Fluid Mixing: Homogenization Emulsification

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Lecture 2 Slide No. 1 Slide No. 4
Classification of Mixing
Processes
FLUID MIXING  “Fluid mixing” refers to mixing operations in
which the continuous phase is a fluid
HOMOGENIZATION  Although a gas can be used as a fluid (e.g.,
EMULSIFICATION fluidization) a liquid is typically the
continuous phase in fluid mixing processes
Dr. Dang Quoc Tuan  The discrete phase: solid, gas or liquid
Department of Food Technology
International University - VNU
Food Technol ogy Department International University Food Unit Operations 2 Food Technology Department International University Food Unit Operations 2
Content
Slide No. 2
Single-Phase vs. Multiphase Slide No. 5
Mixing
 Classification of mixing processes  Single-phase mixing refers to mixing of
 Applications of mixing in food miscible fluids. This operation is typically
processing called “blending”
 Basic types of mixing equipment  Multiphase mixing refers to mixing
Stirred tank: main components
immiscible phases, i.e.:
Impellers: features & characteristics
High viscosity mixing in stirred tanks – solid-liquid mixing -- suspension
In-Line mixers – liquid-liquid mixing -- emulsification
 Emulsification/Liquid-Liquid Mixing – gas-liquid mixing -- absorption
 Mixing time/ Power for mixing
Slide No. 3 Slide No. 6

Classification of Mixing Processes
Fluid Agitation and Mixing
System Operation Mass Transfer
The term “mixing” refers to all those operations Operation
that tend to reduce non- uniformity in one or Homogeneous Pumping, --
more of the properties of a material in bulk (e.g., liquid recirculation, heat
concentration, temperature). Mixing is one of the transfer
most important operations in food- and bio- Miscible liquids Blending Turbulent and
processing. molecular diffusion
Solid-liquid Suspension Adsorption, leaching
Uniformity ≈ Homogeneity (extraction),
dissolution
Mixing of a fluid with other media (solids, liquids) Liquid-liquid Dispersion/ Extraction
is an extremely common operation encountered (immiscible liquids) Emulsification
in countless applications in the food industry Gas-Liquid Emulsification Absorption, stripping
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Examples of Typical Mixing Mixing Equipment-

Applications Classification
 Blending Mixing is typically conducted with:
 Precipitation and Crystallization  mechanically stirred tanks
 Chemical reaction  in-line dynamic mixers
 Fermentation  in-line static mixers
 Solid-liquid suspension  high-shear mixing equipment
 Liquid-liquid emulsification  mixing equipment for highly viscous
 Gas sparging materials (e.g., polymers)
Importance of Mixing in the Food Mechanically Stirred Tanks and

Industry Reactors
Many technological processes require or are greatly
enhanced by:
• rapid homogenization of miscible components (in
Motor
single phase systems)
Gearbox
• intimate contact between two or more distinct
phases (in multiphase systems), thus, enhance
mass transfer. Shaft
Baffle
• Heat transfer. The rate of heat transfer from the
broth through the walls of the vessel to the cooling Impeller
water depends on mixing conditions.

Mass Transfer Operations in

Slide No. 9
Mechanically Stirred Tanks and Slide No. 12
Mixing Processes Reactors: Symbols

Tank shape = cylindrical (occasionally square cross section)
 All mass transfer processes are enhanced Gearbox Motor
by:
high mass transfer coefficients • DT = Internal diameter of tank
• HT = Internal height of tank
large interfacial area • H = Z = Liquid height
• B = Baffle width
 Mixing can contribute to achieve both S23 H • Di = Diameter of impeller
 However, most mixing operations are • Ci = Impeller clearance
S12 • Cb = Baffle clearance
associated with the generation of
Ci
interfacial (contact) area Cb Di
Baffle, B
DT
Impeller, Di
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The “Standard” Tank Baffles and Vortexing

A gap b/w the baffles and the wall: to prevent stagnation
• H/D = 1 (D- tank dia) behind the baffles and accumulation of materials (e.g. solids)
• Di/D = 1/3
Baffled tank: Unbaffled tank:
• Ci/Di = 1 (Ci- impeller clearance; No vortex Vortex
Di- impeller diameter)
Typically 4 baffles
• B/D = 1/10 (academic) or 1/12 (industry) are used in fully-
• Number of baffles = 4 baffled tank
• Baffle length = full

• B/D =1/72 or 1/100 (gap b/w baffle and
tank)
• Bottom shape = flat
Mechanically Stirred Tanks : Impeller Types

Other Geometric Characteristics
Impeller can be classified as follows:
 Shape of tank bottom (flat, dished,
conical, hemispherical) I. radial impellers (e.g, Rushton turbines,
paddles, flat-blade turbines, Smith
 Baffle length (full, half) impellers)
 Number of baffles II. axial impellers (e.g., marine propellers,
 Baffle position pitched-blade turbines, fluidfoil impellers)
 Gap between baffles and tank (B) III. close-clearance impeller (e.g., anchors,
 Gap between baffles and tank bottom helical ribbons, gates)
Baffles I. Radial Impellers

 Baffles are typically introduced to • Radial impellers pump radially.
prevent vortex formation and convert • They are used primarily with low-viscosity
liquids in baffled tanks.
tangential (rotational) flow into axial • Disk turbines can be used for gas dispersion.
(vertical) flow
 Baffles are always used in turbulent flow • Common types include:
systems (low viscosity fluids) – Rushton turbine (6-blade disk turbine)
 Baffles are not used in laminar flow (high – paddle
viscosity fluids) – flat-blade turbines
– curve-blade turbine
– retreat-blade turbine
– Smith impeller
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Examples of Radial Flow Flow Generated by a Radial

Impellers Impeller in a Stirred Tank
Flat-blade turbine Spiral Turbine

(Source: Chemineer) After Tatterson, 1991
After Tatterson, 1991
Food Technology Department International University Food Unit Operations 2 Food Technology Department International University Food Unit Operations 2

Examples of Radial Flow Characteristics of Common
Impellers Radial Impellers
• Paddles. Simple and inexpensive, medium-to-
strong radial flow and shear, intermediate power
consumption, good for simple applications at small-
to-medium scales
• Flat-blade turbines. Similar to paddles but with
stronger radial flow power, consumption, and shear.
Used in transition flow.
Disk Turbine (Rushton Turbine) R500 Sawtooth Impeller
(Source: Lightnin) • Curve-blade turbine. Similar to flat- blade
Rushton turbines (Disk turbine) turbines
Strong radial flow, high power Radial Flow Impeller for High
consumption, significant shear, good for Shear Applications
gas dispersion

Example of Radial Flow Impeller for
Gas Dispersion II. Axial Impellers
Concave- • Axial impellers pump primarily (but not

Blade exclusively) vertically, either upwards or
Turbine downwards.
(Smith
Turbine) • They are used mainly with low-viscosity
liquids in baffled tanks.
• They are typically used in a downpumping
mode.
• High-solidity impellers are used with gas.
Smith impeller. Similar in performance to Rushton turbine,
but particularly well suited for gas dispersion
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Axial Impellers Flow Generated by Axial

Impellers
Common types include:
– marine propeller Flow generated by
Flow generated by
– pitched-blade turbine true axial impellers mixed-flow impellers
(~propeller, A-310, HE-3) (e.g., 45° pitched-
– fluidfoil impeller blade turbine)
– high-solidity ratio impellers (e.g.,
Prochem)
Examples of Axial Flow Impellers Flow Generated by an Axial Impeller

in a Stirred Tank
After Tatterson, 1991 After Tatterson, 1991

Example of Axial Flow Characteristics of Common
(Hydrofoil) Impeller Axial Impellers
• Marine propeller. Oldest constant-pitched impeller,
usually cast (cannot be easily inserted in a manhole),
expensive, low power consumption, high pumping
rate
• Pitched-blade turbine. Very common, simple,
usually 45°, effective for solid suspension; mixed
flow; medium power consumption, good pumping
rate
• Hydrofoil impellers. Many types exist; expensive,
near constant pitch for improved axial flow, low
Maxflow W Impeller power consumption, high pumping rate
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Examples of Close Clearance

III. Close-Clearance Impellers Impellers
• Close-clearance impellers are primarily used

with high-viscosity fluids in unbaffled
tanks.
• Close-clearance impellers scrape fluid off the
tank wall and off the impeller.
• They generate a complex flow pattern and
have a pumping action similar to that of a Double Helical Auger Impeller Anchor Impeller
displacement pump. Ribbon Impeller
(Source: Chemineer)
Close-Clearance Impellers Blending Capabilities of Different

Impellers
• Common close-clearance impeller types
include: Impeller Viscosity Range
– anchors Open Impellers < 100,000 cP
-Propellers < 200 cP
– helical ribbons -Turbines < 5000 cP
– gates -Paddles < 100,000 cP
– kneaders Close-Clearance Impellers
-Anchors 5,000 – 50,000 cP
– Z- and sigma-blade impellers -Helical Ribbons 30,000 – 25x106 cP
Note: Viscosity of water = 1 cP, milk= 3 cP
High-viscosity Mixing In-Line Mixers

Examples of Close Clearance
Impellers  In-line mixers are small mixing devices placed
in the same line where the materials to be
mixed are flowing.
 Two types of in-line mixers exist:
– dynamic mixers, where the mixing energy is
provided from the outside
– static (motionless) mixers where the fluid
itself provides the mixing energy
After Oldshue, 1984

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In-Line Dynamic Mixers Static Mixers

 In-line dynamic mixers consist of small high-
speed mixers placed inside a casing fed with a
continuous stream of the materials to be
mixed.
 The residence time of in-line mixers is usually
of the order of seconds.
Source: Chemineer
Example of a Two-Stage Rotor Stator Static Vortex

for In-Line High Shear Mixer Mixer for
Turbulent Flow
Source: Chemineer
Greerco (Chemineer)
After Myers et al., Chem. Eng. June 1997
In-Line Static Mixers METHODS OF EMULSIFICATION

PREPARATION
• Static mixers consist of mirror image inserts
Two steps for emulsification:
(elements) placed inside a pipe, capable of • Breaking of internal phase into droplets by
altering the fluid flow, and rearranging the putting energy into the system
distribution of fluid elements across the pipe • Stabilization of droplets
cross section.  Homogenization is a process where two immiscible phases are
• Static mixers are only capable of forced through a narrow aperture under relatively high pressure,
causing sufficiently high shear to create small droplets.
homogenizing the content of the pipe across  Emulsions are prepared in large volume mixing tanks and refined
its cross section but not along its length. and stabilized by passage through a colloid mill or homogenizer.
 Stabilizers and/or surfactants in solution then form an interfacial
layer, preventing emulsion coalescence
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EMULSIFICATION High-Speed, High-Shear Rotor-

EQUIPMENT Stator Mixer
The main types of homogenizer are:
• High-speed rotor-stator mixers are devices
1. high-speed mixers in which a rotor rotates at high speed inside
2. high-pressure homogenizers a casing provided with slots. A small gap
3. colloid mills exists between the rotor and the stator.
4. ultrasonic homogenisers • As the liquid (and its dispersed phase)
5. hydroshear homogenisers and
move through the rotor-stator assembly
microfluidisers.
(Fellows, p. 112) they are subjected to high shear, resulting
in break up effects.
They are high-shear emulsification
equipments
1. High-Shear Mixing Equipment Example of High-Speed, High-

• High-shear mixers: used to generate high velocity Shear Rotor-Stator Mixer
gradients across small distances (resulting in high
shear stress and shear rates) in order to disperse,
break up, or homogenize a second immiscible phase.
• Different devices base on different physical
mechanisms are used to produce high shear.
• Include:
– (high speed) rotor-stator devices
– valve homogeneizers, such as:
• valve homogeneizers
• ultrasonic homogenizers
Silverson Machines, Inc.
High-Shear Equipment Valve Homogenizers

include: • Valve homogenizers pump material at
• (high speed) rotor-stator devices high pressure (30-500 bar) through small
• valve homogeneizers, such as: orifices.
– valve homogeneizers • The high velocity in the orifices
– ultrasonic homogenizers produces high shear.
• The equipment operates in line and can
be used to produce emulsions,
dispersion, and suspensions.
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Valve Homogenizer Colloid Mill
Five Star Technologies
IKA®
Greerco (Chemineer)
Colloid Mills Ultrasonic Homogenizers

• In-line machines designed to finely homogenize,
disperse solids, and emulsify immiscible liquids • Ultrasonic homogenizers pump material at
• Mixing head consist of a rotor (revolving disk) and a high pressure (up to 150 bar) through a
stator (static disk) separated by an extremely small small orifice placed in front of a vibrating
gap (0.001-0.03 in.)
• Stirring speed are usually extremely high (2000-
ultrasonic blade.
14,000 rpm) • The high velocity in the orifice produces
• Flow rates are usually small (as a result of the small high shear, and the blade produces
rotor-stator gap) microcavitation that results in emulsions,
• Less power-efficient and produce more heat than
rotor-stator homogenizers.
dispersion, and suspensions of the
• Require cooling during their operation. dispersed phase.
Ultrasonic Homogenizer
Colloid Mill
After Harnby et al., 1985

Greerco (Chemineer)
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Hydroshear Homogenizers Impeller Reynolds Number

• A double-cone shaped chamber, a tangential feed
pipe at the centre, outlet pipes at the end of each • The impeller Reynolds number, Re,
cone. defined as:
• The feed liquid: at high velocity; to spin in
increasingly smaller circles and increasing velocity
until is discharged.
• The differences in velocity between liquid adjacent is a product of the non-dimensional analysis.
layers: high shearing forces + ultra-high frequency
vibration  droplets in a range of 2–8 µm. • Compare this Re with the Reynolds
• A microfluidiser : operates by pumping fluids into a number for a pipe:
chamber and causing shear and turbulence when
they interact and producing droplets of less than
1µm in diameter, within a narrow size range
Summary of the typical equipment Estimation of mixing time

in different fields of emulsification
• A measure of mixing efficiency
• The time of achieving a given degree of
homogeneity
• Test by pH or concentration probe
tm = 4 tc tc – circulation time
For Rushton turbines (high Re > 5000):
V – liquid volume
Di – impeller diameter

Estimation of mixing time
tm = 4 tc tc – circulation time
Mixing Time
Power Consumption for

Mixing
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Mixing time vs Re Power Equation

The impeller Power Number, Np (also called Po, or the
Newton number, Ne) is a non-dimensional variable:
• i.e.:
Re < 10: laminar flow (Np is a function of the impeller type and the geometric
Re> 5000: turbulent flow and dynamic characteristic of the system)
Power Equation for Geometrically

Similar Systems
• For geometrically similar (including same type of
impeller) stirred tanks and impeller all geometric ratios
are the same
Power Consumption • Hence, NP does not change with scale between tanks:
for Mixing Fluids

• Fr – Froude Number, defined as:
• Froude number: physical interpretation:
Power Equation for Baffled,

Power Consumption
Geometrically Similar Systems
 The power dissipated (or consumed) by the
impeller, P, is one of the most important • When baffles are present, no vortex occurs,
variables to describe the performance of an i.e., the gravitational forces become
impeller in a tank unimportant, and the Power Number
 P is a function of all the geometric and physical becomes independent of Fr:
variables of the system
 Dimensional analysis can be used to establish a
relationship between P and the independent
variables
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Typical Power Curve for Slide No. 67

Power Dissipation in the Slide No. 70
Impellers in Baffled Tanks Laminar Flow Regime
In the laminar regime power dissipation is:

– independent of the density of the liquid
– directly proportional to the viscosity
– strongly affected by the agitation speed (PN2)
– strongly affected by the impeller diameter
(PD3)
Power Curve: Slide No. 68

Laminar Flow Regime Transitional Flow Regime

• For Re<10 the flow in a baffled tank is • For ~10<Re<~10,000 the flow regime
laminar cannot be well characterized as either fully
• Theoretical and experimental evidence laminar or fully turbulent
shows that: • Depending on the type of impeller NP may
decrease with Re or decrease and then
increase with Re before entering the
• i.e.: turbulent flow regime
Slide No. 69
Power Curve: Turbulent Flow Regime

Laminar Flow Regime Re<10
• At high Reynolds numbers (Re>10,000) the flow in
• In the laminar flow region the power a baffled tank is turbulent
dissipated by an impeller is given by: • Theoretical and experimental evidence shows that
NP is independent of Re:
where k” is a proportionality constant that • i.e.:

depends on:
– type of impeller
– geometry ratios for the system P – power
Np- power number
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Correlation between power number and Reynolds number for
Mixing two fluids, with equal volume:
Rushton turbine, paddle and marine propeller without sparging
Average density:
Average apparent viscosity

(vessel with baffles):
For shear-thinning fluids:
For shear-thickening fluids:
Power Number Curves for Slide No. 74 Slide No. 77
Various Impellers Further Readings:

R. Paul Singh, Dennis R. Heldman. 2013. Introduction
to food engineering. Academic Press. 5th Edition. (Ch.
13.4)
P.J. Fellow. 2016. Food processing technology:

Principles and practice. CRC Press. Woodhead
Publishing Limited. 3rd Edition. (Ch. 4.2, Ch. 5)
HW:
-Handout: #7.6
-E&E (Ch. 12, p. 286): #3, #4
After Bates et al., Ind. Eng. Chem. Proc. Des. Devel. 1963 2
Slide No. 75
MIXING OF NON-NEWTONIAN FLUIDS

It is important to calculate the Apparent Viscosity for a certain
shear rate, µa
For shear-thinning power law fluids, Metzner and Otto
equation:
Constant =11-13, usually 12; N = rotation in rps

For shear-thickening fluids, Calderbank and Moo-
Young equation:
then:
Food Technology Department International University Food Unit Operations 2
13

Fluid Mixing: Homogenization Emulsification

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2/5/2022

Lecture 2 Slide No. 1 Slide No. 4

Slide No. 3 Slide No. 6

Slide No. 7 Slide No. 10

Examples of Typical Mixing Mixing Equipment-

Slide No. 8 Slide No. 11

Importance of Mixing in the Food Mechanically Stirred Tanks and

water depends on mixing conditions.

Mass Transfer Operations in

Mixing Processes Reactors: Symbols

Slide No. 13 Slide No. 16

The “Standard” Tank Baffles and Vortexing

• Baffle length = full

Slide No. 14 Slide No. 17

Mechanically Stirred Tanks : Impeller Types

Slide No. 15 Slide No. 18

Baffles I. Radial Impellers

Slide No. 19 Slide No. 22

Examples of Radial Flow Flow Generated by a Radial

Flat-blade turbine Spiral Turbine

Slide No. 20 Slide No. 23

Slide No. 21 Slide No. 24

Concave- • Axial impellers pump primarily (but not

Slide No. 25 Slide No. 28

Axial Impellers Flow Generated by Axial

Slide No. 26 Slide No. 29

Examples of Axial Flow Impellers Flow Generated by an Axial Impeller

After Tatterson, 1991 After Tatterson, 1991

Slide No. 27 Slide No. 30

Slide No. 31 Slide No. 34

Examples of Close Clearance

• Close-clearance impellers are primarily used

Slide No. 32 Slide No. 35

Close-Clearance Impellers Blending Capabilities of Different

Note: Viscosity of water = 1 cP, milk= 3 cP

Slide No. 33 Slide No. 36

High-viscosity Mixing In-Line Mixers

After Oldshue, 1984

Slide No. 37 Slide No. 40

In-Line Dynamic Mixers Static Mixers

Slide No. 38 Slide No. 41

Example of a Two-Stage Rotor Stator Static Vortex

Slide No. 39 Slide No. 42

In-Line Static Mixers METHODS OF EMULSIFICATION

Slide No. 43 Slide No. 46

EMULSIFICATION High-Speed, High-Shear Rotor-

Slide No. 44 Slide No. 47

1. High-Shear Mixing Equipment Example of High-Speed, High-

Silverson Machines, Inc.

Slide No. 45 Slide No. 48

High-Shear Equipment Valve Homogenizers

Slide No. 49 Slide No. 52

Valve Homogenizer Colloid Mill

Five Star Technologies

Slide No. 50 Slide No. 53

Colloid Mills Ultrasonic Homogenizers

Slide No. 51 Slide No. 54

After Harnby et al., 1985

Slide No. 55 Slide No. 58

Hydroshear Homogenizers Impeller Reynolds Number

Slide No. 56 Slide No. 59

Summary of the typical equipment Estimation of mixing time

For Rushton turbines (high Re > 5000):