Mixer
Mixer
Submersible Mixers:
Planning Information
0,75 Di
Di
CCW
CCp
CW
CO
CO
A
CB
CO
Table of Contents
Page
Preface 2
1.
Definitions 3
2. Introduction to mixing technology
5
3.
Rheology 9
4.
Fields of application 14
5.
Mixer Sizing 16
6.
Flow build-up 19
7.
Theoretical circulation time 22
8. Flow velocities and flow distribution
23
9. Submersible mixer with bottom diffusers
27
10. Transportation of solids in activated sludge
31
11. Flow guidance and mixer positioning
35
12. Typical mixer sizing information and RFQ data sheet
44
13.
References 46
Preface
This know-how brochure gives an overview of how KSB submersible mixers of the small blade (Amamix) and
large blade (Amaprop) variety have been utilized in the past and which applications are possible.
The possibilities of application for submersible mixers are too complex to be fully treated by this document;
therefore, it does not aim for completeness.
For the planning and selection of submersible mixers it is important to consider the criteria identified within
this document. Ignoring these criteria may result in failures of the mixers, installation accessories and
ultimately the overall process.
Should you have any further questions regarding applications that have not been dealt with here, feel free to
contact KSB, Inc. for support ([email protected], 804-222-1818).
Jared S. Wray, P.E.
KSB, Inc. Water & Wastewater Division
Product Manager
Submerged Propeller Devices
Definitions
The terms used in conjunction with mixing and flow technology are defined as follows:
Aeration
Gas (typically air) is introduced to the fluid in order to trigger oxygen
transfer and/or mixing.
For example: Surface aerators, bottom diffusers and nozzles / ejectors are
used for the generation of bubbles and oxygen transfer.
Thickening
Process of moisture removal to concentrate a substance or fluid.
For example: condensed milk, the mixing in of fillers, or the raising of
viscosity, e.g. through polymerization.
Emulsification
This refers to the mixing of two or more liquids, which are immiscible
(un-blendable). Mixtures which after the mixing process do not separate
are termed stable emulsions.
For example: diluted soluble oil, long-life milk
Homogenization
The process of evenly distributing concentrations or differences in
temperature within one or more combined soluble fluids. The mixer has
the task of shortening the time taken to achieve even distribution and
maintaining or establishing a homogeneous state.
For example: Neutralization, pH level adjustment, prevention of layer
formation.
Flow generation
The generation of fluid flows required in process technology.
For example: Horizontal flows in the elimination of phosphate and
nitrogen in sewage treatment.
Definitions
Rheology
Suspension
Mixing with the aim of generating a uniform concentration of solids
throughout the fluid. The breaking apart and prevention of sedimentation
and floating layers.
For example: Lime milk, sewage sludge, liquid manure. About 95% of fluids
which are agitated by mixing machinery are suspensions.
Improvement of heat
transfer
Thinning
Agitation to change concentration/viscosity.
For example: Stirring of paints prior to application.
Activated Sludge
Wastewater with biological floc responsible for treatment, which are kept in
suspension and aerated. For the purposes of this document it shall have a
sludge volume index (SVI) value of 100 ml/g and 80% of the total solids
(TS) shall be volatile solids. Sludge with varying properties will not be
completely mixed due to abundance of inorganics.
For example: Wastewater found within typical oxidation ditch or
sequencing batch reactor (SBR).
processes.
known. For example, note the above photograph (fig. #1) which
depicts a typical activated sludge tank in operation. By just
The following sketched action plan has proved itself reliable in the development of new mixing processes.
results?
However a description of
actual condition?
available in excess?
etc.
inspection by equipment
flows.
Turbulent flows are three
dimensional flows.
Turbulent flows are temporary
flows.
The above information means
manufacturer is necessary.
Information Required for
Mixer Selection
As previously mentioned, the
knowledge of all relevant
parameters to the mixing
system is an absolute must for
Trouble Shooting
is impossible in a suspension,
installed?
useful.
positioned?
information.
the selection.
As a general rule one could say that the more data available, the better the selection of the mixing
equipment will be.
8
Rheology
Rheological Properties:
Rheology is a relatively young
discipline which was founded
together with the American
Society for Rheology in 1929
where Professor Bingham gave
the discipline its name. The
discipline centers on the
measurement, description of,
and explanation behind flowing
liquids under the effects of
deformations.
Rheological investigation is an
integral part of both research
and quality/production control.
Its use in various branches of
industry such as chemistry,
biology, pharmacy, and the
food and beverage industries
underlines rheologys growing
significance. Even in the field of
characteristics.
Rheology
Viscous
Elastic
Plastic
Viscoelastic
10
Rheology
Viscosity:
Force = Velocity
Surface
Distance
(fig. #8).
Force
Distance
Fluid
Stationary plate
11
Rheology
decrease in viscosity.
figure #9.
Ne
o
wt
ni
an
12
Rheology
Applied Rehology:
A typical example of shear-thinning behavior is displayed by ketchup or whipped cream in a can: if the bottle
is shaken with a reasonably constant motion, then the previously reluctant fluid will begin to flow. Once the
bottle is placed on the table again, the contents return to a more solid state.
This is all very relevant because the majority of municipal and industrial waste sludge exhibit shear-thinning
behavior, and therefore possesses intrinsic viscosity. Such example is shown below in the following figures #10
& #11, which show the affect that mixing has on such sludges.
13
Fields of Application
Nitrification (Aeration)
Thickener
Neutralization
Denitrification (Anoxic)
Selector tank
Oxidation ditches
Sand trap
Disinfection
Pump station
Buffer tank
Reaction tank
Storage tank
Fig. #12 - Hartford County, MD WWTP utilizes > 100 submersible mixers for various applications
14
Fields of Application
1. Sludge Agitation
Suspending or re-suspending
viscous media
Pratical Application:
of.
pumpable mixtures of
15
2. Flow Generation
water)
Mixer Sizing
Mixer Sizing:
velocity)
24656 : 2010-03.
installations)
F3 - forces resulting from geometry losses
Energy Density = P1 / V
[fig #13]
power)
etc.)
resistances.
16
Mixer Sizing
The calculated required thrust is compared with the available thrust of the mixers and provides the required size and
number of mixers to be used. Once the mixers are selected on a basis of thrust, then power requirement can be
determined because the mixers input power (P1) at the operating point (given thrust) is known via factory testing as
shown in figure #14. This factory testing is done in accordance with the relatively new ISO 21630 standards released
in 2007. Note that there is no direct correlation or simple calculation to compare thrust to power; therefore it is not
appropriate to size or compare mixers on a power basis!
17
Mixer Sizing
the:
tank geometry
tank volume
obstructions
inlets / outlets
aeration
propeller diameter
propeller speed
propeller hydraulic design
motor efficiency
18
Flow Build-up
Flow Build-up:
After the mixer has started-up and reached operating thrust, the flow will slowly build-up as illustrated
below in figure #15 until it has reached the equilibrium conditions (average flow velocity).
Flow Build-up
Intensive mixing is achieved when the jet flow comprises the entire tank volume and induces a bulk flow
(channel flow). The bulk flow is subjected to swirls induced by the propeller, but certain geometry
dependent fluid dynamics (flow mechanics) will develop in every tank. Typical features are demonstrated
below (fig. #17) in a racetrack type tank equipped with a partition.
Flow Build-up
Furthermore a flow separation develops behind the partition and displays itself as a relatively stationary
flow obstruction to the main flow. The reduced cross-section - due to this separation of flow - accounts for
the majority of the losses with this particular geometry.
The build-up of the flow is terminated as soon as the equilibrium conditions have been reached (fig. #18).
This is achieved when all forces impeding the build-up of flow are effective and there is no further increase
of the bulk flow. It is this equilibrium condition that is most often desired in wastewater applications.
21
One should not mistake the theoretical circulation time for the
V tank
circulation
Q mixer
t circulation
(s)
V tank
(ft3)
Q mixer
(ft3/s)
22
Flow Velocities:
correct?
Velocity
(ft/s)
0.33
0.50
0.50
Flow Distribution:
Medium-fine or medium-
0.66
upstream pre-treatment
equipment.
1.15
2.00
same particles.
23
Further complicating the situation is the fact that a simple calculation method capable of providing the
velocity at a certain point in the tank does not exist. In fact, it requires a very time consuming and
expensive computational fluid dynamics (CFD) model simulation to solve this problem. KSB provides such
CFD models for very special tank geometries or as requested by the customer, but typically such detailed
local velocities are not necessary to ensure adequate mixing for the process.
6 mixers
Tank Volume:
Channel Depth:
16.5 ft
7,770 SCFM
Propeller :
8.2 ft
Power (P1):
4.7 hp
Energy Density:
0.10 W/ft3
25
26
27
28
29
Vair
Uplift velocity of the air
ft/s
ft/s
Total velocity
ft/s
Vliquid
VTotal
The travel time of the bubbles is therefore significantly reduced by the swarming effect. This is a direct result of
the inverse relationship between travel time and total upward velocity.
Now if a horizontal flow is added to these fluid mechanics (fig. #30), the shape of the swirl-type flow will
change. Or in the ideal case, swirl type flow will be completely neutralized and fluid dynamic conditions will
arise which are similar to those of laminar flows.
Horizontal Flow
10
Solids Transport:
An extensive separation of
on solids type.
ft/s.
guidance.
may be accomplished by
mechanical agitation/guidance
installations/structures in the
31
10
Under flow
Under flow
32
10
Sediments
Solids which are carried to the center by the
flow cannot move away from there
Fig. #33 Hydraulics of round tank
Many times round tanks with center drain are routinely emptied or run at low water levels. In these cases
submersible high speed mixers should be utilized to allow maximum run time during draw down. A
recommended minimum water level will be provided by manufacturer, which gives minimum operating
level for optimum mixing performance without vortex formation. However mixer operation (for propeller
diameters < 24 in.) below this level is acceptable as long as the motor remains submerged.
Taking the tank geometry, the flow pattern and the solids transportation into account, a favorable tank
drain can be designed to ensure the hydraulic transportation of solids out of the tank.
Special concerns regarding tanks with overflow weir outlet
When the outlet is arranged close to the surface (i.e. on overflows or outlet channels of pre-treatment tanks
that have been retrofitted for de-nitrification), a vertical flow higher than the sinking velocity of the
particles is absolutely necessary for the solids transportation (i.e. solids must be forced upwards). With
special care this can be achieved with the use of submersible mixers (figure #34).
33
10
mixers.
concentration of specifically
draining.
34
11
Propeller Hydraulics:
As discussed in section 6 the
mixers capacity highly depends
on the propeller diameter, the
speed and its hydraulic
characteristics. Please refer back
to this previous section for
basics regarding propeller
hydraulics.
The running conditions of the
mixer are also highly dependent
on the hydraulic condition of
the tank. The propeller capacity
itself is constant and typically
Generally speaking, the flow jet stream (impetus) should start from a
the smooth running of the mixer in order to prolong its service life. At
the same time, the operational efficiency of the mixing system will
propeller.
KSB verifies all results and positioning guidelines via a combination of
Tank shapes with higher loses
outlets
can be accomplished by
obstructive installation
the propeller
propeller
forces.
35
11
In general negative influences on the suction side of the propeller impair its ability to run smoothly, and on the
discharge side increase energy density.
General Tankage Considerations
For process success the tank design is as equally important as the mixer hydraulics and positioning. In particular the
following data clearly shows that tank shape can highly affect thrust, creating over 350% variation. Since thrust is
related to the required mixer power/size; tank selection will directly impact the capital and/or operational cost of the
mechanical equipment.
Tank Shape
Volume Approx.
Needed Thrust
Round
150,000 ft3
170 lbf
1.00
Ring channel
150,000 ft3
150 lbf
0.88
Rectangular
150,000 ft3
220 lbf
1.29
150,000 ft3
530 lbf
3.12
150,000 ft3
250 lbf
1.47
150,000 ft3
220 lbf
1.29
*Standard activated sludge tank geometries of equal volume being mixed to achieve average blulk flow velocity of 1 ft/s.
Round Tanks
In relation to other shapes, round tanks are inexpensive to manufacture. However cost increase when multiple tanks are
required because common wall construction cannot be utilized and there is a larger land space requirement. They also
produce a low amount of tank geometry-related losses. This means that low energy density for mixing can be reached
in these tanks given the same volumes. The flow distribution is problematic though, as incorrect positioning of the
mixer can easily lead to the generation of unwanted flow patterns. The desired flow pattern must be defined based on
the results required.
Possible results:
1. To remove solids from the tank (e. g. the cleaning of storm-water tanks)
2. To hold solids in movement (suspension) (e. g. activated sludge tank, sludge silos etc.)
36
11
Wall Mount
Fig. #36 Round Tank Positioning for Solids
Suspension
37
11
behind the mixer. However when correctly sized and positioned the
via bridges.
examples.
Sufficient Mixing
Flow Seperation
Sedimentation
38
11
Rectangular
In relation to other shapes, rectangular tanks can offer a
large capital cost advantage when multiple tanks are
required. This is typically because of shared wall and
walkway design as well as reduction of land space
requirements.
However as a result the rectangular tank design does
sacrifice approximately 30% in mixing efficiency. The loss
in mixing efficiency is primarily a result of corner vortices
as can be seen in the adjacent figure #38.
It should be noted that even though these vortices act as a
flow obstruction, there is random localized movement of
39
11
However the mixing energy density in racetrack tanks can be greatly improved by the addition of guide vanes.
These guide vanes located at the bend help to direct flow around the tight turn and minimize the flow
obstructing vortex. Long guide bends, which extend at least one channel width along the downstream side of
the channel, can reduce the necessary mixer thrust by more than 50%. See below figure #40 for a schematic
representation of normal guide bend on the left and CFD analysis vector results for a long guide bend on
the right.
40
11
11
42
11
43
12
Sizing Information:
Throughout this document we have stressed the importance of working closely with a competent
manufacturer to select the best mixer for a given application. The particular details and methods oriented
with submersible selections are covered in the Mixer Sizing section 5 of this document. In that section it is
also made clear that the energy density is not a good tool for mixer sizing. However with the better
understanding provided by this document it is possible to use some typical energy density values for
planning purposes. Therefore you will find below a table of typical energy densities for KSB submersible
mixers. Please be sure to consider the associated notes when utilizing these values. Also be sure to note that
the table clearly shows trends such as the inverse relationship between tank volume and energy density.
Notes / Assumptions:
Concrete tank walls
No aeration considered. Typically aeration will increase energy density by at least 5%
Typical activated sludge medium with TSS < 1%
Design criteria is average velocity of 1 ft/s
Race track (oxidation ditch) assumed to have long (extend downstream) guide bends
44
12
45
13
References
1. International Organization for Standardization, Pumps Testing Submersible mixers for
wastewater and similar applications, ISO 21630, 2007
2. Verband Deutscher Maschinen und Anlagenbau, Agitators in activated sludge tanks of wastewater
treatment plants Information on planning, project design and construction, VDMA 24656, 2010
3. Metcalf & Eddy, Inc., George Tchobanoglous, Franklin L Burton, H. David Stensel, Wastewater
Engineering Treatment and Reuse 4th Edition, 2003
4. Fred Koch, KSB Fluid Mixing Manual, 2001
Photographs
All of the photographs for this booklet were taken by KSB or its representatives, unless otherwise noted.
Contributing Authors
Jared S. Wray, P.E., born in 1982 studied Mechanical Engineering at the University of Delaware. After
completing his studies, he became a design engineer for an independent consulting firm. Since 2008 he
has been employed by KSB, Inc. and held positions in both the Energy and Wastewater divisions. Since
2011 he holds position of Product Manager for Submerged Propeller Devices in the USA.
Thomas Koch, born in 1972 studied Civil Engineering and majored in water and sewage management at
the University of Applied Science in Suderburg. Since 2001 he has been employed by KSB
Aktiengesellschaft as the mixer expert. Since 2010 he holds position of Head of Product Management
Submerged Propeller Devices.
Fred Koch, studied Mechanical Engineering. Throughout his career he worked for Pendraulik, Flygt,
and EMU. In 2001 he was employed by KSB as the Head of Product & Application for mixers. Mr.
Koch retired from KSB in 2008.
46
KSB, Inc.
4415 Sarellen Road
Henrico, VA 23231
www.ksbusa.com