Agitation and mixing

1
 Agitation vs.
vs Mixing

Agitation – induced
d d motion of
f a materiall in a
specified way
– Usually a circulatory pattern inside a container

Mixing – random distribution, into and through

one another, of two or more initially separate
phases
– Various degrees of homogeneity
 Introduction
Applications
(1) dispersion of solvable solid
(2) homogenization of miscible liquids
(3) mixing and dispersion of immiscible liquids
(4) m
mixing
x ng between gas and lliquid
qu d
(5) suspension of solid particles in liquid
(6) acceleration of chemical reaction and physical transport

Agitation methods
mechanical
h l agitators
gas agitation
jet mixing
static mixer
tubular mixing
3
 Agitation Equipment
T-Junctions
Junct ons
Static Mixers
Tank or vessel
– Cylindrical in form with a vertical axis
– Rounded or flatten tank bottom
– Depth ≅ diameter
Impellers
– Axial-flow – generate currents parallel with the axis of the
impeller shaft
– Radial
Radial-flow
flow – generate currents in a tangential or radial
direction
– Propellers, paddles, and turbines
 Motionless mixers

T-junction
j ((similar flow rates)) Pitot tube (different flow rates)

Perforated plates (orifices) Flanged perforated plates

supported on a rod

I j t mixer
Injector i with
ith a h
helical
li l bbaffle
ffl
Hellical mixing elements with
alternating directions (Kenics)
Kenics® Static mixers
Komax® static mixer
Pump recirculated tank(homogenizer)
 Mechanically agitated mixing equipment

A set of mixing
equipment consists of:
a mixing tank
a driving motor with
speedd reducer
d
an agitator
some attached parts.
Agitator is the main
part, like an impeller in
a pump to give
mechanical energy to
liquid.

9
 Types of agitators – axial type
propeller

standard type：
yp
S/d=1，Z=3
blade end speed
p :
5~15 m/s, maximum 25 m/s

helical ribbon
Standard
St nd d ttype：
p
S/d=1, B/d=0.1
Z=1-2
1 2 (2 for
f ttwin
i ribbon
ibb ttype))
low speed, the outer edge is
very close to the tank wall
(close clearance impeller). 10
 Types of agitators – radial type
blades
standard type
d/B=4-10，Z=2
blade end speed 1.5~3 m/s

anchor and frame

standard type： B/d=1/12
d’/d=0.05-0.08,
’/d 0 05 0 08 d’=25-50
’ 25 50 mm
d’- distance between the tank
wall and the outer edge of the
anchor
blade end speed 0.5-1.5
0 5-1 5 m/s
11
 Propellers

Propellers
P ll – axial-flow,
l fl high
h h speed
d impeller
ll f for
liquids of low viscosity
– Small – 1150-1750 r/min
– Large – 400-800 r/min
– Pitch – ratio of movement of liquid over fixed
distance to propeller diameter
– Standard – 3-blade marine propeller with square
pitch (1.0)
– Rarely
R l exceed d 18” in
i di
diameter
t
 Paddles

Two or four
f blades
bl d turning on a verticall shaft
h f
– Simple mixing problems
– 20-150 r/min
– Length usually 50-80% of inside diameter
– Width is 1/6th to 1/10th of length
– Use with baffles at high speed to achieve good
mixing
 Turbines

Multi-bladed
l bl d d paddle
ddl agitators with
h short
h bl
blades
d
– Turn at high speed on centrally-mounted shaft
– Smaller diameter; 30-50% of diameter of vessel
– Effective over wide range of viscosities
 Types of agitators – radial type turbines

straight blades
on disk (Rushton)
( )

curve blades on
disk

open straight
bl d
blades
(paddle)

open curve
bl d
blades
15
 Agitator types

Concave-blade
CD-6 impeller 3-blade marine propeller Pitched-blade turbine

Simple straight-blade turbine

Disk turbine
(paddle)
 Agitator types

Flat blades disk

three-bladed turbine with flat t bi ((more bl
turbine blades)
d )
mixing propeller vertical blades

Turbine with inclined Curved blade turbine Shrouded

Sh d d tturbine
bi ((consisting
i ti off
blades (usually45°) a rotor and a stator)
 Agitator types
Cage beater impeller (usually
mounted on the same shaft
with a standard propeller)

Anchor paddle
Sawtooth edges flat plate turbine

Hollow shaft and hollow

p
impeller assemblyy
shrouded screw
Gate paddle
impeller and heat
exchange coil
Special
p mixers for powders
p and
pastes

Ribbon blender for

powders
double cone blender

T i shell
Twin h ll (V
(Vee ttype)) T i rotor
Twin t
Special
p mixers for powders
p and
pastes

Batch muller Twin mullers

Double-arm
D bl Some types of
mixer and kneader blades for the
double-arm kneader
 Flow Patterns

Depends
D d on type off impeller,
ll characteristics
h of
f
fluid, size and proportions of tank, baffles, and
agitator

Swirling – stratification at various levels with no

longitudinal flow between levels
 Types of agitators
It can b
be di
divided
id d b
by fl
flow pattern
tt

axial-flow
l fl
The main flow in tank is a circulation on
axiall direction
d (& tangential)
l) with
h little
l l
turbulent.
Suitable for mixing of low viscose
liquids, particle suspension and heat
transfer enhance.

Propeller small diameter,

diameter high speed,
speed large flow rate and
low head.
Helical ribbon large diameter and mixing range
range, low speed,
speed
low head. Special design for high viscosity liquid. 22
 Types of agitators

Radial-flow
Complicated radial and tangential flow.
For low & middle viscosity liquids in
dispersion of immiscible liquids,
chemical reaction and heat transfer.
transfer

turbines: high speed，wide

speed wide blade，low
blade low flow
rate and high head.
straight blades
blades: long vane, low speed and
low head, for high viscosity liquids.

anchor and frame ：very large diameter and mixing range,

very low speed and head. Suitable for high viscosity liquids
and
d capable
bl of
f preventing
i theh deposit
d i on tankk wall.
ll
23
 Baffle and draft tube
tangential vortex
vortex- by centrifugal force. The
liquid level on tank center will fall to form a
forced vortex. The high the speed , the
deep the vortex.
result effective volume reduced and mixing
effect worsen. Sometimes gas is absorbed
from lower liquid level to disturb operation.

Solution 1 install baffles on tank

wall.
Maximum 8 baffles (usually 4),
called “fully baffled”
24
 Baffles and draft tube
Solution 2 off
off-central
central installed
agitator will improve the
operation with increased power
consumption.
draft tube improving mixing
through
h h controlling
ll the
h flow
fl
velocity and direction, reducing
the short cut.
cut Especially for
particle suspension.

25
 Large tanks
agitation: side
entering impellers
Vortex inhibition: off-centering
off centering & baffles

Axial or radial impellers Off-center located Lateral baffles

without baffles produce impellers reduces reduces the
vortexes the vortex vortex
 Flow patterns:
p
radial vs axial impellers

Radial impeller Axial impeller

Multiple-impeller tank
 Standard dimensions
Standard geometry D=
D T/2;T/3
w H= T
4 baffles a= D/4
b= D/5
c= T/2;T/3
d
d= 0 75D
0.75D
w T/10
d

c
D

T b
Circulation, Velocities, and Power
Consumption
Volume of fluid circulated by impeller must be
sufficient to sweep out entire vessel in reasonable time

Velocity of stream leaving impeller must be sufficient to

carry current to remotest parts of tank

In mixing, also need turbulence

– Results from p properly
p y directed currents and large
g velocity
y
gradients
d in lliquid
d

Circulation and generation of turbulence both consume

energy
Large impeller + medium speed = flow
S ll iimpeller
Small ll + hi
high
h speed
d = turbulence
b l
 Flow pattern in mixing tank
Flow pattern is related with the geometries of tank,
tank stirrer
and baffle, liquid properties and stirrer speed.
For agitation operation, the useful flows are axial and radial,
not the tangential. rotating speed, rps

Stirrin R
Stirring Re R = D2 N ρ / μ
Re DN = u Ti speed
Tip d

For a fully baffled standard tank with an 6 straight blades

turbine, the following flow regimes hold:
1＜ Re＜10 near the turbine: laminar flow,
other zones: almost static
Re＞10 laminar axis flow, flow starts from blade’s tips
p
100＜Re<103 transition, around turbine: turbulent flow,
other zones: laminar axis flow
Re>103 turbulent in whole tank 32
 Mixing mechanism
(1) molecular diffusion：occurring in molecular scale
(2)turbulent diffusion ： caused by vortex dissipation,
existed in vortex size .
(3)convective diffusion：caused by convection, occurring in
large scale spaces.
Convective flow breaks the liquid into large drops (macro
mixing); the drops are then broken into smaller ones by
vortex
t x deformation
d f m ti n (inter-drop
(int d p mixing
mixin ) ； those
th s vortex
t x
breakage and deformation will increase or renew the
contacting area between drops with different concentration
and promote the molecular diffusion.
A fully homogeneous mixing depends on molecular diffusion.

In comparison, the turbulent diffusion is about 105~107 times

of
f molecular
l l diff
diffusion
i anddddominates
i t th the tturbulent
b l t agitation.
it ti
33
 Mixing sensitive processes
Considering that a mixer consumes (depending on its shape,
dimension and agitation speed) a determined amount of
mechanical power,
power it can be dissipated inside the vessel by
inducing large flow rates (bulk motion) or high levels of
turbulence due to liquid shear (shear stresses). Typically,
axial impellers promote bulk motion while radial ones promote
instead shear stresses.
Processes promoted by mixing may be classified on the basis
of their sensitivity to bulk motion or shear stress promotion:
Bulk motion controlled processes – those which do not need
to create new interface (blending, heat transfer promotion)
or which must allow the availability of the actual interface
f exchange
for h processes (solid
( lid suspension).
i )
Shear rate controlled processes – those which efficiency
rely on the generation of inter
inter-phase
phase exchange surface (gas
(gas-
liquid and liquid-liquid dispersions).
 Mixing mechanism of heterogeneous systems

low viscosity liquids

Large vortex is broken into small ones by shearing effect.
effect
The viscose resistance converts part of the mixing energy
into heat.
heat
Strong mixing effect occurs at the zone near the agitator.
Total circulation flow rate is the most important for this
type of mixing.

high viscosity liquids

In the laminar zone, mixing depends on the total flow. But
the agitator efficiency is low at turbulent zone.
Large diameter and low speed agitators should be used.
35
 Mixing mechanism of heterogeneous systems

gas-liquid systems

Th mechanism
The m h ism is similar
simil tot the
th liquid-liquid
li id li id systems.
s st ms
Gas is dispersed as bubbles in the liquid .
The gas-liquid interface tension is stronger than that of
liquid-liquid and the dispersion of gas is more difficult. As
a result,
result the sizes of bubbles are larger than liquid drops.
drops
The large density difference between gas and liquid
makes the gas bubbles rise to the top of the liquid.
liquid
High shearing agitators are often used to generate
relative small gas bubbles (radial types are preferable).
preferable)

36
 Mixing mechanism of heterogeneous system

solid-liquid systems

The purpose of the agitation are

• to suspend the particles homogeneously in the liquid
• to reduce the thickness of liquid film on particle surface
in
n order to accelerate the reaction
react on or transport processes.

critical speed for suspension

minimum rotating speed needed to suspend all particles.
It is
i af
function
ti off agitator
it t diameter
di t and
d ttypes.

37
 Mixing mechanism of heterogeneous system

Immiscible liquid-liquid systems

O phase
One h s is continuous
ti s and
d another
th is dispersed.
dis s d
For zone near the agitator, the shearing effect is strong
under high
hi h turbulent and small liquid drops will be
achieved. In the zone far away from the agitator, the
drops will agglomerate into larger ones.
ones
The breakage and agglomeration processes increase and
renew the interface of the liquids, so strengthen the
inter-phase mass transfer.
If a surface act
activation
vat on agent iss added in
n th
thiss system,
the agglomeration will be weaken and the size of liquid
drops tends to be uniform.
38
 Why Dimensionless Numbers?

Empirical
E i i l correlations
l ti t estimate
to ti t theth power
required to rotate a given impeller at a give
speed with respect to other variables in
speed,
system:

– Measurements of tank and impeller

– Distance of impeller from tank floor
– Liquid depth
– Dimensions of baffles
– Viscosity, density, speed
Dimensional analysis for fluid agitation systems

Basic quantities
Characteristic length: Impeller diameter D (m)
Characteristic time: Inverse impeller speed: 1/N (s)
Characteristic mass: Liquid density and cube
off impeller
i ll diameter:
di ρ D3 (kg)
(k )
Derived quantities
Characteristic velocity: Impeller diameter and speed: DN (m/s)
Characteristic pressure: Density and velocity
square: ρ D 2 N 2 (Pa)
Characteristic flow rate: Velocity
y and area ND3 ( m3 /s )
 Dimensionless numbers

N D2 ρ Wbrake
Reynolds N Re = ; Power N Po =
μ N 3 D5 ρ
N 2 D3 ρ N2D
Weber N We = ; Froude N Fr =
σ g
Qi
Flow N Q =
ND3
 Dimensionless Mixing Numbers
Fl
Flow rates
t s pumped
dbby th
the impeller
i ll
pumping flow rate Q：
flow rate pumped through a “reference”
reference surface of the agitator

Pumping Number NQ=Q/ND3

Where Q is the volumetric flow rate, measured over a fixed control
surface (depending on the agitator type), N is the rotational speed (rps), D
is the impeller diameter.
diameter

For turbulent flow, NQ is a constant, not a

function of Re
Q ∝ ND 3

Typical NQ values:
Standard flat-blade turbine, NQ = 1.3
Marine propellers, NQ = 0.5
0.5-0.9
0.9 (dep. on pitch)
4-blade 45° turbine, NQ = 0.5 42
 Dimensionless Mixing parameters
Flow rates pumped by impeller

Total circulating flow rate Q’ :

all
ll circulating
i l ti flow
fl rate
t in
i the
th tank
t k by
b th
the entrainment
t i tffrom the
th
agitator，Q’ > Q.

Circulating flow rate number NQ’ = Q’/ND3

For turbulent flow(Re>103) ⎧⎪ ⎡⎛ D ⎞ 2 ⎤ ⎫⎪

N Q' = N Q ⎨1 + 0.16⎢⎜ ⎟ − 1⎥ ⎬
& standard geometry: ⎪⎩ ⎢⎣⎝ d ⎠ ⎥⎦ ⎪⎭

43
Pumping
p g number
 Dimensionless Mixing parameters
Mechanical power required by impeller P
The power P dissipated divided by ρN3D5 corresponds to an
important dimensionless parameter of mixers,
mixers the Power Number NP:

Power Number NP=P/ρN3D5

Where P is the mechanical p power dissipated

p ((watts),
) measured at
the tip of the blades, N is the rotational speed (rps), D is the
impeller diameter and ρ is the fluid density.

NP is ratio of drag force to momentum flow, NP is analogous to

the friction factor f for CD .
Typical values:
Standard flat-blade turbine, baffled vessels NP = 5
Standard flat-blade turbine, unbaffled vessels NP = 1
M i propellers,
Marine ll NP = 1
45
 Calculation of Power Consumption
P = NP N D ρ 3 5

At low Re (<10), density is no longer a factor:

KL
NP = P = K L N 2 D3 μ
Re
At Re >10 000 in baffled tanks, P is independent of Reynolds Number
and viscosity is not a factor:

N P = KT P = KT N 3 D 5 ρ

KL and KT are constants for various types of impellers and tanks

Please note the dependency of P on μ or ρ depending on the flow regime

(laminar or turbulent).
 Power constants at low (KL) and high (KT)
R
Reynolds
ld number
b
Type
yp of Impeller
p KL KT

Propeller, 3 blades
Pitch 1.0 41 0.32
Pitch 1.5 55 0.87
Turbine
6-blade disk (S3=0.25 S4=0.2) 65 5.75
6 curved blades (S4=0.2) 70 4.80
6 pitched
pit h d blades
bl d s (45°
(45°, S4=0.2)
0 2) - 1 63
1.63
4 pitched blades (45°, S4=0.2) 44.5 1.27
Flat paddle
paddle, 2 blades (45
(45°, 36 5
36.5 1 70
1.70
S4=0.2)

Anchor 300 0 35
0.35
 Correlations and p
power curves

For a compl
complicated
cated m
mixing
x ng process, d
dimensional
mens onal analys
analysiss iss
often used to correlate the experimental data and find
the empirical Eqs.

With a standard mixing unit, following results can be

found from the dimensional analysis
Pw ⎛ ND 2 ρ N 2 D ⎞
Pw = f ( N , D, ρ , μ , g ) NP = = f⎜ , ⎟ N P = f ( Re, Fr )
ρN D
3 5
⎝ μ g ⎠

NP —— power number
Re —— stirring Reynolds number for flow pattern
F —— Froude
Fr F d number
b f for circulating
i l ti flflow with
ith f
free surface
f
48
NP vs Re for different turbines
Power number NP vs. Re: baffled & unbaffled tanks
(marine propellers and helical ribbons)

Propeller

Helical ribbon
unbaffled
NP vs Re for p
propellers
p
NP vs Re f
for different
ff impellers
mp
Effects of D/T for two axial flow impellers

Decreasing D/T ratio

 NQ vs Re
(Pitched blade turbine)
(Pitched-blade
 Mixing processes: blending
Blending is the mixing operation aimed to homogenise
two or more miscible liquids by agitation.
The blending efficiency depends on the global flow rate
moved by the impeller (bulk motion controlled process).
The residence time required to achieve complete
homogenization of inlet flow rate is called “mixing time”
(tT).
) For
F non
n n viscous
is s liquids
li ids it is commonly
mm nl assumed
ss m d that
th t
the mixing time correspond to the time required by the
impeller to recirculate 5 times the whole tank content.
content
2
5V 5π T H 2
const ⎛ T ⎞
2
const ⎛ T ⎞
tT = = = ×⎜ ⎟ NtT = ×⎜ ⎟
Q ' 4 N Q ' ND 3
NQ ' N ⎝ D ⎠ NQ ' ⎝ D ⎠
NQ’ = circulating flow rate number
N = rotational speed, rps
T = tank diameter, m
H = liquid height, m
 g time vs Re
Blending
 Mixing time correlations
For standard Rushton turbine (fully turbulent regime) the total
flow rate circulated by the impeller is Q
Q’=0
=0.92ND
92ND2T , it follows:

5π T 3
2 2
5V 4.3 ⎛ T ⎞ ⎛T ⎞
tT = = = ×⎜ ⎟ NtT = 4.3
4 3× ⎜ ⎟
Q ' 4 × 0.92 ND T
2
N ⎝D⎠ ⎝D⎠
tT = m
mixing
x ng ttime,
me, s Mixing
g time factor
N = rotational speed, rps
T = tank diameter, m
H = liquid height, m

For HE-3 high-efficiency impeller (fully turbulent regime) the

mixing time factor is:
1.67 0.5
⎛T ⎞ ⎛H⎞
NtT = 16.9 × ⎜ ⎟ ⎜ ⎟
⎝D⎠ ⎝T ⎠
 Mixing time correlations
For standard Rushton turbine (fully turbulent regime) the total
flow rate circulated by the impeller is Q’=0.92ND2T , it follows:

5π T 3
2 2
5V 43 ⎛T ⎞
4.3 ⎛T ⎞
tT = = = ×⎜ ⎟ NtT = 4.3 × ⎜ ⎟
Q ' 4 × 0.92 ND T
2
N ⎝D⎠ ⎝D⎠
tT = mixing time, s Mi i time
Mixing i f
factor
V = liquid volume, m3
N = rotational speed, rps
D = impeller diameter,
diameter m
T = tank diameter, m
H = liquid height, m
 Mixing Time factor correlations
For Rushton turbine (fully turbulent regime) the mixing time
factor is:the
1/Fr
2 1/2 1/6
tT ( ND 2 ) 2/3 g 1/6 D1/2 ⎛D⎞ ⎛ T ⎞ ⎛ g ⎞
ft = = NtT ⎜ ⎟ ⎜ ⎟ ⎜ 2 ⎟ When Re>105, ft ≅ 5
H 1/2T 3/ 2 ⎝T ⎠ ⎝H ⎠ ⎝N D⎠

For HE-3 high-efficiency impeller (fully turbulent regime) the

mixing time factor
f is:

1.67 0.5
⎛T ⎞ ⎛H⎞
NtT = 16.9 × ⎜ ⎟ ⎜ ⎟
⎝D⎠ ⎝T ⎠
 Mixing time factors in agitated vessels

Dashed lines:
unbaffled
b ffl d ttanks
k

Solid lines:
baffled tanks
Dimensionless p
parameter dependency
p y on Re
summary
 Solid particle suspension
Processes involving solid particle suspension in liquids
(leaching, solid catalysed reactions, crystallization, ...) are
often carried out in agitated systems.
systems
The role of agitation is to made available to mass and
heat exchange all the solid surface,
surface therefore all particle
should move freely inside the tank. This is a bulk motion
controlled process.
p

Aim of agitation:
g
• Produce a homogeneous mixture
• Dissolve solids
• Catalyze a chemical reaction
• Promote growth of a crystalline
crystall ne product from a
supersaturated solution
 Solid particle suspension regimes
Four different
d ff regimes applyl ffor solid
l d suspension:
1) Incomplete suspension: all or part of particle rest at the
bottom tank
tank, forming “fillets”
fillets . This regime may be
acceptable only if the amount of unsuspended particles is
small;
2) On-bottom suspension: particles are suspended or, at least,
move on bottom.
3) Off-bottom suspension: all ll particles
l do not rest at bottom
for more than 1-2 seconds (Just Suspension regime). This
a commonly adopted working regime of suspension;
4) Homogeneous suspension: particles are uniformly
distributed inside the whole tank (particle
p concentration is
almost constant). It is a high power requiring regime and it
is impossible to achieve for heavy particles. It is needed
for very special applications.
applications
 Solid particle suspension
The most used correlation to estimate the Just Suspension
agitation
g speed
p (NJS) is that p
proposed
p by
y Zwietering:
g
0.45
⎛ Δρ ⎞
N JS = Sυ d
0.1 0.2
⎜g ⎟ D −0.85 B 0.13 Dimensional correlation!
p
⎝ ρ L ⎠

NJS= just suspension speed, rps

S geometry f
S= factor, -
ν= kinematic viscosity, m2/s
dp= particle diameter, m
g = gravitational
it ti l acceleration,
l ti m/s2
Δρ = particle to liquid density difference, kg/m3
ρL = liquid density , kg/m3
D = impeller diameter,
diameter m
B = particle mass to liquid mass ratio x 100, %
 Shape Factor
Factor, S
I
Impeller
ll ttype T/D T/E S
(E is height of
impeller above vessel
floor)

6-blade turbine 2 4 4.1

D/W = 5 3 4 7.5
NP = 6.2 4 4 11.5
2-blade paddle 2 4 4.8
D/W = 4 3 4 8
NP = 2.5 4 4 12.5
3-blade
3 bl d propeller
ll 3 4 6.5
6 5
NP = 0.5 4 4 8.5
4 2.5 9.5
For the same geometry, critical speed is about
th same for
the f standard
t d d tturbine
bi and d paddle
ddl
However, turbine requires twice as much power
as paddle, and 15-20 times as much power as
propeller
Sole purpose to suspend solids – use propeller
For good gas dispersion or high shear – use
turbine
Power required for complete suspension of solids
in agitated tanks using pitched-blade turbines
 Gas Liquid dispersions
Gas-Liquid
Gas liquid mechanically agitated systems are used for those
processes where a gas-liquid
gas liquid mass transfer phenomena are
involved (hydrogenation, chlorination, oxidation, ...).

Th role
The l of
f mixing
i i isi to:
t
• generate as much interfacial area as possible (by disrupting
the gas phase)
• disperse the bubbles throughout the liquid
p th
• keep the bubbles
u s in
n th
the liquid
qu ((i.e.
. . rrecirculate)
c rcu at ) for
sufficient time
• homogenize the liquid concentration
• enhance mass and heat transfer coefficients.

To this aim,
aim impellers that produce large shear stresses
(high velocity turbines) are preferable.
 Gas Liquid dispersions
Gas-Liquid
The gas phase is fed on the lower
part of the tank, below the
impeller, through a gas sparger.
Gas spargers may consist simply
of open end tubes or may be
slightly more complicated
p
(perforated rings, porous plates).
The importance of gas sparger is
not as crucial as in other non
agitated systems (e.g. bubble
columns)) as the ggas phase
p
dispersion is mainly performed by
the impeller.
sparger
 Gas Liquid dispersions regimes
Gas-Liquid
Depending
p g on the agitation
g speed
p N and the gas
g flow rate
QG different dispersion regimes hold:
ÎSurface aeration
(open systems)

Highly
Hi hl gas
Complete
a) & b) Flooding Loading recirculation
dispersion
regime
 Gas-Liquid dispersions regimes

Correlation to regime transition parameters estimation:

⎛ T ⎞ ⎛ NF D ⎞
35
3.5 3.5
35
⎛T ⎞
2
QG
Flooding Î Loading (NF) = 30 ⎜ ⎟ ⎜ ⎟ ⇒ Fl F = 30 ⎜ ⎟ FrF
N F D3 ⎝ ⎠ ⎝
D g ⎠ ⎝D⎠
0.5
⎛ T ⎞ ⎛ N CD D ⎞
05
0.5 00.55
⎛T ⎞
2
QG
Loading Î Compl. Disp. (NCD) = 0.2 ⎜ ⎟ ⎜ ⎟ ⇒ FlCD = 0.2 ⎜ ⎟ 0.5
FrCD
⎝D⎠ ⎝ g ⎠ ⎝D⎠
3
N CD D
2
⎛ T ⎞ ⎛ NR D ⎞
5 5
⎛T ⎞
2
QG
Compl. Disp.Î High Gas Rec. (NR) = 13 ⎜ ⎟ ⎜ ⎟ ⇒ Fl R = 13 2
⎜ ⎟ FrR
⎝D⎠ ⎝ g ⎠ ⎝D⎠
3
NR D
 Gas-Liquid power requirements
The gas strongly affects the fluid dynamics inside the tank as it
interferes in the impeller momentum transfer. Therefore
correlations of NP valid for single phase do not hold anymore.
anymore
The figure shows how the ratio of power in gassed conditions (Pg)
over the power consumed in ungassed systems (P) varies with the
Fl
Flow N b (Fl) att constant
Number st t gass flow
fl ratet Q G:

Pg/P always < 1

Power curves at constant gas rate for Rushton turbines.

 Gas-liquid dispersion empirical correlations
Michel & Miller correlation to predict Pg in standard systems:
Dimensional correlation ((SI units required)
q )
⎛ P ND ⎞
2 3
m
P=ungassed power requirement [W], Pg [W]
Pg = β ⎜ 0.56 ⎟ N [rps], D [m], QG [m3/s]
⎝ QG ⎠ β= 0.83
0 83 (Rushton turbine
turbine, standard geometry)
m=0.45 normally coalescent liquids

Van’t
V ’t Riet
Ri t correlation
l ti tot calculate
l l t the
th volumetric
l t i gas-liquid
li id
mass transfer coefficient (kLa) in standard systems:
β Dimensional correlation (SI units required):
⎛ Pg ⎞ γ Pg [W], VL [m3] liquid volume kLa [1/s], vsg
k L a = α ⎜ ⎟ vsg
superficial gas velocity (Qg/Stank) [m/s]
⎝ VL ⎠
Coalescent Non coalescent
systems systems
α 0 026
0.026 0 002
0.002
β 0.4 0.7
γ 0.5 0.2
 Pg/P vs QG for different impellers

Pg/P always < 1

Typical power curves for gassed agitators (D (D.T.=

T = disc turbine; V.D.=
V D = vaned
disc; P.B.T. = pitched blade turbine. All curves for one N and D.)
 Liquid-liquid dispersions
Liquid-liquid
Li id li id dispersion
dis si operations
ti s may
m be b performed
f m d in i
agitated tanks provided by high shear rate impellers
(e g turbines).
(e.g. turbines)
As in the case of gas dispersion, the interfacial surface
between p phases is g
generated by y the agitation
g and varies
with it. Also the droplet size of the dispersed phase will
depend on the degree of the agitation being the result
off the
h two opposite processes of f disruption
d (d
(due to
agitation) and coalescence.
Li id li id systems
Liquid-liquid t are characterised
h t i d by b major
j
complexity with respect to solid-liquid and, also, gas-
liquid dispersions.
dispersions In particular,
particular in some cases,
cases it is not
possible a priori to establish which one of two
immiscible p phases will p perform as dispersed
p and
continuous one.
 Mean diameter of drops
The main global parameter describing the characteristic of
dispersion is the mean droplet diameter dp. Considering that the
droplets are characterised by a dimension distribution, the average
di
diameter
t usually
ll adopted
d t d is i the
th surface-based
f b d mean diameter
di t
(Sauter diameter) dS obtained starting from the ratio of total
volume to total surface of all dispersed drops in the volume:

ntot
π di3
ψ Vdisp ∑n i
6 ntot d S3 dS ntot= total
t t l number
b of fddrops
= = i =1
ntot
= = ψ = disp. phase hold-up
6ntot d S2 a = specific surface, m2/m3
∑nπd
a S disp 2 6
i i
i=1

6ψ
Sauter mean diameter dS =
a
 Liquid-liquid dispersions
Liquid-liquid dispersion operations may be performed in
agitated tanks provided by high shear rate impellers
(
(e.g. t bi
turbines).
)
As the impeller action is produce high liquid
deformations (shear) in order to deform drops of
disperded phase and break them in smaller ones, this
action depends on the ratio of fluid kinetic energy at
the impeller tip speed to a surface-tension stress based
on D which define the Weber Number (We):

ρC ( ND )
2
ρC N 2 D 3 ρC= density of continuous phase
We = =
σ σ σ= surface tension
D
 Correlation for dS
Several empiric correlation have been proposed to estimate
mean drop d diameter
ameter depend
depending
ng on ag
agitation
tat on conditions,
cond t ons,
relevant to different mixing devices.

Rushton turbine: d S D = 0.058 (1 + 5.4ψ ) We −0.6

06

Static Kenics mixers: 0 35We −0.6 f −0.4

d S D = 0.35
ρC v 2 D
We =
Where: σ
D = pipe diameter, m
v = average fluid velocity, m/s
DΔP
f = = friction factor, -
2 ρC v L
2
 Design of agitation

(1) Decide the type and geometry of the tank and the agitator.
(2) Find the performance of the installation first, including the
size, rotating speed and power, then scaling up to
commercial scale.

Scaling up criteria
geometric
t i similarity
i il it all
ll the
th sizes
i have
h same ratio, h as H/D.
ti such
dynamic similarity there are same velocity ratio and direction on
corresponding
c rr p n ng p points.
nt .
kinetic similarity all have same forces ratio on corresponding points
(with same Re, Fr or We).
where： Re：the ratio of inertia to viscous forces
Fr： the ratio of inertia to gravitational forces
W = N3D2ρ /σ ：the
We th ratio
ti of
f inertia
i ti tto surface
f ttension
i
79
 Relevant parameters
D = impeller diameter (m),
(m) N = impeller speed (1/s)
Ws = shaft power, Wbrake = brake power (W or HP)
T = tank
t k diameter,
di t Z = liquid
li id llevell m.
Viscosity Pa.s, density kg/m3, Surface Tension N/m
Qi = impeller
i ll pumpingi capacityit ((m3/s)
/ )
 Scale Up
Scale-Up
Based
B d on geometrical
t i l similarity,
i il it if possible
ibl
Power consumption predicted by curves of NP vs NRe
ROT for power
– ½-1 hP per 1000 gal of thin liquid gives “mild” agitation
– 2-3 hP p
per 1000 gal
g gives
g “vigorous”
g agitation
g
– 4-10 hP per 1000 gal gives “intense” agitation
– Actual power delivered to the liquid
R ti of
Ratio f Dimpeller to
t Dvessel
– Dispersing a gas in a liquid – 0.25
– Contacting
g two immiscible
mm liquids
q – 0.4
– Blending – 0.6 or more
Smaller the impeller, higher the impeller speed
 Scaling up criterion
(1) power consumption
i per volume
l (Pw
P /V) =Const.
C
Used for constant liquid properties and relatively small
scaling-up
li ratio.
ti G d for
Good f t b l t mixing
turbulent i i d i t d
dominated
situation in fully turbulent flow.
N13 D12 = N 23 D22

(2) Tip speed constant

Keep the agitator torque constant in a geometrical
analogue system. Suitable for operation of high head.
N1 D1 = N 2 D2

(3) Reynolds number, Re= Const.

N1 D12 = N 2 D22
82
 Scaling up criterion
(4) Froude number, Fr=Cost.

N12 D1 = N 22 D2

(5) Webber number, We= Const.

N12 D13 = N 22 D23

Which scaling up process should be used?

depends on the practical situation.

83