Created in COMSOL Multiphysics 6.

Mixer

This Application is licensed under the COMSOL Application License 6.0.

All trademarks are the property of their respective owners. See www.comsol.com/trademarks.
About the Mixer Application
The purpose of the Mixer application is to provide a user-friendly interface where
scientists, process designers, and process engineers can investigate the influence that vessel,
impeller, and operational conditions have on the mixing efficiency and the power required
to drive the impellers. Derived values such as the mixing time and the power number are
outputs from the simulations. The application can be used to understand and optimize the
design and operation of the mixer for a given fluid. But, maybe most importantly, it can
be used as a starting point for your own application for the modeling and simulation of
mixers and reactors.

The application demonstrates how parts and cumulative selections can be used to
automatically set domain and boundary settings in the embedded models. These settings
can be created automatically, even when the choices an application user makes create very
diverse geometries.

OVERVIEW
There are three different types of tanks that you can specify in your simulation: Dished
bottom tanks, flat bottom tanks, and cone bottom tanks.

Dished bottom tank Flat bottom tank Cone bottom tank

There are eleven different types of impellers: Six axial impellers and five radial impellers.

Example of axial impeller Example of radial impeller

The application simulates mixers with a single impeller shaft with one or several impeller
turbines (see the figure below). The tank can be equipped with baffles in order to improve
mixing. Baffles are especially required when radial impellers are used.

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 The workflow in the Mixer application is quite straightforward and the annotated
screenshot below shows the main steps. Start by defining the operating conditions, which
include the fluid properties and the rotational speed of the impellers.

The different parameters for the tank’s dimensions include the type of tank, the diameter,
the tank height, and the number of baffles. You can enter 0 in the Number of baffles text
field if you do not want to include any baffles (see the figure below).

Note that the tank’s cylindrical portion is positioned with its base at z = 0. This implies that
the dished and cone bottom sections are positioned just below the xy-plane. If you define
a flat bottom tank with a fillet radius on the lower cylinder edge, then this fillet section is
also placed just below the xy-plane. If you specify a zero fillet radius for a flat bottom tank,
then the base of the tank is positioned in the xy-plane, that is, at z = 0.

The impeller shaft’s lowest portion is also positioned at z = 0 by default. You can change
its position, length, and diameter. However, the impeller shaft is always placed in the
middle of the tank perpendicular to the xy-plane.

Reset Update Create Run Visualize Create Open

input geometry mesh simulation results report documentation

Ribbon with
two tabs

Enter operating
conditions
Select tank type

Define impeller
shaft

Send email with

the report attached

Expected
computation time

Status Plot settings Mixing time scales Flow number

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The Status section reveals the status of the geometry, mesh, and results displayed in the
graphics. If you make a change that influences the results, then this information will appear
in this section. You can also set the application to send an email to a specified recipient,
with an attached simulation report, once a simulation has been computed (see the E-mail
Report section in the figure above).

You can add impellers by clicking the Impellers tab in the Ribbon in the Windows®
operating system, or by clicking the Impellers button on Linux® and Mac® operating
systems. This adds an item to the Impeller list. Several impellers can be added to the same
shaft and distributed along its height by specifying the positions along the z-axis. In order
to change the settings of an impeller, select it in the list, make the desired change in the
settings fields, and click the Update button in the Geometry section of the Ribbon. Make
sure to click this button, otherwise the changes will not take effect.

The dimensions and configuration of the different impellers can be controlled to a great
extent. For example, if you select a pitched impeller, you can cut different areas, round its
edges, define the pitch angle, and define asymmetrical blades, which are wider above the
rotation plane than below. If you add several impellers to a shaft, you can also rotate them
slightly around the z-axis in order to evenly distribute the blades when viewed from above
in an xy-plane projection (see the θ angles in the figure below)

Impellers ribbon
tab
Impeller selection

Impeller dimensions
and position θ3
Direction of
impeller position θ2
Blade settings
θ1

The application results show the velocity field, both in a 3D cut plane and in the form of
3D streamlines. In addition, a cross-section plot shows the eddy diffusivity and the

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streamlines within the yz-plane in the center of the mixer. Also the shear rate is shown in
a cross section plot. Note also that the shape of the free liquid surface is calculated and that
the cross-section plane can be rotated around the main axis (see the figure below). The 3D
cross section scales the deformation of the shape of the liquid surface for optimal
visualization, while the 2D cross section shows an unscaled deformation (1:1)

Rotate
cross section
and display
mixing time
and flow number

To create a mixer model with a set of impellers other than the default, follow this
procedure:

1 Run the Mixer application.

2 Select the Impeller tab.
3 Press Shift and then click in the Impeller list until you have selected all impellers.
4 Click the Delete selected button.
5 Select the Impellers tab in the Ribbon.
6 Click the button for the desired impeller.
7 In the Impeller Settings tab, enter the desired values.
You can repeat steps 5 through 7 in order to add several impellers.
8 Click the Update button in the Geometry section of the Ribbon.
9 Select the Home tab in the Ribbon and the click Mesh>Coarse.
10 Click the Compute button.

It is also possible to change the dimensions, the type of tank, and the shaft settings. You
can do this in the Home tab, then use the Update button to create the new geometry.

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In Email Message section you can send an email when the computation is ready by selecting
the Send an email with the report attached when solved check box and entering an email
address in the text field below. If needed, click the Email Settings button to open the
Outgoing Server (SMTP) dialog box. With the preference settings, the app will use either the
email preferences set in COMSOL Multiphysics when using the Test Application feature or
the preferences in COMSOL Server if the app is run on COMSOL Server. Select the
Override preferences check box to specify a host and port, connection security, a username
and password, and a from email address. Those settings are saved in the app. This sends a
report with the settings and the computed results.

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Impeller Types
As mentioned above, there are two different types of impellers included in COMSOL
Multiphysics: Axial and radial impellers.

Axial impellers give the flow an axial component that provides mixing along the z-axis of
the mixer. This type of mixer is appropriate for fluids that are sensitive to high shear rates.
For example, fermentation processes have living cells in the reactor solution, which would
be killed by high shear rates. In these processes, axial impellers are often selected and
baffles are usually omitted.

Radial impellers force the flow in the radial direction and only give an axial component
once the flow hits the walls of the vessel. In order to achieve good mixing, these impellers
rely on high shear rates and the presence of baffles, which disrupt tangential flows that
would lead to poor mixing.

There is also an anchor impeller available, which is classified as a radial impeller, since it
does not introduce an axial flow component. However, the anchor impeller does not
induce a radial flow like a conventional radial impeller does.

When specifying the operation of all impellers included in COMSOL Multiphysics, the
default direction is specified looking at the xy-plane from above. A positive angular
velocity (ω) is defined as counterclockwise and clockwise is negative (see Figure 1 below).

The convention is valid for angles as well. A positive angle (θ) is defined as
counterclockwise measured from the x-axis in the xy-plane.

The inner edges of the impeller blade are defined as the vertical edges closest to the hub
and the outer edges are the vertical edges away from the hub.

Figure 1: Positive and negative angular velocity as defined in COMSOL Multiphysics.

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PITCHED IMPELLER
The simplest axial impeller is the pitched impeller (see Figure 2 below) which can be
configured for rectangular blades or for isosceles trapezoid-shaped blades. These blade
shapes can be created with wider outer or inner edges.

Attachment to Smaller inner Larger outer

the impeller hub blade width blade width

Cut at the upper Cut at the upper

and inner edges and outer edges

Cut at the lower Cut at the lower

and outer edges and inner edges

Figure 2: Possible configurations of impellers with symmetrical blades.

In order to create asymmetrical blades, the upper portion of the blade can be made wider
than the lower portion. Optionally, the impeller can then be flipped vertically to have the
wider part of the blade facing downwards. The pitch angle can be varied between 0 and
90 degrees. The outer vertices can also be rounded using fillets.

Upper part of the blade

wider than lower part

Pitch angle

Figure 3: Asymmetrical blade. The upper part of the blade is wider than the lower part.

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The figure below contains the notation used for the pitched impeller in the Part Library.
The full list of parameters and their descriptions are found in Table 1.

Figure 4: Notation used for the pitched impeller.

PITCHED IMPELLER WITH BENT BLADES

A bend may be used to decrease the pitch in the outer region (away from the hub) of the
impeller blade. Bending results in a less aggressive pitch angle at the outer edges. Only the
upper and outer edges of the blades can be bent in COMSOL Multiphysics. However, you
can flip the impeller vertically to obtain a bend or wider part that faces downwards. The
upper portion can also be made wider than the lower portion to obtain an asymmetrical
blade.
Attachment to Rectangular Asymmetric Blade bend at the
the impeller hub blade bend blade upper and outer edges

Cut at the lower Bend Cut at the upper

and outer edges angle and inner edges

Figure 5: Available blade bend and cut operations.

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The vertices of the outer vertical edge can be rounded using fillets. The figure below shows
an impeller with asymmetrical blades and rounded vertices.
Cut upper and Fillets create
inner edges a rounded bend

Figure 6: Asymmetrical impeller blades with rounded outer vertices.

The figure below contains the notations used for the pitched impeller with bent blades in
the Part Library. The full list of parameters together with their descriptions is found in
Table 1.

Figure 7: Notation used for the pitched impeller with bent blades.

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PITCHED BLADE IMPELLER WITH CONSTANT PITCH
For regular pitched impellers, the pitch increases with the radius of the impeller blades,
since the blades travel with increasing velocity as the radius increases. This means that if
the rotating impeller was allowed to move freely in the axial direction, the outer edge of a
regular pitched impeller will want to travel at a higher axial velocity than the inner edge.
This subjects the impeller blade to a high bending moment. The pitched impeller with
constant pitch adapts the pitch angle with the increasing radius so that the outer and inner
edges have the same axial velocity during rotation.

The impeller with constant pitch can be designed with isosceles trapezoid-shaped blade
projections (the blades are not flat). The blades can also be cut on both upper and lower
edges to achieve different impeller shapes (see figure below).

Attachment to “Twisted” Smaller inner Larger outer

the impeller hub rectangular blade blade width blade width

Cut upper and Cut upper and

inner edges outer edges

Cut lower and Cut lower and

outer edges inner edges

Figure 8: Pitched impellers with constant pitch and different blade shapes.

The inner pitch angle can be varied in order to change the axial and radial components of
the flow induced by the impeller. The pitch angle is then automatically calculated to give
a constant pitch.

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The outer vertices of the blades can be rounded, which gives additional freedom in the
design. The figure below shows a propeller created by using fillets and cuts and applying
those on a pitched impeller with constant pitch.

Fillet on upper
and outer vertex

Fillet on lower
and outer vertex

Large fillet radius

yields a propeller shape

Figure 9: Impeller of propeller type created using isosceles trapezoid-shaped blade projections
and large fillet radii for the outer vertices of the blades.

The figure below contains the notations used for the pitched impeller with constant pitch
in the Part Library. The full list of parameters with their descriptions is found in Table 1.

Figure 10: Notation used for the pitched impeller with constant pitch.

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HYDROFOIL IMPELLER
Impellers with blades that are curved along the vertical edges are called hydrofoil impellers.
These are similar to pitched blade impellers, but give an additional pressure difference
across the blade with a lowered pressure on the convex side.

In addition to varying the curvature radius of the blades, the shape of the impeller blade
projections can be varied to achieve the same freedom in the design of hydrofoil impellers
as in the case of the pitched impeller mentioned above. This implies that isosceles
trapezoid-shaped blade projections, asymmetrical blades with a wider upper part, and cut
blades can be used to create the desired design. Fillets make it possible to create impellers
of the propeller type.

As in the case of the pitched impeller type, the pitch angle can be varied to control the
relation between the radial and axial flow created as the impeller rotates.
Rectangular curved Asymmetrical blade with wider
blade with attachment at the hub upper part of the blade

Curved Cut upper and

blades inner edges
Flip
horizontal

Flip
vertical

Large fillet Cut lower and

radius outer edges

Figure 11: The curved blades can be shaped to create a large variety of impeller designs.

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The figure below contains the notations used for the hydrofoil impeller in the Part Library.
The full list of parameters with their descriptions is found in Table 1.

Figure 12: Notation used for the hydrofoil impeller.

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HYDROFOIL IMPELLER WITH CONSTANT PITCH
In the same fashion as the pitched impeller, the hydrofoil impeller creates an axial flow
velocity that increases with the radius as the impeller rotates. This subjects the blade to a
bending moment. A hydrofoil impeller with constant pitch adapts the pitch angle in order
to obtain an almost constant pitch of the projection of the curved blade along the radius.
Note that it is very difficult to obtain an exactly constant pitch with increasing radius since
the blades are curved.

As in the case of regular hydrofoil impellers, the hydrofoil impeller with constant pitch
gives an additional pressure difference across the blade with a lowered pressure on the
convex side.

The impeller blade can be designed with cut blades and asymmetrical blades. Fillets can be
used to create impellers of the propeller type.
Rectangular curved Cut upper and Cut lower and
and twisted blade inner edges outer edges

Cut wider
outer edge

Large fillet Cut lower and

radius outer edges with fillets

Figure 13: Hydrofoil impellers with constant pitch.

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The figure below contains the notation used for the hydrofoil impeller with constant pitch
in the Part Library. The full list of parameters with their descriptions is found in Table 1.

Figure 14: Notation used for the hydrofoil with constant pitch.

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THE C-SHAPED DOUBLE BLADE IMPELLER
This is an axial impeller that is suitable for fluids with relatively high viscosity. It consists
of two pitched blades equipped with a c-shaped double-blade part that adds shear at the
outer radius. This configuration can be used to create the so-called Intermig® impeller.

The impeller can be designed with different pitch angles on the arms. The angles of the
c-shaped part can also be varied. The profile can be adjusted by changing the vertical angle
of the c-shaped part while keeping the upper and lower blades parallel. In addition, the
angle of the back of the “c” can be varied while keeping the lower and upper blades parallel
but displacing them in the xy-plane.
C-shaped Adapt for clockwise
double blade and counterclockwise rotation

Impeller arm

Varying angle of Varying pitch angle

c-shaped profile

Figure 15: The c-shaped double blade impeller.

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The figure below contains the notations used for the c-shaped double blade impeller in the
Part Library. The full list of parameters with their descriptions is found in Table 1.

Figure 16: Notation used for the c-shaped double blade impeller.

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RUSHTON TURBINE
Axial impellers, such as the Rushton turbine, work by pumping the fluid towards the wall
of the vessel and then letting the collision of the fluid with the wall supply the axial mixing
and turbulence. In order to avoid tangential flows that would result in poor mixing, baffles
are often used in combination with Rushton turbines. Rushton turbines induce a relatively
high shear rate and are therefore appropriate in processes where the fluid is not sensitive
to shear rates.

The turbine can be designed with different blade lengths and different disk diameters.

Impeller blade

Impeller disk

Figure 17: The Rushton turbine.

The figure below contains the notations used for the Rushton turbine in the Part Library.
The full list of parameters with their descriptions is found in Table 1.

Figure 18: Notation used for the Rushton turbine.

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THE RUSHTON TURBINE WITH BACKSWEPT BLADES
This type of turbine is similar to the normal Rushton turbine. The backswept blades allow
for smoother operation with lower shear rates. It is possible to vary the blade length and
the disk diameter, as well as the curvature and blade angle relative to the perimeter of the
disk.
Impeller blade

Direction of
rotation Impeller disk

Figure 19: The Rushton turbine with backswept blades.

The figure below contains the notations used for the Rushton turbine with backswept
blades in the Part Library. The full list of parameters with their descriptions is found in
Table 1.

Figure 20: Notation used for the Rushton turbine with backswept blades.

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THE SMITH TURBINE
This is a turbine that resembles the Rushton turbine. It has the same properties but
somewhat smoother operation with lower shear rates. The length of the blades, the
diameter of the disk, and the radius of curvature of the blades can be varied when creating
the impeller geometry.
Impeller blade

Direction of
rotation Impeller disk

Figure 21: The Smith Turbine.

The figure below contains the notations used for the Smith turbine in the Part Library.
The full list of parameters with their descriptions is found in Table 1.

Figure 22: Notation used for the Smith turbine.

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THE BACKSWEPT BLADE IMPELLER
This impeller type is suitable for fluids with low viscosity and density, for example, gases.
The curvature creates smooth operating conditions with relatively small shear rates
compared to straight blades. The impeller can be designed with different blade lengths and
curvatures.

Impeller Curvature
blade radius

Direction of
rotation

Attachment to the hub

Figure 23: The backswept impeller.

The figure below contains the notations used for the backswept blade impeller in the Part
Library. The full list of parameters with their descriptions is found in Table 1.

Figure 24: Notation used for the backswept blade impeller.

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ANCHOR IMPELLER
This impeller type is suitable for mixing fluids of very high viscosity, for example, Portland
concrete and paints in small amounts. The lower portion of the impeller is shaped like an
ellipse that is cut in the middle. The major axis is equal to the impeller diameter, while the
minor axis is equal to the dished tank’s minor axis where the impeller is placed, minus the
clearance between the impeller and tank wall.
Upper hub

Major axis

Minor axis

Figure 25: Anchor impeller.

The figure below contains the notations used for the anchor impeller in the Part Library.
The full list of parameters with their descriptions is found in Table 1.

Figure 26: Notations used for the anchor impeller.

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Overview of Impeller Parameters
The table below contains the names and descriptions of the input parameters used for the
impellers in the Mixer Module Part Library.
TABLE 1: MIXER MODULE PART LIBRARY PARAMETERS

ab_ib Bending angle of folded section

ac_h_s_ib Shear angle, back of c-shape blades
ac_ib Vertical angle between arm and c-shaped blade
ac_s_ib Internal angle, c-shaped profile
ap_ib Pitch angle of impeller blade
ar_ib Rake angle of impeller
as_ib Relative rotation angle around shaft
d_a_ib Diameter of attachment section
d_hu Impeller hub diameter
d_id Diameter of impeller dish
d_im Impeller diameter
d_is Impeller shaft diameter
d_ta Tank diameter
Da Input diameter for turbulence model
db_im Distance of first impeller hub from bottom
dc_ib Blade width, c-shaped blades
h_an_im Height of anchor impeller
hp_im Impeller position
hp_is Position of the lowest part of the impeller shaft
l_ib Length of the impeller blades, Rushton, Smith
lc_ib Blade length, c-shaped blades
lr_bu_ib Relative position of the bending point along the length of the
upper edge of the impeller blade
lr_cl_ib Relative position of cutting point along the length of the lower
edge
lr_cu_ib Relative position of cutting point along the length of the upper
edge
n_ib Number of blades

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TABLE 1: MIXER MODULE PART LIBRARY PARAMETERS

pa_rd_im Parameter that controls the impeller blade direction, 1 =

clockwise and -1 = counterclockwise
pa_ud_im Flip impeller vertically
rc_h_ib Curvature of backswept Rushton, Smith, and Backswept impeller
rc_v_ib Hydrofoil curvature radius closest to the hub
rf_ib Fillet radius of outer vertices
w_a_ib Blade attachment width
w_bou_ib Width of the folded section at the outer edge
w_cil_ib Width of inner and lower cut
w_ciu_ib Width of inner and upper cut
w_col_ib Width of outer and lower cut
w_cou_ib Width of outer and upper cut
w_ib Impeller blade width
w_o_ib Outer impeller width
wc_ib Blade distance, c-shaped blades
wc_o_ib Outer arm width for c-shaped impeller
wr_ai_ib Ratio between blade width and blade attachment
wr_asu_ib Asymmetry factor for upper part of the width of the impeller
blade: 1 = symmetry, >1 = wider upper part

25 | MIXER
The Embedded Model
The physics behind the application is based on the Mixer Module’s rotating machinery
formulation. The flow is defined by a so-called y+ algebraic turbulence model in
combination with the momentum and mass conservation formulations in the Single-Phase
Flow interface. The rotating mesh is formulated by the moving mesh interface using an
arbitrary Lagrangian-Eulerian formulation for a sliding mesh approach in the domain that
surrounds the impellers. This auxiliary domain is hidden in the application’s UI.

Cylindrical rotating
domain

Figure 27: Cylindrical rotating domain enveloping the impeller and shaft.

The geometry is constructed using different parts available in the Parts Library of the
Mixer Module. The tanks all include a cylindrical rotating domain that completely
envelopes the impellers positioned along the central axis of the tank.

RESULTS
The results show the flow field, the eddy diffusivity created by turbulence, and the time
scale for the mixing process.

The flow field visualizations help in assessing the pattern of the flow. For example, if the
flow is mainly tangential, so that the fluid moves like a merry-go-round around the center,
then you may consider adding baffles.

Note also that you can rotate the position of the cross-section plane by clicking the slider
bar in the Graphics section. It is possible to rotate the cross-section plane both in the 3D
and in the 2D plots.

The cross-sectional plot shows the streamlines in a yz-plane along the main axis of the
mixer. This gives a good indication of the level of compartmentalization of the flow, which
may also be broken up by baffles or by a steeper impeller pitch angle.

26 | MIXER
The eddy diffusivity field is a measure of the mixing efficiency. You can estimate the time
scale of the mixing process by dividing a typical area by the value of the eddy diffusivity.
The time scales for the radial and axial mixing is estimated and shown below the 2D and
3D plots in the user interface.

Note that the application also computes the shape of the free surface for the fluid. This
reveals whether the position of the top impeller is too close to the surface, so that some
mixing power is lost to the gas above the free surface.

Application Library path: Mixer_Module/Applications/mixer

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