MIXER 1

INTRODUCTION

Mixer 1 is used in this plant to mix the residue output (isobutylene and methanol) that
produced from separator 1 and Splitter 2. The mixing process increase the composition of
the residue chemicals by mixing the methanol and isobutylene for the usage in the next
steps that is to separate the Isobutylene and Methanol at the Separator 2. Plus, the mixing
process avoid the wasting of the useful chemicals.
Design intention of this mixer is considered with the chemical factors, mass transfer
factors, heat transfer factor and safety factors. The operating condition of this mixer is by
referring to the simulation that is pressure and temperature of 192.5 kPa and 26.30C with
the both feeds of liquid. The mass balance of the inlet and outlet of the Mixer 1 is as shown
in the table 1 below:

Table 1: Data of material balance for Mixer 1

FUNDAMENTAL KNOWLEDGE

Mixing is a key and common process to improve homogeneity and uniformity of

systems. Mixing occurs when materials are moved from one area to another in a vessel
(Chen et al., 2005; Rushton, 1956). Nonuniformity of systems can be explained as a gradient
of properties such as concentration, viscosity, temperature, colour, concentration, phase,
and temperature (Paul et al., 2004). Mixing operations can be divided into three main
categories, gas-liquid, solid-liquid, and liquid-liquid mixing, the latter of which is the main
focus of the present review. Liquid-liquid mixing plays an important role in producing and
increasing essential interfacial area to improve mass and heat transfer between phases
(O’Rourke and MacLoughlin, 2005; Paul et al., 2004).
Liquid-liquid mixing is applicable for special process objectives such as solvent
extraction and removal or addition of heat (Paul et al., 2004). Blending of miscible liquid is a
very simple operation that is achieved by two mutually soluble liquids in the absence of
resistivity to dissolution at the fluid interface (Paul et al., 2004). Generally, blending of
miscible liquids happens slowly by molecular diffusion and natural convection. Thus,
agitation systems can apply forced convection to obtain homogeneity more rapidly (Rushton,
1956).
Tanks and vessels are the most accessible and universal equipment used in a wide
range of process industries such as esterification and hydrolysis (Paul et al., 2004). Because
natural diffusion in liquids is slow, agitators that provide high shear and good pumping
capacity are common choices for liquid-liquid dispersion and emulsification because they
improve diffusivity (Afshar Ghotli et al., 2013).
Mixing operations are often complex. They not only require understanding the fluid
flow aspects, but also consideration of the mechanical equipment and power requirements
(Chen et al., 2005).

Figure 1: Tanks with mixer

Mixing Time

Mixing time is one of the most significant parameters in liquid-liquid mixing and scale-
up because it is also the time required to obtain a defined degree of uniformity (Montante et
al., 2005; Jakobsen, 2008). It is the time required to achieve desirable mixing and
homogeneity throughout the tank. Impeller speed, the diameter of the vessels and impellers,
the number and placement of baffles, and fluid characteristics such as viscosity are the
effective parameters for determining mixing time (Jakobsen, 2008; Doran, 1995).
In addition, various parameters, such as impeller design, impeller diameter, tank
diameter, impeller clearance, impeller eccentricity, baffles, and presence of a draft tube can
affect mixing time. A calculation of impeller was done in order to get a proper mixing time.
A wide range of impellers has been designed and produced to achieve efficient
mixing commercially. Impeller selection depends on a number of factors, such as viscosity of
fluid, operating conditions, and system flow regime (Paul et al., 2004).
DETAILS CALCULATIONS

Sizing of Mixer 1 (M-1)

Volume
From simulation results,
Flow rate stream 2, F = 8635 kg/h
Density stream 2,  = 736.2 kg/m3
Therefore,
Actual flow rate, F = (8635 / 736.2)
= (11.73 m3/h) / 3600 s
= 0.003258 m3/s

Assume space time = 2.5 min

= 150 s
Therefore,
Volume, V = (0.003258 m3/s) x 150 s
V = 0.4887 m3

Vessel diameter & height

From simulation results,

Viscosity stream 2,  = 0.3883 N.s/m2

From figure 10.57, Chemical Engineering Volume 6, 2nd Edition (pg 472),
Choose mixer with propeller (impeller type),
N = 1750 rpm
= 105000 rps

The form of mixer is a cylindrical vessel

V = 0.4887 m3
(DT2h) / 4 = 0.4887 m3
Where 1.5h = 2.0DT
 h = 1.33DT
Therefore,
(DT2 * 1.33DT) / 4 = 0.4887
Vessel diameter, DT = 0.7763 m = 2.55 ft
1.5h = 2.0DT
h = 1.33 DT
= 1.33 (0.7763)
Vessel height, h = 3.39 ft

Vessel Area

D 0.7763
r= = =0.3882 m
2 2
A=2 πrh+ π r 2
¿ 2 π ( 0.3882 ) ( 1.0325 )+ π (0.38822)
¿ 2.9918 m 2

Impeller & blade

From figure 10.58, Chemical Engineering Volume 6, 2nd Edition,

D / DT = 0.4
and p/D = 1.0
So,
Impeller diameter, D = 0.4 DT
= 0.4 (0.7763)
= 0.3105 m

Blade pitch, p =1.0D

= 1.0 (0.3105)
= 0.3105 m
MECHANICAL DRAWING

Mixer 1 vessel
Diameter = 0.7763 m
Height = 1.0325 m
2
Area = 2.9918 m
Volume of reactor = 0.4887 m3
Vessel Supporter
Diameter = 0.0970 m
Height = 0.2581 m
 1.0325

Inlet and Outlet vessel

Diameter = 0.04 m
Length = 0.03 m
SPECIFICATION DATASHEET

Equipment Specification Sheet

Item Name MIXER 1
Supporting Calculation Appendix A
Subject Specification Data

Mixer 1 dimension Total Height 1.0325 m

Diameter 0.7763 m
Thickness 0.00208 m
Volume 3.1833 m3
Impeller Diameter 0.3105 m
Blade Diameter 0.3105 m
Pressure Operating pressure 192.5 kPa
Design pressure 200.49 kPa
Temperature Operating temperature 26.30C
Design temperature 30C
Reactor material Type Stainless steel 330
Design stress 118 N/mm2
Inlet and outlet nozzle Nozzle diameter 0.04 m
Reactant Inlet phase Liquid
Outlet phase Liquid
Molar flow 240.4 kmol/h
Mass flow 8635 kg/hr
REFERENCES

Afshar Ghotli, R., Raman, A. A. A., Ibrahim, S., & Baroutian, S. (2013). Liquid-Liquid
Mixing in Stirred Vessels: a Review. Chemical Engineering Communications, 200(5),
595–627. https://doi.org/10.1080/00986445.2012.717313
Chen, J. P., Higgins, F. B., Chang, S.-Y., and Hung, Y.-T. (2005). In Physicochemical
Treatment Processes, 47–101, Humana Press, Totowa, N.J.
Jakobsen, H. A. (2008). In Chemical Reactor Modeling, 679–755, Springer, Berlin.
Lacey P.M.C. (1943) Mixing of solid particles, Trans. Inst. Chem. Eng. 21: 53–59
Montante, G., Mostek, M., Jahoda, M., and Magelli, F. (2005). Chem. Eng. Sci., 60,
2427–2437
O’Rourke, A. M., and MacLoughlin, P. F. (2005). Chem. Eng. Process., 44, 885–894.
Paul, E. L., Atiemo-Obeng, V. A., and Kresta, S. M. (2004). Handbook of Industrial Mixing:
Science and Practice, John Wiley, Hoboken, N.J.
Rushton, J. (1956). J. Am. Oil Chem. Soc., 33, 598–604.