Mixing

Mixing
Definition:
• The process of randomization of dissimilar particles with in a system.
• an operation in which two or more components are treated so that each
particle lies as near as possible in contact with a particle of each of the
other ingredient.

Types of Mixture
1. Positive Mixture
2.Negative Mixture
3.Neutral Mixture

1.Positive Mixture:

These are formed from materials such as gases or miscible liquids, in

this case irreversible mixing take place, by diffusion, without the
expenditure of work provided time is unlimited. Generally such material
do not present any problems in mixing.
2. Negative Mixing:
Suspension of solids in liquids is example of such type of mixtures that
require work for their formation and the components of which separate
unless work is continuously expended on them. These are more difficult to
form and maintained.

3. Neutral Mixing:
These are static in their nature the components are hard to mix
spontaneously, nor do they segregate when mixed. Examples include
pastes, ointments, and mixed powders.

Liquid Mixing
The liquid mixing operation has two requirements.
1. Localized Mixing: Required to apply shear to the particles of fluid.

2. General/bulk Mixing: Required to take all parts of the bulk of the

material through the shearing (localized mixing) zone and ensure that a
uniform final product is obtained.
The movement of the liquid at any point in the mixing vessel will have
three velocity components and the complete flow pattern will depend
on variations in these three components in different parts of the vessel.
The three velocity components are,

1. Radial Component: Acting in a direction vertical to the impeller

shaft.

2. Longitudinal Component: Acting parallel to the impeller shaft.

3. Tangential component: acting in a direction that is a tangent to the

circle of rotation round the impeller shaft.
Requirements for liquid mixing:
Liquid mixing is usually performed in a vessel provided with mixing
element, commonly a rotational device, which provides necessary shear
force and produce appropriate flow pattern.

Nomenclature
Where:
D = Impeller Diameter
C = Impeller off Bottom Clearance
B = Baffle
Z = liquid Depth
T = Vessel Diameter
OPTIMUM MIXER SELECTION CRITERIA

A full and accurate specification of the mixing vessel, the process

parameters, and the required mixer performance is the first crucial step to
arriving at an optimum mixing operation. Some of the many other variables
that can affect mixer performance and so need to be considered in arriving
at the optimum mixer design are noted on these pages.
Impeller Type

The function of any mixing impeller is to convert the rotational energy of the
mixer shaft into the correct combination of flow, shear and turbulence to
achieve the required process result.
As no one-impeller design is capable of providing optimum performance
under every process condition, optimum process performance is dependent
upon selecting an impeller design that has the specific characteristics
required by a given process.
Number of Impellers

The use of a single impeller is the usual preferred option on the basis of
cost. However, changes in the ratio of liquid level (Z) to vessel diameter (T)
can have an adverse effect on the flow patterns generated within the vessel.
This can result in the need to consider the use of multiple impellers in order
to achieve an economic solution.

Z/T ratio alone is not the only consideration when determining the number
of impellers required. Multiple impellers may also need to be considered for
other reasons including, when high viscosity fluids are involved, for mixing
at low level during filling and emptying or where draw down from the liquid
surface is a requirement.

Impeller Positioning

Whether utilizing a single or a multiple impeller configuration the positioning

of the impellers within the process fluid can have a significant effect on the
overall process performance. Incorrect positioning can lead to staged flow
patterns, poor dispersion of additives and impellers being out of the liquid at
crucial stages of the process.
D/T Ratio

The ratio of mixing impeller diameter (D) to vessel diameter (T) has a very
significant effect on the performance of most fluid mixers and the optimum
D/T is a function of both process conditions and process requirements.
Normally the optimum D/T will be in the range 0.2 < D/T < 0.5. Some
special applications however, sometimes operate outside this range.

Bottom Clearance

The impeller bottom clearance (C/T ratio) can also have a very significant
effect on the overall performance of a mixer, effecting both power draw and
pumping efficiency. The optimum C/T ratio is essentially dependent upon
impeller type but can also be effected by process conditions.
Normally, the optimum C/T will be in the range: 0.1 < C/T < 0.3.
Vessel Geometry

When designing a vessel for mixer duty it is important to understand the

role that tank geometry plays in determining the final mixer design. Poor
aspect ratios and or inappropriate bottom shapes can both result in
increase mixer cost and in certain circumstances make it impossible to
optimize the mixer design.
• Shaker Mixers
• Impeller Mixers

• Shaker Mixers: such mixers operates on the principle of agitation. They

either oscillates (lab Scale) or rotates (large Scale). These mixers are not
categorized as efficient mixers therefore their use is limited.

• Impeller Mixers: These the most widely used form of mixer for liquids.
These are of three types.
1. Propeller mixers
2. Turbine Mixers
3. Paddle Mixers

1. Propeller Mixers:
Propeller usually resembles ordinary marine
propellers in shape, have small diameter as
Compare to the container and operates at
high speed i.e. around 8000 RPM. These mixers promote longitudinal
movement. The propeller mixers are not effective for the liquids with
viscosity greater than 50P or 500 cP, which is the viscosity somewhat
greater than the viscosity of glycerin or castor oil.
Due to promotion of longitudinal movement and high speed vortexing
and aeration is the major problem associated with the propellers. To
avoid these condition the propellers must be placed deep in the liquid
and symmetry should be avoided. There are number of ways to avoid
vortexing;
 The propeller shaft may be off set from the centre.
 the shaft may be mounted at an angle.
 the shaft may enter the side of the vessel.
 vessel other than cylindrical may be used.
 Use of push pull propeller, in which two propellers are mounted on
the same shaft with opposite pitches.
 use of baffles.
Propellers are best suited for the suspension as they promote
longitudinal currents and is not suitable for emulsification , which
requires high shear.
2. Turbine Mixers:
Turbine mixer uses a circular disc impeller, to which are attached a number
of short, vertical blades, which my be straight or curved. The RPM and the
D/T ratio is some what lower than the
propeller mixer. The blades may have a pitch
giving some axial flow, but commonly the blades
Are flat, thus there is very little axial or radial flow
flow. It means that turbine promote tangentional
flow, providing high shear forces than
Propeller mixers. These shear forces may be
increased further by fitting a diffuser ring.
Diffuser ring is a stationary perforated or slotted
ring which surrounds the impeller, so that the discharged liquid must pass
through the aperture. The diffuser reduces rotational swirling and vortexing.
Turbine mixers are more useful with viscous liquids as compared to
propeller mixer.(100 Ns/m2), approximately that of liquid glucose. Turbine
are not useful for suspending heavy solids, but the high shear forces and
greater viscosity range make them more useful for emulsification.
3. Paddle Mixers:
These mixers use an agitator with flat blades
Attached to the vertical shaft and rotating at low
speed i.e. 100rpm.these mixers promotes radial
and tangential flow with very little longitudinal
flow which may be increased by using paddles
with slight pitch. The diameter is half to two
Third of the diameter of the vessel. An alternate
paddle mixer for viscous liquids is planetary
mixer which rotates on at axis and also with
the walls of the vessel.
Air Jets:
In such systems pressurized air or other gas
introduced from the bottom of the vessel, the
pressure of the air bubbles lift the liquid from the
bottom to the top of the vessel. The liquids which
is to be mixed must be
• low viscous
• Uncreative with the gas
• Nonfoaming

Fluid jets:
In such system one liquid is pumped the
another liquid through nozzles arranged to
permit good circulation of material through out the tank .
 Solid Mixing
A. Segregated Powder B. Ideal mixed C. Randomized Mixing

A B C

Factors to be considered during mixing:

1. Material Density 2. Particle Size
3.Particle Shape 4. Particle Attraction
5. Mixer Volume 6. Mixing Time
7. Mixing order 8. Speed of the mixer
Mixing Mechanism

1. Convective mixing:
This mechanism may be regarded as analogous to bulk transport as in
fluid mixing. Convective mixing in solids occurs by an inversion of the
powder bed, by means of rotation of container, movement of blades or
paddles.

2. Shear Mixing:
it is due to the forces with in the particulate mass, slip planes are set up.

3. Diffusive Mixing:
When random motion of particles with in a powder bed causes them to
change their position relative to one another. Diffusive mixing occur at
the interfaces of dissimilar regions that are undergoing shear.
Mixing Equipment:
Mixers used for solid mixing can be categorized mainly into two types
1. Agitator Mixers
2. Tumbling Mixers

1.Agitator Mixers:
These can be further classified as
 Conventional Mixer
 Planetary mixers
 High Shear Mixers
PLANETARY MIXER DIFFERENT
BLADE ATTACHMENT AVAILABLE
         
 
   

 
   
                                                
 Tumbling Mixer
Application
 Mixing Powder & Granule

Theory
The eight angles shaped tumbler have baffles
on each side. The granules are twisted flowing
along the angle of baffles and mixed again by
the center shaft baffles It can reach the best and
efficient mixing result , the mixing ratio can be
up to 1:10,000
 

Feature
1. Uniform mixing
2. Short mixing time
3. Mixing ratio up to 1:10,000
4. With safety gate and interlock
5. Option to integrate with vacuum suction system and connect to
dry granulator for contained production process and continuous
auto loading.
 Double Cone Mixer

Theory
The core shaped mixer is wide in the middle and
narrow at the both ends. Inside have baffles in the
middle, when the powder or granules are rolling up
and down in the drum and hit the middle baffles ,
the best mixing result can be reached.

Feature
1. Uniform mixing.
2. Simple structure.
3. With safety gate and interlock.
4. Option to integrate with vacuum suction system
and connect to dry granulator for contained
production process and continuous auto loading.
 V-Mixer/twin Shell Mixer

Application
Mixing Powder & Granules 

Theory
The mixing method of the V-shaped mixer is
through rotating the granules rapidly and this
enables the product separating into two cones
then two merge into one again, By repeating
the procedure , the granules will then be
separated and merged again and again to
reach the best mixing result.

Feature
1. Excellent mixing effect.
2. Simple structure
3. Easy cleaning
4. With safety gate and interlock
5. Option to integrate with vacuum suction system and connect to dry
granulator for contained production process and continuous auto loading.
 Mixing of Semisolids

The mixing mechanism depends upon the nature of material, semisolids

show considerable variation in their consistency. The rheological properties
of non-Newtonian materials have an important effect on the mixing operation.
The dilatant or plastic materials are usually difficult more to mix than the
Newtonian materials, but thixtropy may make the mixing easier.
Theory:
In mixing an insoluble powder to a liquid , a number of stages can be
observed as the liquid content is increased.
1. Pellet and powder state:
Addition of small amount of liquid to the bulk of dry powder causes the solid
to ball up and form small pellet. The pellets are embedded in matrix of dry
powder which has cushioning effect and makes the ball difficult to break up.
2. Pellet State:
Further addition of liquid results in the conversion of more dry powder to
pellet state, until all the material is in this state. The mass has coarse
granular appearance, but the pellets do not cohere and agitation will cause
aggregates to break down. Into smaller granules.
3. Plastic State:
As the liquid content is further increased, the character of mixture
changes markedly, the aggregates adhere, the granular appearance is
lost, the mixture becomes more or less homogeneous and of clay like
consistency. Plastic properties are shown and the material is difficult to
shear.

4. Sticky state:
Increase in the liquid content causes the mixture to attain this state, the
appearance become paste like, the surface is shiny and the mass
adheres to solid surface.

5. Liquid State:
Further addition of liquid results in a decrease consistency until a fluid
state is reached. In this state the mixture flows under its own weight.
Mixers for semisolids:
1. Agitator Mixers
• Planetary Mixer
• Sigma Mixers
2. Shear Mixers
• Roller Mills
• Colloidal mills
• homogenizers
3. Ultrasonic Mixers
Poise
Named after the physicist Poiseuille this is the CGS derived
unit of dynamic viscosity of a fluid. When a force of 1 dyne
maintains unit rate of shear of a film of unit thickness between
surfaces of unit area dyne sec cm-2

Conversions 1 poise=0.10 kg m-1s-1

1poise=0.1 N s m-2
1 poise=0.0020885 lbf s ft-2
1poise=0.0671969 Poundal s ft-2
1 poise=0.0000145 reyn
1poise=0.0020885 slugs ft-1s-1
1 poise=100 centipoise
1 poise=1.0 dyne s cm-2
Pitch: Is the displacement a propeller makes in a complete spin of
360° degrees.
 BLENDING / HOMOGENISATION OF MISCIBLE LIQUIDS
Chemical Reactions
• Polymerization
• Simple blending of miscible fluids
• Make-Up Tanks
• Storage, Feed, or Holding Tanks

Information Required for Mixer Selection

• Viscosity • Blend Time
• Density • Volume (s)
• Pressure & Temperature • Any specific process requirement

SOLIDS SUSPENSION

Principally there are five degrees of suspension as follows

• Solids Just Suspended
• Off Bottom Suspension
• Moderate Uniformity
• Nearly Uniform Suspension
• Uniform Suspension
Information Required for Equipment Selection
• SG of Liquid • Percent solids by Weight
• SG of Solid • Slurry viscosity
• Solids size or distribution of range • Degree of Suspension required
MIXING MECHANISMS
Mixing is achieved by a number of different mechanisms, as summarized
in the following table.

Induced by pumping action of the impeller, Fluid moves through the

Convection
different parts of vessel, preventing stratification.

Caused by turbulent flow a wide range of vortices. Smallest in the

Macro-mixing impeller region where dissipation is the highest. Separates bulk of fluid
into smaller elements.

Below the scale of macro mixing fluid elements are further dispersed by
Laminar shear
laminar shearing. Elements are stretched, distorted and folded.

Final smallest scale mixing. Diffusion of reactants takes place and is

Micro-mixing
driven only by concentration gradient.