critical speed ratio of 0.8
would indicate that the operating speed is 20% below the critical speed. A ratio of 1:2 indicates the
operating speed is 20% above critical speed.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-17


PRINCIPLES OF FLUID MIXING
th
3389 128 Ave Phone: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

IMPELLER EFFECT ON CRITICAL SPEED

Weight and Equivalent Weight

Impeller weight can be calculated, knowing the material density and the dimensions of all the impeller
components, but this weight is only directly useful if there is only one impeller on a shaft, located at the
very end of a shaft.

For shaft design calculations, we are concerned with the effect of the weight or equivalent weight of
multiple impellers on the end of the shaft. The equivalent weight is the apparent weight of all the
impellers and is calculated using the following formula.

We = Equivalent weight (LB)


W1,2,3 = Weights of impellers 1, 2, 3 (LB)
L1, 2, 3 = Length (IN)

Illustration No. 8

When impellers are made adjustable, they must be safe at all operating conditions. The simple way to
assume all the impellers are at their lowest possible position, calculate the equivalent weight and critical
speed under this worst-case scenario. If your result is below the maximum critical speed ratio, the
impellers are safe at any position.

The equivalent weight calculated for two or more impellers can be directly input into the critical speed
equation (see “SHAFT LENGTH and CRITICAL SPEED)”.

©Copyright 2003 BRAWN Mixer, Inc. Page 8-18


PRINCIPLES OF FLUID MIXING
th
3389 128 Avenue Phone: 616/399-5600
Holland, MI 49424 Fax: 616/399-3084

NOMENCLATURE

The following terms are used in the sizing and selection of mixers, as well as the design and
installation of these mixers:

A, a, BRSPC bearing space (inches) PC, Q pumping capacity (GPM)


d, SD shaft diameter (inches) Q flow
D impeller diameter (inches) S shear
E, MOD modulus of elasticity SD, d shaft diameter (inches)
F, FF fluid forces (LB) SHP shaft horsepower (HP)
HP horsepower (HP) SPGR, Sp. Gr., S.G. specific gravity
L, L1 length, length of distance 1 (inches) SS shaft stress (PSI)
MB, Mb bending moment (IN-LB) T torque (IN-LB)
MHP motor horsepower (HP) T tank diameter
N speed (RPM) TS tip speed (FT/SEC)
Ncr, NCR critical speed (RPM) V volume (liters) (gallons)
Np impeller power number VISC viscosity (cP) (centipoise)
Nq impeller flow number W, W1 weight, weight of impeller 1 (LB)
NRE, Nre Reynolds Number We equivalent weight (LB)
NUMI number of impellers on shaft Z liquid level (inches)
P power (HP) ρ, DENS density (LB/CU.IN)

©Copyright 2003 BRAWN Mixer, Inc. Page 8-19

You might also like