Side 

Entry Tank Mixers    Project No. 12 
 

SIDE ENTRY TANK MIXERS -

CHARACTERISTICS AND DESIGN CRITERIA

By
Ahmed Mohamed Seliem
Senior Process Engineer
NPC

Project No. 12
February 2015 0

April 2015 1

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Side Entry Tank Mixers    Project No. 12 
 

CONTENTS

1. Applications of Side Entry Tank Mixers

2. Types of Side Entry Mixers

2.1. Fixed Angle

2.2. Swivel Angle

3. Design Parameters

3.1. Mixing Power

3.2. Mixer Orientation

4. Operations Details

5. Conclusions and Recommendations

6. References

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Side Entry Tank Mixers    Project No. 12 
 

Side entry mixer is an efficient converter of energy into fluid motion. Unlike jet mixer
systems, they do not suffer significant energy losses at the pump, in the pipework, in
the bends, or most significantly, at the jet nozzles. In addition, capital costs are lower
and access to in-tank components is not restricted, while the problem of frequent,
urgent maintenance on tanks that must be emptied and cleaned, is eliminated. Side
Entry mixers are also more efficient than top entry mixers, and are significantly less
expensive for larger diameter tanks. Side Entry mixers are ideal for use on tanks with
floating roofs where practical considerations preclude the use of top entry mixers.

1. Applications of Side
Entry Tank Mixers
The majority of Side Entry
mixers are required to meet one
or more of the following duties:
1.1 Crude Oil BS&W Control
To control or prevent the
accumulation of bottom sludge
and water pockets (BS&W)
especially in crude oil storage
tanks at refineries, or terminals. High velocity circulation is necessary to scour
completely the bottom of the tank by maintaining the heavy solids, water and
corrosive salts in suspension. The developed jet flow is used to lift the BS&W into the
body of the crude oil to maintain a relatively clean tank floor.
1.2 Maintain Homogeneity
To maintain homogeneity of refinery finished or intermediate products, or chemical
plant feed stocks to ensure uniform specification. This demands complete movement
throughout the tank with top to bottom “turnover” as well as circulation round the
tank, to ensure that the product at the top, middle and bottom remains uniform to
specification. This may also sometimes apply to crude oil storage especially in
refinery tanks feeding direct to the distillation units.
1.3 Blend
To mix two or more different components to obtain a homogeneous blend in a
specified time to specific requirements. This demands complete top to bottom
“turnover”.
1.4 Heat Transfer
To aid heat transfer while heating or cooling, or to maintain temperature uniformity -
again complete fluid motion, top to bottom “turnover” would normally be required.
Location of mixers relative to the heating element is also important to the success of
the operation.

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Combined Duties: it is possible that one or more of the duties may apply to a
particular application and the most critical duty must determine the selection of
mixer. Generally, the most power demanding duty is blending.

2. Types of Side Entry Mixer

2.1 Fixed Angle
Normally used in blending applications, maintaining homogeneity, or aiding heat
transfer. All these applications demand complete top to bottom turnover and for this
purpose mixers are permanently installed at an angle of 100 to the left of the tank axis.
2.2 Swivel Angle
Swivel Angle mixers incorporate a feature which allows the mixer angle of entry to be
varied through 30°either side of the tank centerline in 10°increments and enables
the entire tank floor to be directly scoured by the impeller flow stream. This is the
only satisfactory solution to BS&W control in large tanks and ensures that the heavy
solids, water and corrosive salts, which settle in areas least agitated by a permanently
fixed mixer, are maintained in suspension. The mixer module is supported in two
hinge bearings which ensure ease of manual angle changing.

3. Design Parameters
Four variables are essential for side entry mixers design (according to Plenty design
criteria). Mixing Power, Impeller Diameter, Mixer Driver (Belt Driven, or Gear
Driven), and Mixer Orientation & Angle Type (Fixed Angle, or Swivel Angle)
3.1 Mixing Power
In general, all refinery Side Entry mixer applications require between 1.1 kW - 4.6
kW per 1000 m3. In rare cases (low BS&W and low viscosity crude oils), it is possible
to install less power. For each application, there is a minimum power (Pmin) below
which a blend or homogeneity will never be achieved regardless of how long the
mixer is operated. For product storage tanks, this figure is generally 1.1 kW per 1000
m3.
The required power (P) for a given duty is as follows (acc. to Plenty design criteria):
P = volume factor x tank ratio factor x viscosity factor x gravity difference factor
x blend time factor
This calculated power must not be less than the minimum power Pmin.
3.1.1 Tank Ratio & Geometry
Side Entry mixers induce a spiral jet flow across the floor of the tank continually
entraining product from other areas of the tank. This jet stream initially only agitates
the higher gravity product in the bottom of the tank. But in time, providing there is the
necessary installed power, this jet will gradually penetrate the higher layers of the

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Side Entry Tank Mixers    Project No. 12 
 

product with sufficient velocity to generate both full top to bottom flow and to break
the interface between the various densities and achieve a full homogeneous mix. If the
actual height/diameter (H/D) ratio is excessive this will influence the total power
required.
3.1.2 Viscosity
The viscosity of the product will also have an effect on the minimum and required
power. The higher the viscosity the greater will be its resistance to the flow generated
by the impeller. Generally (acc. to Plenty design criteria), in viscosities below 50 cP
the effect would be very slight, but above this it is very important to make corrections.
It is not common to perform tank mixing of products with viscosities as high as
2000 cP. It is usually more economical to heat the products being handled to reduce
the viscosity not only to lower the power levels of the mixers, but also the necessary
power for the transfer pumps.
3.1.3 Density Difference
The density spread can have a
considerable effect on the final mixer
power. Generally speaking, the wider
the difference between the density of the
two or more components to be mixed the
more power is required to break the
interfaces between the omponents and
achieve blend. If inadequate power is installed, insufficient fluid velocity would be
developed to break down the interfaces. An indication of the effect on the total mixer
power required is shown below.
3.1.4 Time
It will be appreciated that to blend the tank contents in 12 hours would require approx.
half the power required to do the same duty in 6 hours and approx. twice as much
power as would be necessary in 24 hours. The required power is inversely
proportionating to the mixing time.
It is, however, necessary to appreciate that some time is required to get the tank
contents in motion before the necessary flow pattern is established to enable the
mixing process to start.
3.2 Mixer Orientation & Angle Type
In order to maximize flow regime within the tank, Plenty experience shows that all
mixers selected should be contained with a 90 degree quadrant and approximately
22 1/2 degrees apart. The positioning of the mixers on the tank depends upon the
application.

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3.2.1 Crude Oil BS&W Control

The main purpose of the mixers in this application is to ensure the developed jet flow
is used to lift the BS&W into the body of the crude oil to maintain a relatively clean
tank floor. The Swivel Angle mixers used can be varied to direct flow up to
30 degrees either side of the centerline of the tank, so that all areas of the tank are
swept. It is particularly important to prevent sludge build-up or blockage around the
tank outlet so the mixer group should be situated directly opposite the tank outlet.
3.2.2 Blending, Maintaining Homogeneity and Heat Transfer
It is assumed that these duties are with ‘clean’ product and so Fixed Angle mixers are
used. As with Swivel Angle mixers, all should be approx. 22.5 degrees apart and with
90 degree quadrant. If it is possible to operate the mixers during ‘pump up’ time, up to
50% of process power or time can be saved. To maximize the additive mixer effect of
inlet flow and mixer jet stream it is recommended that the mixer group be situated
approx. 22.5 degrees to the left of the tank inlet. If it is not possible to utilize the
‘pump up’ time, the position of the mixer group is not critical. Swivel Angle mixers
locked in the 10 degree left position can be used for these duties.

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Mixer Positioning: Fixed Angle Mixers  

Mixer Positioning: Swivel Angle Mixers

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Rushton describes
1 blending in large tanks and
Oldshue et aL, evaluate
factors for effective
blending. The 70-120 angle
with a flat bottom tank
plan centerline as shown in
Figure 5-23G has been
shown to be optimum for
efficient blending in small
and large tanks. The angle
should be to the left of the
centerline and the propeller
should rotate clockwise
when viewed from the
shaft or driver end. [3]
The results for low
viscosity fluids (0.3 to 1.0
1 cp) relate time for a
complete blend using a
side-entering 3-blade
propeller mixer starting
with a full stratified tank
(no baffles) of two liquids.

θ = Blending time, min/ k' = Proportionality constant depending upon system/ ρh = Density for heavy
fluid, lb/cu ft/ ρl = Density for light fluid, lb/cu ft/ D, = Impeller diameter, ft/ T = Tank diameter, ft/
HP = Impeller horsepower used by the system, ft lbs/sec, or HP
This time is considerably longer than for the arrangement with the second fluid
entering the suction of the operating propeller. [3]
For side entering horizontal mixers not limited to blending operations, there are
1 some differences in recommendations concerning the physical location of the
impeller: [3]
1. The impeller should be located ½ to 1½ times the impeller diameter away from the
tank wall in plan. 2. The impeller centerline should be 3/4 to 2D off the tank bottom.
3. The impeller shaft should make a plan angle of 80 to 300 (100 optimum) to the left
of a centerline of the tank.
Blending is usually involved in developing uniform viscosities, densities, and
1 temperatures. For best blending performance, the mixer should be operating while a
second fluid is added to an initial tank of original fluid. This aids in preventing the
tank contents from stratifying. [3]

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Side Entry Tank Mixers    Project No. 12 
 

4. Operations Details
(acc. to plenty instructions)
Swivel Angle Mixers
Normally used for suspension of sludge, solids etc.,
with occasionally a further requirement for blending
(mixer set in 10° left position). For optimum
mixing efficiency, the mixers should be operated on
the following swivel program.
Clean or New tanks - Solids Suspension

30° left, 10° right, 20° left, 20° right, 10°

left, 30° right, 30° left etc., angle changes being
made every 2/3 month max.
Dirty Tanks - Solids Suspension
Programs as for clean tanks but initially the mixer should operate for approximately
8 hours on one angle per batch i.e., first batch 30°
left, second batch 10° right, and so on until such
time that the deposits are reduced to a reasonable
level. Then revert to a change of swivel angle every
2/3 months.
Blending, Maintaining Homogeneity &
Temperature

The mixer should be positioned at the 10°left angle

to ensure full top to bottom turnover.

Typical mixing action in a 
crude oil storage tank

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5. Conclusions and Recommendations

1. Side entry mixers are required to meet one or more of specific duties as crude
BS&W control, blending, homogeneity, and heat transfer.
2. Fixed Angle mixers normally used in blending applications, maintaining
homogeneity, or aiding heat transfer. All these applications demand complete
top to bottom turnover, while Swivel Angle mixers are used in crude BS&W
control.
3. Four main parameters are essential for side entry mixers design. Mixing
Power, Impeller Diameter, Mixer Driver, and Mixer Orientation.
4. For each application, there is a minimum power (Pmin) below which a blend or
homogeneity will never be achieved regardless of how long the mixer is
operated.
5. The required power is inversely proportionating to the mixing time, however,
some time is required to get the tank contents in motion before the necessary
flow pattern is established.
6. The mixers positioning on the tank depends upon the application. All should
be approx. 22.5 0 apart and with 90 0 quadrant. Swivel Angle mixers should be
situated directly opposite the tank outlet and can be varied to direct flow up to
30 0 either side of the tank centerline.
7. NPC usually complains that tank mixers are not effective in crude oils
blending. NPC mixers are Swivel Angle mixers which are mainly used in
crude BS&W control. Swivel Angle mixers locked in the 10 degree left
position can be used for blending after re-checking the required power for
blending from Plenty Co. and assuring that the available mixers kW is
exceeding the Pmin
8. NPC should operate the tank mixers continuously to keep clean tank bottoms
are.
9. NPC to check with Plenty Co. the validity of TK-91,92,93 (naphtha tanks)
mixers to be used in crude oil tanks.
10. For new crude oil tank, TK-116, NPC to determine the main duty for tank
mixers; Blending OR BS&W Control; to correctly specify the new mixers.

6. References
1. SPX Plenty Co., "Heavy Duty side Entry Tank Mixers – Technical Manual"
2. SPX Plenty tank mixers brochure
3. Applied Process Design for Chemical & Petrochemical Plants, Vol. 1, 3rd ed.,
1
Ernest E. Ludwig, Chapter 5, P. 324

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