MIXING
Randomization of dissimilar particles within a system
This is to be distinguished from an ordered system
in which the particles are arranged in an iterative
rule and thus follow a repetitive pattern
Ordered Mixture
a completely homogeneous mixture
where the two components adhere to
each other to form ordered
units. However, a completely
homogeneous mixture is only achievable
adhesive mixture or interactive mixture.
in theory and other denotations were
introduced later such as
A Random Mixture can be obtained if two
different free-flowing powders of
approximately the same particle
size, density and shape are mixed. However, if
powders with particles of different size,
density or shape are mixed, segregation can
occur.
Segregation will cause separation of the
powders as, for example, lighter particles will
be prone to travel to the top of the mixture
whereas heavier particles are kept at the
bottom.
TURBULENT MIXING (TM)
TM
TF Vel
RANDOMIZATION
TURBULENT FLOW (TF)
EDDIES INTENSITY
VELOCITY WITH WHICH EDDIES MOVE
LAMINAR MIXING (LM)
AREAS WHERE LF GENERATES
VISCOUS LIQUIDS
GENTLE MIXING
STATIONARY LAYER
MOLECULAR DIFFUSION (MD)
𝒅𝒎 𝒅𝒄
= −𝑫𝑨
𝒅𝒕 𝒅𝒙
MIXING EQUIPMENTS
COMPONENTS
MIXING TANK
ENERGY SOURCE (impeller, jet mixers)
BATCH (SMALL VOL)VS CONTINUOUS MIXING
In batch mixing all ingredients are loaded into a
mixer and mixed for duration until they are
homogenously distributed or mixed.
Three sequential steps:
1. Weighing and loading,
2. Mixing,
3. Discharge of the mixed product.
IMPELLER
TYPES
FLOW PATTERN
PROPELLERS
Flow pattern of PROPELLERS
AXIAL FLOW PATTERN
TURBULENT FLOW (WORK ON HIGH SPEED)
TURBINES (1000X more viscous than Prop)
ANGLE WITH SHAFT
FOR TAN/RAID. FLOW
CENTRIFUGAL FORCE
PULL ACTION
Semi-solid (quasi solid) MIXING
In between liquid and solid
Doesn’t attain shape of solid
Doesn’t flow like liquid
Mixing stages
1st stage--mixing like solids
2nd stage—mixing like liquids
Stages of Semi-solid MIXING
Powder state Only powder
Pellet state
Add liquid into powder
Powder balls up and finally
Pellets produced.
Material looks coarse granular with
Low rate of homogenization
plastic state
Add more liquid into mass
Granular appearance lost
Mixture becomes homogeneous
Plastic like properties
(low shear with high homogenization)
For mixing to occur shear forces are produced
sticky state
Continuous addition of liquid gives paste like
appearance
Mass flows easily under low stress
liquid state
Further addition of liquid
Loss of consistency until a fluid state reached
High rate of homogenization
Mixing mechanisms like liquid
Sigma blade mixers mix by over-turning the product
(compound stretch), splitting the product and by
shearing the product between the blades and the
bowl.
Tangential and Overlapping Blade Action
In the tangential design, the blades rotate in the container
meeting tangentially. One blade generally rotates faster
than the other blade. Tangential blades are generally used
for material of higher viscosities such as adhesives, rubber
compounds, flush colors, dyes, and pigments.
In the overlapping design, it is necessary that the relative
position of the two blades is unchanged, and as a result,
both the blades rotate at the same speed. Overlapping
blade action is used for materials of lighter viscosities such
as carbon pastes, clay coating, creams, and ointments.
The overlapping blade produces a lower kneading and
shearing compared to the tangential blade action.
planetary mixer is a type of standing/vertical mixer where
the mixer rotates the attachment (agitator) on an axis. This
rotation is similar to how a planet orbits around the sun,
thus the name planetary mixer. This mixer achieves
intense mixing with homogeneity and considered ideal for
mixing viscous pastes in pharmaceutical industries under
atmospheric and vacuum conditions.
Solid mixing patterns
Solid mixing mechanisms
“Shear induced migration”.
Solid mixing equipment
tumblers
