Mixing Calculation

Agitation

• Agitation refers to forcing a fluid by mechanical means

to flow in a circulatory or other pattern inside a vessel.

• Mixing usually implies the taking of two or more

separate phases, such as a fluid and a powdered solid or
two fluids, and causing them to be randomly distributed
through one another.
Purpose of Agitation
1. Blending of two miscible liquids, such as ethyl alcohol
and water.
2. Dissolving solids in liquids, such as salt in water.
3. Dispersing a gas in a liquid as fine bubbles,
- such as oxygen from air in a suspension of
microorganisms for fermentation or for the activated
sludge process in waste treatment.
4. Suspending of fine solid particles in a liquid,
- in the catalytic hydrogenation of a liquid, solid catalyst
particles and hydrogen bubbles are dispersed in the
liquid.
5. Agitation of the fluid to increase heat transfer between
the fluid and a coil or jacket in the vessel wall.
Equipment for Agitation
• Three-blade propeller agitator
• Paddle agitators
• Turbine agitators
• Helical-ribbon agitators
1. Three-blade propeller agitator

FIGURE 3.4-1. Baffled tank and three-blade

propeller agitator with axial-flow pattern:
(a) side view, (b) bottom view
 2. Paddle Agitators
• often used at low speeds, between about 20 and 200 rpm.
• Two-bladed and four-bladed flat paddles are often used, as shown
in Fig. 3.4-2a.

FIGURE 3.4-2. Various types of agitators: (a) four-blade paddle, (b)

gate or anchor paddle, (c) six-blade open turbine, (d) pitched-blade
(45 ) turbine.
• At low speeds mild agitation is obtained in an unbaffled
vessel.
• At higher speeds, baffles are used
- since, without baffles, the liquid is simply swirled
around with little actual mixing.
• The paddle agitator is ineffective for suspending solids
- since good radial flow is present but little vertical or
axial flow.
• An anchor or gate paddle, shown in Fig. 3.4-2b, is often
used.
• It is used with viscous liquids where deposits on walls
can occur and to improve heat transfer to the walls.
• However, it is a poor mixer. Paddle agitators are often
used to process starch pastes, paints, adhesives, and
cosmetics.
3. Turbine Agitator
• Turbines resemble of multibladed paddle agitators with
shorter blades
• used at high speeds for liquids with a very wide range of
viscosities.
• The turbines usually have four or six blades.
• Figure 3.4-3 shows a flat six-blade turbine agitator with
disk.
• They are also useful for good gas dispersion;
- the gas is introduced just below the impeller at its axis
and is drawn up to the blades and chopped into fine
bubbles.
• Often a pitched-blade turbine with only four blades is
used in suspension of solids.
Figure 3.4-3. Baffled tank with six-blade turbine
agitator with disk showing flow patterns: (a) side
view, (b) bottom view, (c) dimensions of turbine
and tank.
4. Helical-Ribbon Agitator

• used in highly viscous solutions

• operates at a low rpm in the laminar region.
• The ribbon is formed in a helical path and is attached to
a central shaft.
• The liquid moves in a tortuous flow path down the center
and up along the sides in a twisting motion.
• Similar types are the double-helical-ribbon agitator
shown in Fig. 3.4-4b and the helical-screw impeller
shown in Fig. 3.4-4c.
FIGURE 3.4-4. Other types of agitators: (a) high-
efficiency, three-blade impeller (b) double-helical-ribbon,
(c) helical-screw.
Agitated Vessel
Power Used in Agitated Vessel
•In the design of an agitated vessel, an important factor is the
power required to drive the impeller.
•Empirical correlations have been developed to predict the power
required. '
•Reynolds number, N Re is defined as:

' Da2 N
N Re  ---- Eq. (3.4-1)
Where: 
Da = impeller (agitator) diameter (m)
N = rotational speed (rev/s)
ρ = fluid density (kg/m3)
µ = fluid viscosity (kg/m.s)
•Power consumption is related to fluid density ρ, fluid
viscosity µ, rotational speed N and impeller diameter Da
'
by plots of power number Np versus N Re
•The power number is defined as:
P
Np  ----------------- Eq. (3.4-2)
N 3 Da5 (SI)
Pg c
Np  3 5 (English)
N Da
Where P = power (J/s) or (W). In English units, P =
ft.lbf/s.
Figure 3.4-5 shows the power correlations for various
impellers and baffles
Figure 3.4-5 Power correlations for various impellers and baffles
(Geankoplis, 4th ed.)
• Curve 1. Flat six-blade turbine with disk (like Fig. 3.4-3 but
six blades); Da/W = 5; four baffles each Dt/J = 12.
• Curve 2. Flat six-blade open turbine (like Fig. 3.4-2c); Da/W
= 8;four baffles each D/J = 12.
• Curve 3. Six-blade open turbine (pitched-blade) but blades at
450 (like Fig. 3.4-2d); Da/W = 8; four baffles each
Dt /J = 12.
• Curve 4. Propeller (like Fig. 3.4-1); pitch 2D four baffles
each Dt /J = 10; also holds for same propeller in
angular off-center position with no baffles.
• Curve 5. Propeller; pitch = Da four baffles each Dt /J = 10;
also holds for same propeller in angular off-center
position with no baffles.
• Curve 6. High-efficiency impeller (like Fig. 3-4-4a); four
baffles each Dt /J = 12.
Example 1 Power Consumption in an
Agitator

A flat blade turbine agitator with disk having six blades is installed
in a tank similar to Fig. 3.4-3. The tank diameter Dt is 1.83 m, the
turbine diameter Da is 0.61 m, Dt = H, and the width W is 0.122 m.
The tank contains four baffles, each having a width J of 0.15 m.
The turbine is operated at 90 rpm and the liquid in the tank has a
viscosity of 10 cp and a density of 929 kg/m3.
a) Calculate the required kW of the mixer.
b) For the same conditions, except for the solution having a
viscosity of 100,000 cp, calculate the required kW.
Solution
• For part (a) the following data are given:
Da  0.61 m W  0.122 m Dt  1.83 m J  0.15 m
90 kg
N  1.50 rev/s   (10 cp)(1 x 10-3 )  0.01  Pa.s
60 m.s
  929 kg/m 3
• Using Eq. (1), the Reynolds number is:
' Da2 N (0.61) 2 (1.50)(929)
N Re    5.187  104
 0.01
• Using Curve 1 in Fig 3.4-5, since
'
Da / W  5 and Dt / J  12, N p  5 for N Re  5.187 104

• Solving for P in Eq. (3.4-2) and substituting known values

P  N p N 3 Da5  (5)(929)(1.50)3 (0.61)5
P  1324 J/s  1.324 kW (1.77 hp)
•For part (b)
-3 kg
  100,000(1 x 10 )  100
m.s

' Da2 N (0.61) 2 (1.50)(929)

N Re    5.185
 100

•This is the laminar flow region. From Figure 3.4-5, Np = 14.

P  N p N 3 Da5  (14)(929)(1.50) 3 (0.61) 5
P  3707 J/s  3.71 kW (4.98 hp)

•Hence, a 10,000-fold increase in viscosity only increases the

power from 1.324 to 3.71 kW.
Agitator Scale-Up
• Scale-up the laboratory-size or pilot-size agitation system to a
full-scale unit.
• Scale-up procedure:
1. Calculate the scale-up ratio R. Assuming that the original
vessel is a standard cylinder with DT1 = H1, the volume is:
 DT21   DT31  ----------------- Eq. (3.4-6)
V1   ( H 1 )   
 4   4 
The ratio of the volume is
V2  DT3 2 / 4   DT3 2 
  3
   3  ----------------- Eq. (3.4-7)
V1  DT 1 / 4   DT 1 

The scale-up ratio is then

1/ 3
V  D 
R   2    T 2 
 V1   DT 1 
----------------- Eq. (3.4-8)
2. Using this value of R, apply it to all of the dimensions in
Table 3.4-1 to calculate the new dimensions. For Example,
Da2 = RDa1, J2 = RJ1 , W2=RW1 ,
E2=RE1 , L2=RL1 , H2=RH1
R = Da2/Da1 = J2/J1 = …
3. Determine the agitator speed N2, to be used to duplicate the
small scale results using N1. The equation is:
n n
1  DT 1 
N 2  N1    N1   ----------------- Eq. (3.4-10)
R  DT 2 
Where n = 1 for equal liquid motion, n = ¾ for equal
suspension solids and n = 2/3 for equal rates of mass transfer
(which equivalent to equal power per unit volume, P1/V1 =
P2/V2 ). This value of n is based on empirical and theoretical
considerations.
4. Knowing N2, the power required can be determined using Eq.
(3.4-2) and Figure 3.4-5.
Example 2 Scale up of Turbine Agitation System

An existing agitation system is the same as given in

Example 1a for a flat-blade turbine with a disk and
six blades. The given conditions and sizes are DT1 =
1.83 m, Da1 = 0.61 m, W1 = 0.122 m, J1 = 0.15 m, N1
= 90/60 = 1.50 rev/s, ρ = 929 kg/m3 and µ = 0.01
Pa.s. It is desired to scale up these results for a
vessel whose volume is 3.0 times as large. Do this
for the following two process objectives:
a) Where equal rate of mass transfer is desired.
b) Where equal liquid motion is needed.
Solution
Since H1 = DT1 = 1.83 m,
the original tank volume, V  (DT21 / 4)( H1 )   (1.83)3 / 4  4.813 m3
1

Volume V2 = 3.0 (4.813) = 14.44 m3.

Following the steps in the scale-up procedure, and using Eq.(3.4-8):
1/ 3 1/ 3
 V2   14.44 
R     
 V1   4.813 
The dimensions of the larger agitation system are as follows:
DT2 = RDT1 = 1.442 (1.83) = 2.64 m, Da2 = 1.442 (0.61) = 0.880 m,
W2 = 1.442 (0.122) = 0.176 m and J2 = 1.442 (0.15) = 0.216 m.

For part (a), for equal mass transfer, n = 2/3 in Eq. (3.4-10):
2/3 2/3
1  1 
N 2  N1    (1.50)   1.175 rev/s (70.5 rpm)
R  1.442 
•Using Eq (3.4-1)

' Da2 N (0.880) 2 (1.175)(929)

N Re    8.453 104
 0.01

•Refer to Figure 3.4-5, Curve 1 and NRe = 8.453 x 104, gives

Np = 5.0
•Using Np = 5.0 in Eq. (3.4-2)
3 5 3 5
P1  N p N D  (5)(929)(1.5) (0.61)
1 a1

P1  1324 J/s  1.324 kW

3 5 3 5
P2  N p N D  (5)(929)(1.175) (0.880)
2 a2

P2  3977 J/s  3.977 kW

•The power per unit volume is P1 1.324
  0.275 kW/m 3
V1 4.813
P2 3.977
  0.275 kW/m 3
V2 14.44
•The value of 0.275 kW/m3 is somewhat lower than the approximate
guidelines of 0.8 to 2.0 for mass transfer.

For part (b), for equal liquid motion, n = 1.0

1 .0 1.0
1  1 
N 2  N1    (1.50)   1.040 rev/s
R  1.442 
P2  N p N 23 Da52  (5)(929)(1.040) 3 (0.880)5
P2  2757  2.757 kW
P2 2.757
  0.1909 kW/m 3
V2 14.44
Mixing Times of Miscible Liquids
•Figure 3.4-6 shows a Correlation of mixing time for miscible
liquid using a turbine in a baffled tank.
•Mixing factor ft is defined as:

f t  tT
ND 
2 2/3
a g 1/ 6 Da1/ 2
1/ 2 ----------------- Eq. (3.4-16)
H Dt3 / 2
'
•Where tT is the mixing time in seconds. For N Re  1000,
ft is approximate constant, then tT N2/3 is constant.
•For scaling up from vessel 1 to another vessel 2 with similar
geometry and with same power/unit volume in the turbulent
region, the mixing times are related by:
11/ 18
tT 2  Da 2  ----------------- Eq. (3.4-17)
  
tT 1  Da1 
•The mixing time increases for the larger vessel.

•For scaling up while keeping the same mixing time, the

power/unit volume (P/V) increases markedly:
11/ 4
P2 / V2  Da 2  ----------------- Eq. (3.4-18)
  
P1 / V1  Da1 

•Usually, in scaling up to large-size vessels, a somewhat

larger mixing time is used so that the power/unit volume
does not increase markedly.
Example 3 Scale-up of Mixing Time in a Turbine
Agitation System

Using the existing conditions for the turbine with a disk as in

Example 1 part (a), do as follows:

a) Calculate the mixing time

b) Calculate the mixing time for a smaller vessel with a similar
geometric ratio, where Dt is 0.30 m instead of 1.83 m. Do this
for the same power per unit volume as used in part (a).
c) Using the same mixing time calculated for the smaller vessel in
part (b), calculate the new power per unit volume for the larger
vessel in part (a).
Solution
In part (a), Dt = 1.83 m, Da = 0.61 m, Dt = H, N = 90/60 = 1.50
rev/s, ρ = 929 kg/m3, µ = 10 cp = 0.01 Pa.s. From example 1,
'
N Re  5.185 104 , Np = 5, P1 = 1.324 kW. For the tank volume,
 (1.83) 2 (1.83)
V1   4.813 m 3
4
The power per unit volume is P1 1.324
  0.2751 kW/m3
V2 4.813

' 4
From the Figure 3.4-6 , N Re  5.185  10 , ft = 4.0. Substituting
in Eq. (3.4-16)
f t  4.0 

tT N1 D
a1 
2 2 / 3 1/ 6
g Da11/ 2
1/ 2 3 / 2
H1 D
t1

4.0 

tT 1.5  0.61 
2 2/3
9.80665
1/ 6
0.611/ 2
1.831/ 2 1.833 / 2
tT  17.30 s
•For part (b)
R  DT 2 / DT 1  0.30 / 1.83  0.1639
Da 2  RDa1  0.1639(0.61)  0.1000m
11/ 18
tT 2  Da 2 
  
tT 1  Da1 
11/ 18
 0.100 
tT 2  17.30 
 0.61 
tT2 = 5.73 s

* Mixing time decrease for smaller vessel from 17.30 to 5.73 s.

•For part (c)
tT2 = 5.73 s for smaller vessel
Calculate the P / V for the larger vessel
11/ 4
P2 / V2  Da 2 
  
P1 / V1  Da1 
11/ 4
0.2751  0.1000 
 
P1 / V1  0.6100 

P1/V1 =39.73 kW/m3