INDUSTRIAL MIXING

by
Ramesh R. Hemrajani
Mixing & Reactor Solutions
RameshHemrajani@Yahoo.com
(908)647-0185
Mixing Technologies
 WORKSHOP OUTLINE
SECTION TOPIC

INTRODUCTION

I FUNDAMENTAL MIXING CONCEPTS

Power numbers, Flow Patterns, Wall Baffles, Impeller Technologies, Scale-Up,
Multi-Stage Mixing Tanks

II BLENDING OF MISCIBLE LIQUIDS

- Feed Strategies

III BLENDING OF VISCOUS LIQUIDS

IV SUSPENSION OF SINKING SOLIDS

- Jet Solids Suspension
- Entrainment of Floating Solids

V IMMISCIBLE LIQUID-LIQUID MIXING

VI GAS-LIQUID DISPERSION
- Three Phase Mixing

VII BLENDING IN LARGE TANKS

Jets, Side Entering Propellers

VIII SLUDGE SUSPENSION IN CRUDE TANKS

IX IN-LINE MIXERS
- Tee Mixers

X HEAT TRANSFER IN AGITATED TANKS

 G EN ER A L O B JEC TIV ES

• D EV ELO P AN U N D ER ST AN D IN G O F M IX IN G C O N C E PTS R E LATIN G TO

P R O C ES S N EE D S AN D TR AN S L ATE TO M IX IN G R E Q U IR E M EN TS.
- LE AR N AB O U T E XP ER IM EN TAL TE C H N IQ U ES FO R Q U AN TIFYIN G
M IX IN G Q U ALITY

• D EV ELO P FAM IL IAR ITY W ITH D E S IG N G U ID ELIN E S FO R S E LECTIN G

AN D S IZIN G M IX IN G S Y STE M S FO R D IFFER E NT FLU ID S YS TE M S.

• E V ALU ATE V AR IO U S TO O LS FO R TR O U B LE SH O O TIN G AN D

R ETR O FITTIN G EX IS TIN G M IX IN G E Q U IP M E N T TO IM P R O V E PR O C E SS
P ER FO R M AN C E .
 CLASSES OF MIXING APPLICATIONS
Mixing Class Physical Mass Transfer/Reaction
Miscible Liquids Blending:lube oils, Slow batch chemical
gasoline additives, for pH reactions, fast reactions in
control, dilution in-line mixers
Liquid/Solid Preparing homogeneous Dissolving, crystallization,
slurries of light and heavy liquid/solid reactions,
solids such as polymers, solvent extraction
catalyst etc.
Immiscible Liquids Washing liquids with Hydrolysis/neutralization
immiscible solvents, reactions, extraction,
cosmetics, salad dressing suspension polymerization
Gas/Liquid Gas scrubbing, steam Absorption, stripping,
heating of liquids oxidizing liquids,
hydorgenation, oxonation of
olefins, chlorination,
~ fermentation
Vicous Liquids Blending polymer solutions Solution polymerization,
— Newtonian paints and pigments, de-ashing of catalyst from
Non-Newtonian
— food products polymers
Heat Transfer Heating and cooling through jackets and internal coils
• OPERATING MODES OF MIXING SYSTEMS
Batch Semi-batch Continuous

• WHY GOOD MIXING

— Minimize investment/operating costs

— High yields when mass transfer limiting
— Enhance profitability

• MIXING EQUIPMENT TYPES

Agitated Tanks Jets In-Line Mixers
Static Mixers Air Lifts Specialty Mixers
 Motor

Gear Box

Shaft
Floating
Solids

Gas
Miscible Liquids
Bubbles
of different ρ & µ

Jacket Immiscible
Liquids

Impeller
Sparger

Sinking
Solids
Cylindrical,
dished bottom
tank with
baffles and dip
pipe
 Mixing Tank Configuration

Side Entering

Bottom Entering

Inclined

Horizontal Cylinder Horizontal Cylinder

Side Entering Top Entering
 Jet mixed systems

Competitor for side entry mixers

Use outside pump to generate a
liquid jet

Jet entrains surrounding liquid
and provides homogeneity

Very low capital cost

Easy pump maintenance
 MIXING SYSTEMS DESIGN APPROACH

• ANALYZE PROCESS AND DEFINE PROCESS MIXING

REQUIREMENTS - ENERGY, SHEAR ETC.

• SPECIFY MIXER TYPE - TANK/ IMPELLER CONFIGURATIONS Jet

—

Type

• SIZE MIXER - D & N, Jet Nozzle Diameter/Velocity

• DESIGN OTHER INTERNALS SUCH AS BAFFLES

• DESIGN MECHANICAL COMPONENTS

IMPELLER BLADES, SHAFT, BEARINGS, SEAL
Estimated Cost

In 1989, the annual cost of inadequate or

poor mixing in the CPI was estimated at

$1-10 billion US/year

in the US alone.