Agitation and Mixing Flow

Sirte University ‫ـــــــــــ ـــــــــــ
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Faculty of Engineering ‫آـــــــــ ا ـــــــــــ‬
Chemical Engineering Department ‫ـ ا ــ اـ‬
Agitation and Mixing of liquids in tanks

Mixing: Intermingling of two or more dissimilar portions of a material, resulting in the attainment
of a desired level of uniformity, either physical or chemical, in the final product.
Agitation: Creation of a state of activity such as flow or turbulence, apart from any mixing
accomplished.
Classification of agitators:
In general, agitators can be classified into the following two groups.
1. Agitators with a small blade area which rotate at high speeds. These includes:
(a) Turbines propellers (Fig.5-1).
(b) Marine propellers (Fig.5-2).
2. Agitators with a large blade area which rotate at low speeds. This is more effective than the
first in the mixing of high viscosity liquids. These includes:
(a) Anchors. (‫)
اة‬
(b) Paddles. (‫)ذو أرش‬
(c) Helical screws. ()
.
The mean shear rate produced by an agitator in a mixing tank ( γ m ) is proportional to the rotational
speed of the agitator (N). Thus
.
γ m = kN --------------------- (5-1)
k: Dimensionless proportionality constant for a particular system.
Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

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For a liquid mixed in a tank with a rotating agitator, the shear rate is greatest in the immediate
vicinity of the agitator.
1. Small blade high speed agitators:

Small blade high speed agitators are used to mix low to medium viscosity liquids (10-50 Pa.s).
Since they are high shear agitators they are useful for mixing pseudoplastic liquids.
Flat blade turbines used to mix liquids in baffled tanks produce radial flow patterns primarily
perpendicular to the vessel wall as shown in Figure 5.3.
In contrast, marine type propellers used to mix liquids in baffled tanks produce axial flow
patterns primarily parallel to the vessel wall as shown in Figure 5.4.
Figure 5.5 shows a turbine agitator of diameter DA in a cylindrical tank of diameter DT filled
with liquid to a height HL. The agitator is located at a height HA from the bottom of the tank and the
baffles which are located immediately adjacent to the wall have a width b. The agitator has a blade
width a and blade length r and the blades are mounted on a central disc of diameter s. A typical
turbine mixing system is the standard configuration defined by the following geometrical
relationships:

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• Six-blade flat blade turbine agitator

• DA = DT/3
• HA = DT/3
• a = DT/5
• r = DT/4
• HL = DT
• 4 symmetrical baffles
• b = DT/10
Agitator tip speeds are commonly used as a measure of the degree of agitation in a liquid mixing
system. It is given by
u t = π .D A .N ----------------------- (5-2)
Tip speed ranges for turbine agitators are recommended as follows:

For low agitation: ut = 2.5 – 3.3 m/s
For medium agitation: ut = 3.3 – 4.1 m/s
For high agitation: ut = 4.1 – 5.6 m/s
If turbine or marine propeller agitators are used to mix relatively low viscosity liquids in unbaffled
tanks, vortexing develops. In this case the liquid level falls in the immediate vicinity of the agitator
shaft. Vortexing increases with rotational speed N until eventually the vortex passes through the
agitator. As the liquid viscosity increases, the need for baffles to reduce vortexing decreases.
Volumetric circulating capacity: A marine propeller can be considered as a ceaseless pump. In this
case its volumetric circulating capacity QA is:
ηπNDA3
QA = ----------------------- (5-3)
4
Where: η : Dimensionless efficiency factor (approximately 0.6)

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The best mixing: To get the best mixing process the tank turnover rate (IT) should be at a
maximum, where (IT) is the ratio of volumetric circulating capacity to the tank volume (IT = QA/V).
For a given tank volume V, this means that the circulating capacity QA should have the highest
possible value for the minimum consumption of power.
2. Large blade low speed agitators:

Large blade low speed agitators are used to mix relatively high viscosity liquids and depend on
a large blade area to produce liquid movement throughout a tank. Since they are low shear agitators
they are useful for mixing dilatant liquids. A gate type anchor agitator is shown in Figure 5.6.
The flow pattern in a baffled helical screw system is shown in Figure 5.7. Baffles are not
required if the helical screw is placed in an off-centred position since in this case the system
becomes self-baffling. However, off-centred helical screws require more power to produce a
comparable mixing result.

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Dimensionless groups for mixing:

In the design of liquid mixing systems the following dimensionless groups are of
importance:
1. Power Number:
PA
P0 =
ρN 3 DA5
2. Reynolds Number for mixing:
It represents the ratio of the applied to the opposing viscous drag forces.
ρND A2
Re M =
µ
3. Froude Number for mixing:
It represents the ratio of the applied to the opposing gravitational forces.
N 2 DA
FrM =
g
4. Weber Number for mixing:
It represents the ratio of the applied to the opposing surface tension forces.
ρN 2 DA3
WeM =
σ
Weber number is only important when separate physical phases are present in the liquid mixing
system as in liquid-liquid extraction.
Where:
ρ : Liquid density (kg/m3) µ : Liquid viscosity (Pa.s), σ : Liquid surface tension (N/m)
PA : Agitator power consumption (Watt) N : Agitator rotational speed (rev/s)
DA : Agitator diameter (m)
By dimensional analysis, it can be shown that the power number P0 can be related to the Reynolds
number for mixing Re M and the Froude number for mixing FrM by the equation
P0
φ= = C. Re Mx ----------------------- (5-4)
FrMy

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Where:
C: Overall dimensionless shape factor which represents the geometry of the system.
φ : Dimensionless power function.
In liquid mixing systems, baffles are used to suppress vortexing. Since vortexing is a gravitational
effect, the Froude number is not required to describe baffled liquid mixing systems. In this case the
exponent "y" in equation (5-4) is zero, that is " FrMy = 1 ".
Thus for non-vortexing systems equation (5-4) can be written as
φ = P0 = C. Re Mx
Or as LogP0 = LogC + xLog Re M ----------------------- (5-5)
Power curves:
A power curve is a plot of the power function φ (or the power number P0) against the
Reynolds number for mixing Re M on log-log coordinates. Each geometrical configuration has its
own power curve and since the plot involves dimensionless groups it is independent of tank size.
1. For baffled non-vortexing system:
Figure (5-8) shows the power curve for this system configuration. It can be distinguish three
flow regions:
• Laminar flow region (AB): [Re M < 10] − −− → x = -1 and C = 71 of eq.(5-5)
• Transition flow region (BCD): [10 < Re M < 10000] − −− → x and C are vary continuously.
• Turbulent flow region (DE): [Re M > 10000] − −− → x = 0 and C = φ = P0 = 6.3
Calculation procedure:
1. Calculate ReM from equation of Reynolds number.
2. Read P0 (or φ ) from figure (5-8).
3. Calculate the agitation power from equation of power number as follow
PA = P0 ρN 3 D A5

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2. For unbaffled vortexing system:

Figure (5-9) shows the power curve for this system configuration. Up to point "C", Fig.(5-9) is
identical with Fig.(5-8), as the Reynolds number for mixing increases beyond point "C" in the
unbaffled system, vortexing increases and the power falls sharply.
Calculation procedure:
1. Calculate ReM from equation of Reynolds number.
2. Read P0 (or φ ) from figure (5-9).
3. Calculate the agitation power from the following equation
y
 N 2 DA 
PA = φρN D 
3 5
A 
 g 
α − Log (Re M )
Where, y=
β
For six-blade flat blade turbine agitators of DA = 0.1 m:
α = 1 and β = 40
The power curves given in Fig.(5-8) and Fig.(5-9) were obtained for experiments using Newtonian
liquids. It is possible to calculate the apparent viscosities of non-Newtonian liquids in agitated
tanks from the appropriate power curves for Newtonian liquids.

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Example #1:
Calculate the theoretical power for a six-blade flat blade turbine agitator with diameter DA = 3 m
running at a speed of N = 0.2 rev/s in a tank system conforming to the standard tank configuration
illustrated in Figure 5.5. The liquid in the tank has a dynamic viscosity µ = 1 Pa.s and a density of
ρ = 1000 kg/m3.
Solution:
The Reynolds # for mixing is
ρND A2 1000 × 0.2 × (3)2

Re M = = = 1800
µ 1
From Fig.(5-8),
φ = P0 = 4.5
The theoretical power for mixing is
PA = P0 ρN 3 D A5 = 4.5 ×1000 × (0.2 ) × (3) ∴ PA = 8748 Watts Ans.
3 5
------------------------------------------------------------------------------------------------------------------------
Example #2:
Calculate the theoretical power for a six-blade flat blade turbine agitator with diameter DA = 0.1 m
running at N = 16 rev/s in a tank system without baffles but otherwise conforming to the standard
tank configuration illustrated in Figure 5.5. The liquid in the tank has a dynamic viscosity µ = 0.08
Pa.s and a density of ρ = 900 kg/m3. For this configuration α = 1 and β = 40.
Solution:
The Reynolds # for mixing is,
ρND A2 900 × 16 × (0.1)2

Re M = = = 1800
µ 1
From Fig.(5-9),
φ = 2 .2
α − Log (Re M ) 1 − Log (1800)
Calculating y, y = = = −0.05638
β 40
The theoretical power for mixing is:
−0.05638
 (16 )2 × 0.1 
y
 N 2 DA 
PA = φρN D 
3 5
 = 2.2 × 900 × (16 )3 × (0.1)5 ×   − − → PA = 76.83 Watts Ans.
A 
 g   9.81 

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Agitation and Mixing of liquids in tanks

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

1. Small blade high speed agitators:

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

• Six-blade flat blade turbine agitator

Tip speed ranges for turbine agitators are recommended as follows:

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

2. Large blade low speed agitators:

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

Dimensionless groups for mixing:

DA : Agitator diameter (m)

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

Or as LogP0 = LogC + xLog Re M ----------------------- (5-5)

• Turbulent flow region (DE): [Re M > 10000] − −− → x = 0 and C = φ = P0 = 6.3

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

2. For unbaffled vortexing system:

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

ρND A2 1000 × 0.2 × (3)2

ρND A2 900 × 16 × (0.1)2

Fluid Mechanics II F. Al-Taher, 01.06.2010 Spring 2009-2010

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