MASTERING

MIXING
FUNDAMENTALS
A technical guide
from the experts in
the industry
2019

Technical Guide
 Mixer Tech
Guide

Website: www.haywardgordon.com | Email: [email protected]

Hayward Gordon has supplied impeller type fluid agitation equipment to the process industries for over
40 years acquiring considerable expertise in this field. Combining both experience and theory, this
section covers the basics of fluid mechanics of mixing, the main criteria for mixer sizing and
application limitations of fluid mixers.

Fluid Mixing
Technically, matter in the liquid or gas state is considered a fluid. For the purposes of “fluid mixers”, a
fluid is defined as a liquid (or mixture of liquids), which may contain modest amounts of solid particles
or gas bubbles. The presence of solids or gas must not alter the basic capacity of the fluid to “flow”
and be pumped about in the mixing vessel by a mixing impeller.

A liquid must always be present, either “thin” with a water-like viscosity or “thick” with a relatively high
viscosity. The thickest liquid that can be handled with a fluid mixer will typically have a viscosity less
than 500,000 centipoise.

The simplest and most common fluid mixing application is simply to add liquid “A” to liquid “B”, where
the liquids are soluble in one another, and blend them to uniformity. Application requirements can
include the time available to mix the liquids and the degree of uniformity to which they must be mixed.

The second most common mixing application is the suspension of solid particles in a liquid. This can
be for the purpose of dissolving the solids, leaching out valuable components in the solids, allowing
the solids to participate in a chemical reaction with the liquid, or simply to keep the solids in
suspension. The typical maximum concentration of solids which can be effectively mixed with a fluid
mixer is 70-75% solids by weight.

Other functions of fluid mixers include dispersion of a gas into a liquid, dispersion of insoluble liquids
into one another and heat transfer applications.

Mixing impellers are designed to “pump” fluid through the impeller and produce “turbulence” - both of
these effects are essential to mixing. They produce “fluid velocity” and “fluid shear” respectively. Fluid
velocity produces movement throughout the mixing vessel, intermixing material in one part of the tank
with another, prevents solids from settling out and produces flow over heating or cooling coils when
necessary. Fluid shear, in the form of turbulent eddies, is essential to micro-mixing within the large
velocity streams breaking up gas bubbles or immiscible liquids into small droplets.

All mixing impellers produce both fluid velocity and fluid shear, but different types of impellers produce
different degrees of flow and turbulence, either of which may be important, depending on the
application.

Fluid Mechanics of Mixing

All impellers produce two results within the mixing chamber: circulation of fluid and fluid shear. The
power “P” consumed by an impeller is related to the volumetric circulation rate “Q” (pumping capacity)
and the velocity Head “Delta H” from the impeller by:

P = QrDH
The pumping capacity of an impeller is defined as the volumetric flow rate normal to the impeller
discharge area. The pumping capacity of an impeller is proportional to its diameter and speed:

Q a ND3
The head difference between the “suction” and “discharge” surfaces of an impeller blade results in
fluid shear, which is also proportional to impeller diameter and speed:

DH a N 2 D 2
In general form:
P a r ( ND 3 )( N 2 D 2 )
P = kr ( ND 3 )( N 2 D 2 )
P = kr ( N 3 D5 )

This development illustrates one of the basic principles of fluid mixing: for a constant horsepower, as
impeller size increases, more power is expended on flow and less on shear. A large impeller running
at a slow speed produces high pumping and low shear. Conversely, a small impeller running at high
speed produces relatively low pumping capacity and high fluid shear.

Some process, such as flocculation, are shear sensitive and require high flow, low shear mixing. Other
processes, such as gas dispersion, are at the other end of the scale and require high shear mixing.
The selection of a mixer for a particular application depends on numerous process factors, some of
which are:

• Type of application (high flow or high shear requirements)

• Viscosity, % solids, amount of gas addition
• Tank Geometry
• Retention time and/or blend time

Viscosity Effect
The previous equations show the effect that a fluid’s density has on the power draw of a mixing
impeller. The next most common factor affecting power draw is viscosity. The graph below shows the
relationship between viscosity and a mixing impellers power response - power draw increases with
increasing viscosity. Every impeller has a Power Number vs. Reynolds Number curve similar to the
one show below. The straight line portion at the left hand side is the laminar range which develops into
the transition range and finally reaches a plateaus at a constant power number in the fully turbulent
range. Power numbers of various impellers are normally compared in the fully turbulent range which
typically starts at NRe=103 to 104.

Power Number - Reynolds Number Correlation

100
Power Number, NP

10

0.1
10 0 10 1 10 2 10 3 10 4 10 5
Reynolds Number, NRe

The viscosity of a fluid can have a significant impact on the overall mixer sizing for a particular
application. The graph below shows the relative increase of theoretical tank turnovers for viscosities
from 10 to 10,000 cps.

Basic Essentials of Mixer Sizing

The main sizing criteria for most applications are:

• Torque Invested into the Mix

• Impeller Style
• Impeller Diameter to Tank Diameter (D/T) Ratio
• Mixer Horsepower
• Pumping Capacity
• Impeller Tip Speed
• Superficial Velocity
• Torque/Equivalent Volume

Torque
In order for power (the rate at which work is done) to be meaningful there must be a standard of
comparison. The most common unit to measure linear force is horsepower which is defined as the
energy to move 100 pounds 330 feet in 1 minute or 33,000 Ft-Lbs/Min.

Mechanical transmission products, such as gearboxes, are evaluated on the basis of torque or
rotational energy. Rotational power is defined as force times angular velocity. The angular velocity of a
mixing impeller is normally measured in revolutions per minute (RPM).

The amount of torque applied to a fluid mix is one of the most important factors in determining mixing
results. Using the most common units, torque is defined as:

HP ´ 63025
Torque = [inch - lbs]
RPM

As can be seen from the equation, at a given horsepower, a relatively high mixer speed and small
impeller diameter will result in lower torque (and therefore a lower mixing level) than a larger impeller
turning at a lower speed.

Impeller Styles
Mixing impellers fall into one of two categories: Radial Flow or Axial Flow.

Radial flow impellers have multiple flat blades mounted parallel to the axis of the mixing shaft. The
blades can be attached to a disc forming a “closed” impeller or on a simple hub making an “open” style
impeller. Typical uses are gas/liquid dispersion, liquid/liquid dispersion, flash mixing and low level
mixing applications.

Axial flow impellers have blades which make an angle of less than 900 with the mixing shaft axis.
These impellers are further classified as A) constant angle of attack or B) variable angle of attack. The
first group includes pitched blade turbines and the second group includes propellers and hydrofoils.
Typical applications include simple blending, solids suspension and flocculation.


Radial Flow Turbines

Power Number, NP = 2.5 to 4.75

Pumping Number, NQ = 0.95 to 1.23

Applications:
• High Shear
• Gas\Liquid Dispersion
• Liquid Liquid Dispersion
• Low Level Mixing

Pitched Blade Turbines

(Constant Angle of Attack)

NP = 0.9 to 1.62
NQ = 0.68 to 0.86

Applications/Uses:
• Moderate Shear & Moderate Flow
• Moderate Viscosity Mixing
• High Intensity Mixing for Flow
Dependent Applications
• Inexpensive “Axial Flow” Impeller

Low and Mid Solidity Hydrofoils

(Variable Angle of Attack)

NP = 0.3 to 0.6
NQ = 0.6 to 0.7

Applications/Uses:
• High Flow & Low Shear
• Low to Moderate Viscosities
• Limited Gas Dispersion for High Solidity Design
• Positioned Relatively High off Tank Bottom

Impeller Diameter/Tank Diameter (D/T) Ratio

The impeller diameter to tank diameter ratio typically falls in the range of 0.25 to 0.4. The low end of
the range is used for waterlike viscosities and increases as the mixture viscosity increases. Refer to
page 2.07 for optimum D/T ratios for various viscosities.

Horsepower

Although horsepower on its own is not enough to define the size of a mixer for most (flow sensitive)
applications to ensure a certain process result, it is still an important consideration. Some applications,
such as gas/liquid or liquid/liquid dispersions are quite sensitive to the HP invested.

The equation to determine the power draw of one impeller is:

N P D 5 N 3 SG
BHP =
6.124 ´ 10 7
Where: NP = Impeller Power Number [Dimensionless]
D = Impeller Diameter [Feet]
N = Impeller Speed [RPM]
SG = Fluid Specific Gravity

And: NP is adjusted for viscosity, proximity, blade width and number of blades.

Primary Pumping Capacity (Q)

The equation below calculates the Primary pumping capacity of one impeller and does NOT include
entrained flow. Total flow (Primary + Entrained) is often considered to be 2.5 to 3 times greater.

Q = 7.48 NQ N D3 [USGPM ]
Where: NQ = Pumping Number [Dimensionless]
D = Impeller Diameter [Feet]
N = Impeller Speed [RPM]

Tip Speed (TS)

Impeller tip speeds are normally in the range of 400 to 1500 FPM. Tip speed is a more important
criteria for some applications than others, ie. flocculation or dispersion.

TS = π D N [FPM]
Where: D = Impeller Diameter [Feet]
N = Impeller Speed [RPM]

Superficial Velocity (SV)

Normally used for solid suspension applications and compared to the settling rate of the solid in
question. Superficial Velocity is calculated using the following equation:

Q
SV = [ FPM ]
7.48 A
Where: Q = Pumping Capacity [USGPM]
A = Tank Cross Sectional Area [Ft2]

Torque per Equivalent Volume (TQ/Eq V)

This is an extremely useful ratio which is the basis for all Hayward Gordon mixer sizing and describes
the level of mixing for any application.

æ BHP × 63025 ö
TQ ç ÷
=ç N ÷ [in - lbs / Eq.Vol]
Eq V ç SG V ÷÷
ç
è ø
Where: V = Working Volume of Tank [USG]
SG = Fluid Specific Gravity

 Equation Summary

Impeller Diameter (ft) Torque per Equivalent Volume (in-lbs/Eq. Vol)

æ BHP × 63025 ö
æ 6.12 E 7 × HP × 0.85 ö
0.2
TQ ç ÷
=ç N ÷
D = çç ÷÷
è SG × N × N 3
ø Eq V ç SG ×V ÷÷
P ç
è ø

Impeller Power Draw (HP) Superficial Velocity (FPM)

N P D 5 N 3 SG Q
BHP = SV =
6.124 ´ 10 7 7.48 A

Pumping Capacity (usgpm) Equivalent Tank Diameter (ft)

Single Impeller Used to determine equivalent tank diameter of
square or rectangular tanks
Q = 7.48 N Q N D 3
Dual Impellers TEq = 1.13 L ×W
Q = 1.8 × Single impeller

Impeller Tip Speed (fpm) Velocity Gradient (sec-1)

BHP × 1000
TS = π D N [FPM] G = 444
V ×µ

Where: D is Impeller Dia in [Feet] T is Tank Dia in [Feet]

N is Impeller Speed [RPM] V is volume in [US Gal]
Q is Pumping Capacity [USGPM] BHP is Brake Horsepower
HP is Nameplate Horsepower TQ is Torque [In-lbs]

 POWER & PUMPING NUMBERS OF VARIOUS IMPELLERS

Axial & Radial Flow Impellers Hydrofoil Impellers

Impeller Style NP NQ Impeller Style NP NQ
4PBT45 1.62 0.86 4HP45
4PBT32 1.0 0.71 3AL45
4RBT90 3.60 1.10 3AL39 CONTACT
4RSB90 2.52 0.95 3AM45 FACTORY
6RD90 4.75 1.23 3AH39
6RDC90 3.20 1.50 4AH45

Notes

Power numbers assume fully baffled vessels with water-like fluid and proximity correction factors (off
bottom and multiple impellers) of 1.0.

Pumping numbers allow calculation of the primary pumping capacity only, entrained flow is often
considered to be 2.5 to 3 (or more) times greater. Pumping numbers assume Impeller Diameter to
Tank Diameter ratio (D/T) is 0.33. The NQ values given can be modified for different D/T ratios in the
range of 0.2 to 0.45 by using the following equation:

-0.1
æD ö
N QR =ç T ÷ NQ
ç 0.33 ÷
è ø

 Impeller Legend

BLADES PER IMPELLER ROOT PITCH

IMPELLER TYPE ANGLE

AXIAL FLOW IMPELLERS

Designation Key Examples

AL Axial Flow, Low solidity 3AL39, 3AL45
AM Axial Flow, Mid solidity 3AM39, 4AM45
AH Axial Flow, High solidity 3AH39, 3AH45
HP High Efficiency PBT 4HP45, 3HP39
PBT Pitched Blade Turbine 4PBT45, 3PBT32

RADIAL FLOW IMPELLERS

Designation Key Examples

RBT Radial Blade Turbine 4RBT90, 6RBT90
RD Radial Disk 6RD90, 4RD90
RDC Radial Disc Concave Blade 6RDC90
RSB Radial Swept Back 6RSB90, 4RSB90

Glossary
Agglomeration - The combining of finely dispersed particles into larger particles, usually caused by a
re-arrangement of surface forces resulting from a change of environment. (Opposite of Dispersion)

Axial Flow - Fluid flow directed axially along the mixer shaft, from top to bottom (down-pumping) or
from bottom to top (up-pumping).

Baffles - Structure (normally flat plate) mounted vertically on the tank straight sides (can also be used
in bottom heads and cones) to direct the flow vertically in the tank, preventing swirl and vortexing.
[Section TG1-06]

Bending Moment - The product of force times distance. Fluid forces are exerted on a mixer shaft at
each impeller. This force times the distance the impeller is located from the lower bearing of the drive
creates bending moment. [Section TG1-08]

Bearing Life - Bearing life is most often reported as L-10 life, which is the number of hours of
operation under a given set of load conditions during which a bearing has a 10% chance of failure.
The L-10 life is about one-fifth of the average life.

Blending - Mixing two or more miscible liquid components to a specified level of uniformity. [Section
TG1-02]

Consistency - The resistance of a fluid to deformation when subjected to shear stress; usually
synonymous with Viscosity.

Coverage - The distance between the impeller and the liquid surface. Insufficient coverage can cause
vortexing and air entrainment.

Critical Speed - A rotational speed equal to one of the natural frequencies of the shaft and impeller
system. Operating at or near a critical speed will amplify vibrations possibly leading to shaft failure.
[Section TG1-08]

Crystallization - Formation of a solid phase from a liquid solution (Opposite of Dissolving).

Density - The mass per unit volume of a substance. See Specific Gravity.

Dilatant Fluid - A material in which the apparent viscosity increases with increasing shear stress.
(Opposite of Pseudoplastic).

Dispersion - A two-phase system in which one phase is broken into discrete particles which are
completely surrounded by the second phase. Particles may be solid, liquid, or gas. For Mixing
purposes the second phase is generally a liquid.

Dissolving - A change of phase from solid to liquid by combining with a liquid solvent. (Opposite of
Crystallization).

Draft Tube - A hollow stationary cylinder mounted concentrically in the vessel with a mixing impeller
mounted in, above or below it to promote increased vertical fluid flow during agitation.

Dry Well - A sleeve around the output shaft of a drive unit to prevent leakage of the gear lubricant
down the shaft.

D/T - The ratio of impeller diameter (D) to tank diameter (T).

Emulsion - A colloidal dispersion of two or more liquids which are immiscible with each other. See
Dispersion.

Entrainment - The result of the drawing force produced by a flowing fluid which drags additional fluid
(entrained flow) or air (air entrainment) along with the pumped fluid.

Equivalent Volume - The product of vessel volume and the final liquid or slurry specified gravity.

Extraction - A process involving material transfer from one phase to another.

Flash Mixer - An agitator used to mix a small amount of additive into a continuous stream where the
Residence Time is extremely short. It most often refers to addition of chemicals which cause or aid
Flocculation in water or waste treatment operations. [Section TG2-02]

Flocculation - A mixing process whose object is to cause fine particles to collide and/or Agglomerate
to larger sizes or to adhere to larger particles so they can more easily be separated from the liquid.
[Section TG2-03]

Flooding - In gas-liquid mixing, an accumulation of gas which collects within the Impeller, reducing
liquid circulation to a small fraction of normal, and thereby reducing mixing effectiveness. It can also
occur when air is drawn into the liquid from the surface, either from Vortexing or accompanying solids
which are being wetted.

Foot Bearing - See Steady Bearing

Freeboard - The distance from the liquid surface to the top of the tank.

Gear Types:
Spiral Bevel Gears - Spiral bevel gears have teeth which are curved and oblique, used to
transmit power in gearboxes with intersecting (right angle) shafts. Most efficient gearing for
right angle drives with quiet and smooth operation.

Helical Gears - A gear with teeth on an angle (typically 20-25°) to the axis of rotation, used to
transmit power in gearboxes with parallel or non-intersecting shafts. The most efficient type of
gearing commercially available for mixer drives.

 Worm Gears - A gear used for obtaining large speed reduction between non-intersecting
shafts whose axis are at a 90 degree angle from each other. A less expensive type of gearing
than helical or spiral bevel but much less efficient.

Hindered Settling - Behavior of a Slurry having a high frequency of particle collisions, evidenced by
reduced Settling Velocity. Generally, it becomes noticeable at solids concentrations above 35-40% by
weight, but may occur at much lower concentrations if the particles are extremely fine or highly
irregular in shape. [Section TG1-03]

Hold-up - In gas-liquid mixing, the increase in batch volume over the liquid volume, resulting from the
gas which is Dispersed into the liquid.

Impeller - The portion of the agitator imparting force to the material being mixed. Propellers,
Hydrofoils, Turbines, Gates, Anchors, and Paddles are all types of Impellers. [Section TG1-05]

Impeller Blade - One of the vanes on any type of Impeller, sometimes mis-used to indicate the entire
Impeller.

Laminar Flow - Fluid flow characterized by long, smooth flow currents, mainly in the same direction
as the bulk of the flow with little interaction between them. See Turbulent Flow.

Newtonian Fluid - A fluid whose rate of flow is proportional to the stress applied to it. The Viscosity is
therefore constant and independent of shear stress.

Non-Newtonian Fluid - A fluid whose rate of flow is not proportional to the stress applied. The
Viscosity is variable and may increase or decrease with stress, with time, or with a combination of
both. See also Pseudoplastic, Thixotropic, Dilatant.

Pitch - The angle the blades make with a horizontal plane.

Power Number - A number which characterizes the power response of a particular impeller geometry.
[Section TG1-01]

Propeller - A two, three or four bladed Axial Flow Impeller, having helically shaped blades.

Proximity Factor - A correction factor used in Impeller power calculations to allow for geometric
variations, such as Impeller-to-tank bottom distance, Impeller-to-liquid surface distance, multiple
Impeller spacing, etc.

Pumping Number - A number which characterizes the pumping capacity of a particular impeller
geometry.

Pumping Capacity - The volumetric discharge rate of an Impeller operating at a given speed. Primary
Pumping Capacity includes only the fluid that actually travels through the impeller, Total Pumping
Capacity includes entrained flow. [Section TG1-01]

Radial Flow - Fluid flow from the tank center to the walls. Impellers that draw from above and below
and discharge it towards the tank wall, perpendicular to the mixer shaft, are radial flow impellers.
[Section TG1-05]

Rapid Mixer - See Flash Mixer.

Residence Time - The average time a process component remains in the mixing environment in a
continuous process.

Reynolds Number - A dimensionless number used to characterize fluid flow data. The ratio of inertial
to viscous forces.

Scrapers - Flexible or hinged members attached to the outer periphery of an Anchor Impeller to
scrape the vessel wall, preventing buildup and improving heat transfer.

Service Factor (Gearbox) - The service factor of a gear drive is defined as the lowest AGMA
mechanical power rating (strength or durability) of any pinion or gear in the drive divided by the
nameplate power of the motor.

Settling Velocity - The velocity attained by a particle freely falling in a fluid due to gravity. See
Terminal Settling velocity and Hindered Settling. [Section TG1-03]

Slinger - A device attached to a shaft above the liquid level to prevent the liquid from climbing or
splashing up.

Slurry- A mixture of liquids and insoluble solids; ie. Solid Suspension.

Solid Suspension - A mixture of an insoluble solid material in a liquid. There are numerous degrees
of suspension used in mixing such as: Just Suspended, Off Bottom, and Moderately Uniform

Solids Wetting - Dispersing solid particles so that a liquid film coats each particle.

Sparger - Pipe(s), pipe rings or cones for introducing a gas below the liquid surface in a tank; most
often located below the Impeller.

Stabilizer - A device attached to an Impeller which directs the fluid flow pattern generated by rotation
so as to dampen shaft deflection. The two most common forms of stabilizers are fins (flat plates
attached to the individual impeller blades) and stabilizer rings (pipe section normally attached to the
bottom of the impeller blades).

Steady Bearing - A radial shaft support bearing mounted in the vessel bottom used to reduce
deflection in long shaft installations. Sometimes called a "foot bearing".

Superficial Velocity - An average velocity value used in computations of fluid flow due to the
complexity of velocity distribution in the system. Usually encountered in gas-liquid systems, where it is
the volumetric flow-rate divided by the cross sectional area of the tank. [Section TG1-01]

Swirl - the rotation of a liquid about an agitator shaft where little relative motion within the liquid is
obtained.

Thixotropic - A material whose Viscosity drops gradually even at a constant shear stress, as opposed
to materials whose viscosity changes instantaneously with changing shear stress. When shear stress
is removed, viscosity of Thixotropic materials gradually increases again. These materials may also be
Pseudoplastic or Dilatant.

Torque - The torsional moment exerted by a body (such as an Impeller) rotating at constant speed.

Turbine - A multi-bladed impeller (usually three to six blades).

Liquid Seal - Also referred to as a manometer seal. A liquid "trap" around a shaft to prevent vapor
leakage from the vessel, used only in very low pressure systems.

Viscosity - The measure of resistance of a fluid to flow when a force is applied to it. Water at room
temperature (20°C) has a viscosity of one centipoise.

Viscosity Factor - The correction factor applied to standard Impeller power draw to account for the
difference caused by high liquid Viscosity.

Vortex - A depression occurring in a liquid surface when an agitator Swirls the liquid; a whirlpool.

Water Horsepower - The standard brake horsepower an Impeller will draw when operated in a
waterlike liquid (viscosity =1 centipoise, Specific Gravity = 1.0) under standard conditions of Baffling
and geometrical arrangement.

 Nomenclature

Symbol Definition Typical Units

A Tank Cross Sectional Area ft2
BHP Brake Horsepower HP
D Impeller Diameter inches
G Velocity Gradient ft/sec/ft or s-1
HP Motor Nameplate Horsepower HP
L Tank Length feet or inches
µ Viscosity at Design Temperature cps
N Impeller Speed RPM
NP Impeller Power Number Dimensionless
NQ Impeller Pumping Number Dimensionless
NRE Reynolds Number Dimensionless
Q Impeller Primary Pumping Capacity US GPM
ρ Density lbs/ft3 or kg/m3
SG Specific Gravity Dimensionless
SV Superficial Velocity ft/min
T Tank Diameter feet or inches
TEQ Equivalent Tank Diameter feet or inches
Tr Hydraulic retention time minutes or seconds
TQ Torque in-lbs
V Tank Volume US Gallons
W Tank Width feet or inches
Z Liquid level in Tank feet or inches

 Mixer Tech
Guide

Website: www.haywardgordon.com | Email: [email protected]

 Blending
This section deals with blending of miscible fluids. If left for a long enough period of time, miscible
liquids will dissolve in one another and form a homogeneous solution. The majority of liquid/liquid
blending applications fall into this category. Applications involving immiscible (insoluble) fluids are
classified as dispersion applications which involves very different mixer sizing methods.

The selection procedure is valid for blending operations in fully baffled, vertical cylindrical tanks with
fluid viscosities up to 50,000 cps. Higher viscosity applications and other tank configurations may
require different sizing techniques.

This procedure introduces the main criteria used for mixer sizing in blending applications. In addition,
working through the following steps will allow the individual to better understand some of the
calculations preformed by our Mixing Assist computer program.

Step 1

Complete the Application Data Form found on page 2.20; this will ensure that all pertinent information
required for a mixer selection is available.

Step 2

Use the Mixer Sizing Work Sheet (Pg. 2.21) and the basic mixer equations found in Section TG1 to
calculate the following:

• Calculate an equivalent volume, this is equal to the batch volume multiplied by the fluid specific
gravity.

• Determine the Mixing Intensity Level required using the descriptions on Pages 2.03-2.05.
Check to see if the application falls within the Portable Mixer range - Pg. 2.08. If so, select the
mixer from this chart, otherwise proceed to the next step.

• Determine the number of impellers required and their optimum position by referring to the chart
on Pg. 2.06.

• Using the guidelines on Pg 2.07, determine initial Impeller Diameter to Tank Diameter (D/T)
ratio and from this, calculate the proposed Impeller Diameter.

• Select an impeller style using viscosity limits on Pg. 2.07 and descriptive literature. Record
Impeller Factor from Pg. 2.05 on the Mixer Sizing Work Sheet.

 • Refer to the appropriate Selection Chart, Pages 2.09 - 2.14, selecting the correct chart by
using the final fluid viscosity. Record the Required Torque at a few different mixer speeds.

• Calculate Invested Torque which is equal to Required Torque x Impeller Factor.

Step 3

Calculate the BHP for the impeller diameter and RPM chosen (for the purpose of this example we will
ignore viscosity and proximity corrections). At this point a number of iterations are normally required to
fully utilize available hardware, i.e. a finite number of motor and gearbox sizes are available. This is
accomplished by fine tuning the mixer speed and impeller diameter (and therefore the HP required).
Finally check impeller tip speed, it should be in the range of 400 to 1500 FPM.

Step 4

We have now satisfied the process requirements of the application and the final step is to
select/design suitable mechanical components. Based on the application requirements or experience,
identify the appropriate gearbox service factor (1.25, 1.5 etc.) and the L-10 bearing life (30,000 hrs.,
50,000 hrs., 100,000 hrs. etc.). Refer to Section TG8 for mechanical design fundamentals.

 MIXING INTENSITY LEVELS
Review the mixing application and the process requirements and then use the following table to
choose a mixing intensity level. The table on the following page can be used as a cross reference for
some of the main mixer manufactures mixing intensity levels.


Mixing Maximum Viscosity Maximum SG Description and
Intensity Ratio* Difference Typical Applications
Level

Ratio of Maximum Storage or Holding Tanks

Viscosity Component to Difference in SG of Feed Tanks
Mild Minimum Viscosity Components does not Non-Critical Blending Operations
Component does not Exceed 0.2. “Long” Blend Time
exceed 10:1. Fluid Surface Barely in Motion
Ratio of Maximum Most Common Requirement
Viscosity Component to Difference in SG of Non-Critical Reaction Tanks
Moderate Minimum Viscosity Components does not Make-Up Tanks
Component does not Exceed 0.4. Blend Tanks
exceed 50:1. Surface Rippling at Low Viscosities
Ratio of Maximum Critical Make-Up Tanks
Viscosity Component to Difference in SG of Critical Blend Tanks
Strong Minimum Viscosity Components does not Non-Critical Heat Transfer
Component does not Exceed 0.5. Shorter Blend Times
exceed 200:1. Surface with Moderate Roll
Ratio of Maximum Critical Mixing Applications
Viscosity Component to Difference in SG of Critical Reaction Tanks
Vigorous Minimum Viscosity Components does not Most Heat Transfer
Component does not Exceed 0.6. Tanks with pH Feedback
exceed 500:1. Surface in Rolling Boil
Ratio of Maximum Critical Reaction Tanks
Viscosity Component to Difference in SG of Good Heat Transfer
Intense Minimum Viscosity Components does not Rapid Blend Times
Component does not Exceed 0.8. Surging Surface, Some Vortexing
exceed 5,000:1.
Ratio of Maximum Special Critical Applications
Viscosity Component to Difference in SG of Critical Reaction Tanks
Violent Minimum Viscosity Components does not Critical Heat Transfer
Component does not Exceed 1.0. High Shear Requirements
exceed 10,000:1. Surface Splashing and Vortexing

*If fluid components are less than 100 cps, any Mixing Intensity Level can be used.

 CROSS REFERENCE OF MIXING INTENSITY LEVELS


Hayward Gordon Philadelphia Chemineer Lightnin

Mild Mild 2 Mild

Moderate Moderate 3 Moderate
Strong Not Defined 4 Not Defined
Vigorous Vigorous 5 Violent
Intense Not Defined 7 Not Defined
Violent Violent 9 Not Defined




BLEND TIMES
Blend time is a function not only of the degree of mixing, but also the density differences and viscosity
differences between components. For ideal components with negligible density or viscosity
differences, blend times can be estimated using the chart on the following table.

Blend times can be as much as ten times the values shown in the table for components with density or
viscosity differences, or with unusual characteristics. Blending results are affected by the particular
nature as well as the viscosity of the components. The relative concentrations of components and the
method of adding them to the batch, as well as temperature and surface tension can significantly
affect blend times. Blending never really reaches a distinct end point. A mixture just achieves greater
uniformity. Different applications will have different criteria for determining adequate homogeneity. For
example, it is important for a batch of paint to be as uniform as possible to avoid off-colour defects, but
a blend of similar petroleum oils need not be perfectly uniform. Therefore blend time is not an absolute
quantity and is normally not the primary selection criteria.

 BLEND TIMES


Mixing Viscosity Blend Time Mixing Viscosity Blend Time
Intensity (cps) (Min.) Intensity (cps) (Min.)
Waterlike 5-10 Waterlike 1-2
250 10-20 250 3-7
MILD 1,000 20-30 VIGOROUS 1,000 5-9
5,000 60-120 5,000 30
10,000 120-240 10,000 50
Waterlike 3-5 Waterlike 1
250 5-10 250 2-3
MODERATE 1,000 10-15 INTENSE 1,000 5
5,000 50 5,000 20
10,000 90 10,000 40
Waterlike 2-3 Waterlike <1
250 4-8 250 1-2
STRONG 1,000 7-10 VIOLENT 1,000 2-3
5,000 40 5,000 5
10,000 70 10,000 10


IMPELLER FACTORS
Once an impeller style has been chosen for the application, use the following table to pick the
appropriate Impeller factor which then determines the final Invested Torque the application requires.

Impeller Style Impeller Factor, FI Impeller Style Impeller Factor, FI

3AL39 1.0 4HP45 1.1
4AL45 1.0 4PBT45 1.2
3AH39 1.0 4RBT90 1.3
3AM45 1.0 4RSB90 1.3

 IMPELLER POSITIONING
Recommendations given below are guidelines for use in the absence of previous application
experience.

Impeller Number of Maximum C1 C1 Minimum

Style Impellers Z/T Optimum Range C2 Submergence*

1 1.0 ---
Radial 0.3D 0.16D - 0.5D 0.4D
2 1.5 0.67Z
1 1.2 ---
PBT 0.67D 0.3D - 0.7D 0.6D
2 1.9 0.67Z
1 1.25 ---
HP 0.9D 0.5D - 1D 0.75D
2 2.0 0.67Z
1 1.3 ---
Hydrofoil 1.0D .7D - 1.3D 0.9D
2 2.1 0.67Z

*For good mixing, minimal vortexing.

 Optimum D/T Vs. Viscosity

 Portable Mixer Blending Selection Chart

Viscosity Tank Volume (US Gallons) Mixing

(cps) 25 50 100 200 500 1000 2000 3000 5000 Action

1.0
DC-14
(1) 3.5"
DC-13
(2) 3.25"
GC-14
(1) 9.5"
GC-14
(1) 9.5"
GC-13
(2) 9.0"
GC-34
(2) 10.5"

(1) water BT = 12 BT = 20 BT = 16 BT = 30 BT = 33 BT = 35 MILD
(1)
kerosene DC-14 DC-14 DC-14 DC-12 GC-13 GC-12 GC-12 GC-34 GC-15
(1) 3.5" (1) 3.5" (1) 3.5" (1) 4.0" (2) 9.0" (1) 10.5" (1) 10.5" (2) 10.5" (2) 12.5"
BT = 2 BT = 3 BT = 6 BT = 8 BT = 6 BT = 12 BT = 24 BT = 21 BT = 21 Vigorous
(32)
cream DC-14 DC-13 GC-14 GC-14 GC-13 GC-34 GC-11
100 (1) 3.5" (2) 3.25" (1) 9.5" (1) 9.5" (1) 10.0" (2) 10.5" (2) 11.5"

BT = 8 BT = 12 BT = 11 BT = 21 BT = 36 BT = 26 BT = 36 MILD
(100) SAE DC-14 DC-14 DC-12 GC-13 GC-12 GC-12 GC-34 GC-15 GC-2
oil (1) 3.5" (1) 3.5" (1) 4.0" (2) 9.0" (1) 10.5" (1) 10.5" (1) 11.5" (2) 12.5" (2) 13.0"

BT = 2 BT = 4 BT = 5 BT = 3 BT = 8 BT = 16 BT = 24 BT = 17 BT = 25 Vigorous

DC-14 DC-13 GC-14 GC-14 GC-13 GC-34 GC-11 GC-15

250 (1) 3.5" (2) 3.25" (1) 9.5" (1) 9.5" (1) 10.0" (1) 11.5" (2) 11.5" (2) 12.5"

(240) MILD
mayonnais BT = 7 BT = 10 BT = 7 BT = 16 BT = 31 BT = 42 BT = 38 BT = 49
e, DC-14 DC-12 GC-13 GC-12 GC-12 GC-34 GC-15 GC-2 GC-3
lard (1) 3.25" (1) 4.0" (2) 9.0" (1) 10.5" (1) 10.5" (1) 11.5" (1) 13.0" (2) 13.0" (2) 14.25"
BT = 4 BT = 5 BT = 3 BT = 5 BT = 14 BT = 21 BT = 30 BT = 26 BT = 34 Vigorous
DC-13 GC-14 GC-14 GC-13 GC-34 GC-11 GC-15 GC-2
(2) 3.25" (2) 6.5" (1) 9.0" (1) 9.0" (1) 10.5" (2) 10.5" (2) 11.5" (2) 13.0"

500 BT = 8 BT = 10 BT = 13 BT = 33 BT = 42 BT = 50 BT = 57 BT = 66 MILD

DC-14 GC-13 GC-12 GC-12 GC-34 GC-15 GC-2 GC-3
(1) 3.25" (2) 7.75" (2) 9.0" (1) 10.5" (1) 10.5" (1) 13.0" (2) 13.0" (2) 13.0" Vigorous
BT = 7 BT = 3 BT = 4 BT = 9 BT = 21 BT = 22 BT = 26 BT = 39
(900) DC-13 GC-14 GC-14 GC-12 GC-34 GC-11 GC-15 GC-2 GC-3
yogurt (2) 2.75" (2) 6.0" (2) 6.0" (1) 10.0" (1) 10.5" (1) 11.5" (2) 11.5" (2) 12.5" (2) 13.0"

(900) 1000 BT = 10 BT = 10 BT = 19 BT = 14 BT = 35 BT = 48 BT = 57 BT = 67 BT = 99 MILD
castor oil GC-13 GC-12 GC-12 GC-11 GC-15 GC-2 GC-3
(900)
(2) 7.75" (2) 7.75" (2) 7.75" (1) 11.5" (1) 12.5" (1) 12.5" (2) 13.0"

glycerin BT = 3 BT = 6 BT = 9 BT = 10 BT = 19 BT = 38 BT = 40 Vigorous

GC-14 GC-14 GC-12 GC-34 GC-11 GC-15 GC-2 GC-3
2500 (2) 5.5" (2) 5.5" (2) 7.0" (2) 9.0" (2) 10.0" (2) 10.5" (2) 11.5" (2) 13.0"

MILD
BT = 11 BT = 22 BT = 24 BT = 22 BT = 39 BT = 70 BT = 107 BT = 112
GC-12 GC-12 GC-11 GC-15 GC-2 GC-3
(2) 7.75" (2) 7.75" (2) 10.0" (2) 10.5" (2) 11.5" (2) 13.0"

(2500) BT = 5 BT = 9 BT = 8 BT = 14 BT = 27 BT = 37 Vigorous
honey GC-14 GC-12 GC-34 GC-11 GC-15 GC-2 GC-3
5000 (2) 5.5" (2) 7.0" (2) 7.75" (2) 9.0" (2) 10.0" (2) 11.5" (2) 12.5"

BT=17 BT = 18 BT = 27 BT = 34 BT = 60 BT = 82 BT = 128 MILD

(3000) GC-12 GC-11 GC-15 GC-2 GC-3
blackstrap (2) 7.0" (2) 9.0" (2) 10.0" (2) 11.5" (2) 12.5"
BT = 9 BT = 9 BT = 12 BT = 17 BT = 32 Vigorous
molasses
GC-13 GC-12 GC-34 GC-15 GC-2 GC-3
10000 (2) 6.0" (2) 6.5" (2) 7.0" (2) 9.5" (2) 10.0" (2) 11.5"

BT = 20 BT = 33 BT = 53 BT = 42 BT = 89 BT = 120 MILD
GC-34 GC-11 GC-15 GC-3
(2) 7.5" (2) 9.0" (2) 9.5" (2) 11.5"

BT = 11 BT = 13 BT = 21 BT = 25 Vigorous
(10000)
corn syrup GC-12 GC-34 GC-11 GC-15 GC-3
15000 (2) 6.0" (2) 7.0" (2) 7.75" (2) 9.0" (2) 11.5"

MILD
BT = 24 BT = 32 BT = 46 BT = 58 BT = 72
(11200) GC-11 GC-15 GC-2 GC-3
mustard (2) 7.75" (2) 9.0" (2) 10.0" (2) 11.5"
BT = 12 BT = 15 BT = 21 BT = 29 Vigorous

Note:
-Selections are based on a final fluid specific gravity of 1.10
-Blend Times (BT) indicated are in minutes and are approximate. They are based on blending pure fluids as opposed to blending
two components with different viscosities.






 APPLICATION DATA FORM

 MIXER SIZING WORKSHEET
Use this sheet in conjunction with Application Data Form for Blending Applications

Process Requirements

Batch Volume _______________ D/T Ratio _______________

Equivalent Volume _______________ Proposed Imp. Dia _______________
Mixing Intensity _______________ Impeller Style _______________
Z/T Ratio _______________ Impeller Factor FI _______________
No. of Impellers _______________ Required Torque _____ @ ____rpm
Required Torque _____ @ ____rpm

Invested Torque = Required Torque x Impeller Factor

= ____________________________

First Selection

Gearbox SF / L10 Life _______________ Available Torque _______________

Req’d Shaft Length _______________ Actual Impeller Dia _______________
Mixer Model _______________ HP ______ @ _______ RPM
Impeller(s) _____________________________________________
Shaft _____________________________________________

Second Selection

Gearbox SF / L10 Life _______________ Available Torque _______________

Req’d Shaft Length _______________ Actual Impeller Dia _______________
Mixer Model _______________ HP ______ @ _______ RPM
Impeller(s) _____________________________________________
Shaft _____________________________________________

 Mixer Tech
Guide

Website: www.haywardgordon.com | Email: [email protected]

 Solid Suspension
This section deals with the suspension of “Free” settling solids; that is, there is a small enough
concentration of the solids that the particles are not interfering with each other and therefore can reach
their terminal settling velocity. Applications involving “Hindered” settling use a different selection
procedure.

In addition, this selection procedure assumes operation in a fully baffled, vertical cylindrical tank.

This procedure introduces the main criteria used for free settling mixer sizing in solid suspension
applications. Working through the following steps will allow the individual to better understand the
calculations being done by the Mixing Assist computer program.

Step 1

Complete the Application Data Form found on page TG-1 pg 14; this will ensure that all pertinent
information required for mixer selection is available.

Step 2

Use the Mixer Sizing Work Sheet (Page 14) and basic mixer equations found in section TG1 to
calculate the following:

• Calculate an equivalent volume, this is equal to the batch volume multiplied by the slurry
specific gravity. See Page 6 for equation to determine slurry SG, given solid SG and liquid SG.

• Using the chart on page 4 determine the type of settling (Free or Hindered). If Hindered settling
is encountered. It is possible that a smaller mixer could be used than for a free settling
application.

• Determine the Solid Settling Rate using the graph on page 5. Normally a sieve analysis is
available giving particle size vs. Quantity, ie. 95% - 200 Mesh. A conservative procedure is to
use the largest particle size given, but it is possible to develop a more finely tuned selection -
see the Special Requirements Section on the following page.

• Check to see if the application falls within the Portable Mixer range - Pg. 6. If so, select the
mixer from this chart, otherwise proceed to the next step.

• Determine the Suspension Requirement Factor (FSR) using the chart on Pages 37 and knowing
the degree of suspension required - barely suspended off the tank bottom or to a nearly
uniform suspension throughout the tank. If a FSR of 0.5 or 1.0 is selected, see the Special
Consideration section on the next page.

 • Calculate the slurry height to tank diameter ratio (Z/T) and then determine the number of
impellers required and their position in the tank by referring to the chart on Pg. 8.

• Calculate a Proposed Impeller Diameter using an Impeller Diameter to Tank Diameter (D/T)
ratio of 0.3. The final D/T ratio should be kept in the range of 0.25 to 0.4.

• Determine the Tank Geometry Correction Factor (FG) using the graph on page 9.

• Select an impeller style using the descriptions in section TG5. The most common impellers
used for solid suspension applications are the HP, AM and AL series Hydrofoils. Determine the
appropriate Impeller Factor (FI) from page 7.

• Refer to the appropriate Selection Chart, Pages 10 - 13, selecting the correct chart by using
the particle settling rate. Record the Required Torque at a few different speeds.

• Calculate Invested Torque which is equal to Required Torque x Impeller Factor (FI) x Geometry
Factor (FG) x Suspension Requirement Factor (FSR).

Step 3

• Based on the application requirements, record the gearbox Service Factor and the L-10
bearing life.

• Calculate the BHP for the impeller diameter and RPM chosen (for the purpose of this example
we will ignore viscosity and proximity corrections). At this point a number of iterations are
normally required to fully utilize available hardware, i.e. a finite number of motor and gearbox
sizes are available. This is accomplished by fine tuning the mixer speed and impeller diameter
(and therefore the HP required). Finally check impeller tip speed, it should be in the range of
400 to 1000 FPM for Pitched Blade Turbines and between 400 and 1200 FPM for Hydrofoil
Impellers.

Step 4

• We have now satisfied the process requirements of the application and the final step is to
select/design suitable mechanical components. Based on the application requirements or
experience, identify the appropriate gearbox service factor (1.25, 1.5 etc.) and the L10 bearing
life (30,000 hrs., 50,000 hrs., 100,000 hrs. etc.). Refer to Section TG8 for mechanical design
fundamentals.

 Special Considerations

Dry Solids Addition

Normally the solids are added to the tank in a pre-slurried form (already mixed with fluid). If however
the solids are added to the surface in a dry form which may float, an upper impeller will be required to
promote surface vortexing for better draw-down and wetting of the solids. In addition, the tank baffles
can end short of the slurry surface which will also promote vortexing.

Off-Bottom Suspension Guidelines

For applications where only a minimal level of suspension is required (FSR=0.5-1.0), which may
include bottom draw-off or dissolving situations, the full slurry height need not be used to calculate the
working volume. Instead a slurry height of 0.33 times the tank diameter can be used to calculate this
volume. Using a smaller volume allows selection of a smaller mixer remembering that the mixer is only
influencing this portion of the tank.

Solids Size Range

The size of solids will often vary over a range. To ensure that “over-sizing” the mixer does not occur,
select different Suspension Requirement Factors (FSR) for different solid sizes. For example, suppose
solids are described as 100% - 200 microns and 95% - 100 microns and the application requires
Moderately Uniform suspension for a bottom draw-off operation. Select FSR=1.5 (Moderately Uniform)
for the 100 micron solids and calculate the torque requirement. Then select FSR=1.0 (Off Bottom) for
the 200 micron particles and calculate this torque requirement. The result will be a more appropriately
sized selection than using the largest particle size (200 micron) coupled with a FSR=1.5.

 Unrestricted or Hindered Settling

60

50

Hindered Settling

40
Semi-Hindered
% Solids (by weight)

30

Free Settling
20

10

0
0.0 0.2 0.4 0.6 0.8 1.0

(Solid SG - Liquid SG) / Solid SG


 PORTABLE MIXER SELECTION CHART

Particle Equivalent Volume (Slurry SG x USG)

Settling Suspension
Rate 50 100 200 500 1000 2000 3000 5000 Requirement
(FPM)

1 DC-14 DC-13 DC-13 GC-13 GC-34 GC-11 GC-15 GC-3 Off-Bottom

DC-12 DC-12 DC-34 GC-34 GC-11 GC-2 --- --- Uniform

5 DC-13 DC-12 GC-13 GC-11 GC-2 --- --- --- Off-Bottom

DC-13 DC-11 GC-34 GC-2 --- --- --- --- Uniform

10 GC-13 GC-12 GC-11 --- --- --- --- --- Off-Bottom

GC-34 GC-11 GC-2 --- --- --- --- --- Uniform

15 GC-12 GC-34 GC-15 --- --- --- --- --- Off-Bottom

GC-11 GC-15 --- --- --- --- --- --- Uniform

Propeller spacing of (2) propeller diameters is recommended for GC mixers.

Propeller spacing of (4) propeller diameters is recommended for DC mixers.
Lower propeller off-bottom distance should be 1.5 propeller diameters.

SLURRY SPECIFIC GRAVITY

1
SGSlurry =
X1 X2
+
SGSolid SGLiquid

Where: X1 is weight fraction of solids and X2 is weight fraction of liquid

 SUSPENSION REQUIREMENT LEVELS

Review the mixing application and the process requirements and then use the following table to
choose the appropriate Suspension Requirement Factor.

Suspension
Description and Application Range Requirement Factor
FSR

Solids Just Suspended

Fastest settling particles barely rise clear of vessel bottom, others rise
0.5
higher. Fillets will form in vessel corners. Use when only bottom pump-out
is available or for dissolving solids applications when time is not critical
Off Bottom Suspension
Adequate for the majority of storage applications. Solids are in moderate
1.0
uniformity in the bottom quarter of vessel. Good for bottom draw-off
applications. Continuous suspension. Some filleting.
Moderate Uniformity
Strong turnover; uniformity of solids in bottom three-quarters of tank. Good
1.5
for intermediate draw-off situations. No filleting.

Nearly Uniform Suspension

Closest practical approach to uniform distribution of solids throughout mix.
2.0
Suitable for most top draw-off and overflow applications.

Uniform Suspension
Excellent contact between liquid and solids. Rapid mass transfer. 3.0

IMPELLER FACTORS

Once an impeller style has been chosen for the application, use the following table to pick the
appropriate Impeller factor which then determines the final Invested Torque the application
requires.

Impeller Style Impeller Factor, FI Impeller Style Impeller Factor, FI

3AL39 0.50 4HP45 0.65

4AL45 0.55 4PBT45 0.75
3AH39 0.60 4PBT32 0.65
3AM45 0.51 4RBT90 1.25

 IMPELLER POSITIONING
Recommendations given below are guidelines for use in the absence of previous application
experience.

Impeller Number of Maximum C1 C1 Minimum

Style Impellers Z/T Optimum Range C2 Submergence*

1 0.7 ---
Radial 0.3D 0.16D - 0.5D 0.4D
2 0.9 0.67Z
1 1.1 ---
PBT 0.67D 0.3D - 0.7D 0.6D
2 1.7 0.67Z
1 1.15 ---
HP 0.9D 0.5D - 1D 0.75D
2 1.8 0.67Z
1 1.2 ---
Hydrofoil 1.0D .7D - 1.3D 0.9D
2 1.9 0.67Z

*For good mixing, minimal vortexing.

 Tank Geometery Correction Factor

1.9

1.8

1.7

1.6

1.5
Tank Geometry Factor, FG

1.4

1.3

1.2

1.1

0.9

0.8

0.7

0.6
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Slurry Height to Tank Diameter Ratio, Z/T

 FREE SETTLING SOLIDS SUSPENSION APPLICATIONS
SOLIDS SETTLING RATE = 1 FPM

10000
REQUIRED TORQUE (IN-LBS)

1000

100
1000 10000 100000

EQUIVALENT VOLUME (U.S. GAL.)

 FREE SETTLING SOLIDS SUSPENSION APPLICATIONS
SOLIDS SETTLING RATE = 3 FPM

10000
REQUIRED TORQUE (IN-LBS)

1000

100
1000 10000 100000

EQUIVALENT VOLUME (U.S. GAL.)

 FREE SETTLING SOLIDS SUSPENSION APPLICATIONS
SOLIDS SETTLING RATE = 5 FPM
100000
REQUIRED TORQUE (IN-LBS)

10000

1000

1000 10000 100000

EQUIVALENT VOLUME (U.S. GAL.)

 FREE SETTLING SOLIDS SUSPENSION APPLICATIONS
SOLIDS SETTLING RATE = 10 FPM

100000
REQUIRED TORQUE (IN-LBS)

M
RP
30

10000

M
RP
45

M
RP
84

1000
1000 10000 100000

EQUIVALENT VOLUME (U.S. GAL.)

 MIXER SIZING WORKSHEET
Use this sheet in conjunction with Application Data Form for Solid Suspension Applications

Process Requirements

Batch Volume _______________ D/T Ratio _______________

Equivalent Volume _______________ Proposed Imp. _______________
Dia
Hindered or Free Settling _______________ Geometry Factor _______________
Settling Rate _______________ Impeller Style _______________
Suspension Requirement, FSR _______________ Impeller Factor _______________
FI
Z/T Ratio _______________ Required Torque _____ @ ____rpm
No. of Impellers _______________ Required Torque _____ @ ____rpm

Invested Torque = Required Torque x FSR x FG x FI

= ____________________________

First Selection

Gearbox SF / L10 Life _______________ Available Torque _______________

Req’d Shaft Length _______________ Actual Impeller Dia _______________
Mixer Model _______________ HP ______ @ _______ RPM
Impeller(s) _____________________________________________
Shaft _____________________________________________

Second Selection

Gearbox SF / L10 Life _______________ Available Torque _______________

Req’d Shaft Length _______________ Actual Impeller Dia _______________
Mixer Model _______________ HP ______ @ _______ RPM
Impeller(s) _____________________________________________
Shaft _____________________________________________

 Mixer Tech
Guide

Website: www.haywardgordon.com | Email: [email protected]

 GAS DISPERSION
The third most common mixer application is the dispersion of a gas into a liquid. The role of the mixer
is to decrease the gas bubble size, increasing the total gas surface area, which increases the mass
transfer between the gas and liquid phase. The mixer accomplishes this by creating large velocity
gradients, or shear rates, to break the gas into smaller bubbles. In addition, the mixer should be
sized to ensure it controls the flow pattern throughout the vessel as the mixer and the gas compete
to control the overall flow pattern.

The introduction of a gas into a fluid is to promote either a stripping or addition to the product.
The most common application is air dispersion, where the O2 component of the air is
absorbed into the liquid and used in a chemical reaction. The transfer of oxygen from the air
bubble to the liquid is an example of “mass transfer”.

An example of gas dispersion used to remove a component from a liquid is “nitrogen

stripping”. An inert gas, commonly nitrogen, is bubbled through a liquid to absorb various
gases in the liquid. These various gases will permeate the nitrogen bubbles and leave the
system as the bubbles exit the liquid at the surface level.

Industrial Processes Using Gas Dispersion include:

• Hydrogenation – the production of food batters and creams, nickel reduction
• Carbonations – CO2 gas conversions of hydroxides to bicarbonates
• Air Dispersion – for O2 absorption, e.g. fermentation, oxidation autoclaves

Gas is normally introduced into the fluid by means of a blower or compressor feeding a gas
sparging system located in the bottom of the vessel. In this case, the mixer is required to
disperse the gas, to some degree, and also to provide a strong “mixer controlled” flow pattern
throughout the vessel. Occasionally, the mixer is required to induce gas from the surface into
the mixed fluid while also providing dispersion of the gas throughout the fluid and ensuring a
strong “mixer controlled” flow pattern throughout the vessel.

A mixer can improve mass transfer efficiency by:

• Decreasing the gas bubble size, thereby increasing the
total interfacial area of the gas
• Increasing the gas-liquid interface turbulence, thus
reducing the liquid film resistance
• Giving a uniform gas concentration throughout the tank
contents.
• Increasing the time each bubble spends in the liquid

Gas dispersion applications are broken into two main categories:

• Reaction Rate System (Physical Dispersion of the Gas)
• Mass Transfer Controlled Systems
Further descriptions of these two processes are described below.

 Gas Dispersion Levels Gas Dispersion Level Application

Flooding – Gas controlled fluid

flow pattern

The flow regime where the impeller Not used

has little effect in re-directing the
flow pattern established by the gas.
Gas rises directly to the surface.

Minimal Gas Dispersion – Mixer Reaction rate system (physical

just controls the fluid flow dispersion): The rate of reaction in this
pattern. type of system is controlled by the
rapidity of the chemical reaction of the
At higher speed and/or lower gas
system. The addition of more gas or
addition rate, the bubbles are
mixer horsepower beyond the optimum
pushed out to fill most of the vessel
will not speed up the reaction. Factors
volume, but not uniformly,
other than the rate of mass transfer
especially at the bottom. Bubbles
across the bubble-liquid interface limit
are seen to break in moderately
the process.
uniform pattern across the liquid
surface.

Moderate Gas Dispersion – Mixer

strongly controls the fluid flow
Moderate mass transfer: Limited
pattern.
mass transfer applications. Used in
semi-critical reactors.
Bubbles are driven outward to the
wall of the vessel. Only moderate
dispersion of bubbles at the bottom.

Uniform Gas Dispersion – Mixer Mass transfer controlled: Increasing the

very strongly controls the fluid gas rate or mixer horsepower will give a
flow pattern. corresponding increase in the rate of
The bubbles are reduced further in reaction. Relatively fast chemical
size and distributed uniformly reactions and/or relatively high gas
throughout the vessel with many addition rates usually characterize this
bubbles recycling through the type of process. The rate of mass
impeller several times. Surface is transfer to or from the gas bubbles
seen as a fine uniform froth of directly affects the process result.
bubbles. Typical of fermentors.

 Impellers

Radial disk turbines are often used for gas dispersion with their D/T ratio in the range of 0.23
to 0.35 to ensure good dispersion. With a “square batch”, a single radial disk turbine
mounted 0.5 – 0.75 of the impeller diameter off-bottom is often used. When liquid depth
approaches 1.5 times the tank diameter, two impellers should be used with the top impeller
having a liquid cover of at least one diameter.

A radial disk turbine is often termed a Rushton Turbine. A modification, using half pipes
instead of flat blades, also know as a Smith Turbine, was introduced in the late 1980’s. The
Smith Turbine has a lower power number (about 25% less) than the Rushton impeller, and is
suitable for Reaction Rate Controlled applications at about 25% less HP/ 1000 gallons, since
it will handle more gas without flooding. However, the two styles produce about the same
mass transfer results at elevated power levels.

Most axial flow impellers are not suitable for gas dispersion because rising bubbles easily
disrupt the opposing downflow from the impeller. An exception is the wide blade hydrofoil.
The AH hydrofoil will handle much more gas than a Rushton at equal power, but as with the
Smith Turbine, there is no advantage in mass transfer rate at the elevated power levels. The
AH hydrofoil is suitable for Reaction Rate Controlled applications at about 35% less HP /
1000 gallon than a Rushton. The AH hydrofoil is also employed on multi-phase applications
where good blending and/or solids suspension is also a critical process requirement. At very
low gassing rates, e.g. gold leach tanks, the mid solidity (AM) hydrofoil is used as it can
effectively disperse a small amount of gas while ensuring suspension of the solids and good
tank turn-over.

AH HYDROFOIL RDC IMPELLER

RD IMPELLER AM HYDROFOIL

 Sizing Procedure
• Obtain the actual gas flow rate, QG, in cubic feet per minute for the pressure and
temperature inside the tank. Often, the customer will provide the flow rate going into the
tank at a different temperature and pressure than exists in the tank e.g. SCFM – flow rate
at standard conditions (20°C, 1.0 atm). This has to be converted to ACFM for the tank
conditions.

• Calculate the superficial gas velocity from the gas flow rate (ACFM).

• Calculate the required horsepower for the desired level of gas dispersion from the table
below – dispersion degree assumes water-like viscosity.

Power Required (BHP) at Gassed Impeller

Gas Mass Transfer Controlled
Velocity Reaction Rate System Moderate Mass Transfer
(fpm) (Minimal Dispersion) (Uniform Dispersion)
(Moderate Dispersion)

0.1 0.03 BHP / 1000 USG 0.08 BHP / 1000 USG 0.2 BHP / 1000 USG

0.2 0.06 BHP / 1000 USG 0.13 BHP / 1000 USG 0.3 BHP / 1000 USG

0.5 0.2 BHP / 1000 USG 0.4 BHP / 1000 USG 0.9 BHP / 1000 USG

1.0 0.3 BHP / 1000 USG 0.6 BHP / 1000 USG 1.3 BHP / 1000 USG

2.0 0.6 BHP / 1000 USG 1.2 BHP / 1000 USG 2.5 BHP / 1000 USG

5.0 1.2 BHP / 1000 USG 2.4 BHP / 1000 USG 4.8 BHP / 1000 USG

10 2.2 BHP / 1000 USG 4.3 BHP / 1000 USG 8.4 BHP / 1000 USG

20 4.1 BHP / 1000 USG 7.8 BHP / 1000 USG 15.0 BHP / 1000 USG

NOTES
• Table values based on a Rushton (6RD90) turbine at a D/T ratio of 0.3.
• To achieve Minimal Dispersion at a D/T ratio of 0.25, 25% MORE HP is required
• To achieve Minimal Dispersion at a D/T ratio of 0.35, 25% LESS HP is required
• Smith turbine requires 25% less power than shown to achieve Minimal Dispersion
• AH hydrofoils requires 35% less power than shown to achieve Minimal Dispersion

 • For the selected impeller style, determine impeller diameter based on the D/T range
detailed in the table below.

Impeller Style Typical D/T Range

RD 0.22 – 0.35

RDC 0.22 – 0.35

RBT 0.25 – 0.33

AH 0.30 – 0.40

• Select an initial impeller rotational speed. Note that the diameter and operating speed are
adjusted to meet the required horsepower while maintaining a proper D/T ratio.

• Calculate the Aeration number, NAe

• Refer to the chart Pg/Po vs. NAe (on Page 4.06) to obtain Gassed Power vs. Ungassed
Power for the chosen impeller style.

• Calculate the Froude number, NFr

• Calculate the Gas Expansion power, Pge

• Calculate the Flood Factor to determine the degree of gas dispersion beyond flooded and
therefore the degree of additional power remaining to accomplish other mixing jobs, i.e.
blending and/or solids suspension.

 Gassed / Un-Gassed Impeller BHP Factor
vs.
Aeration Number

1.2

1
Gassed BHP Factor - Pg/Po

0.8

0.6

0.4

0.2

0
0 0.01 0.02 0.03 0.04 0.05 0.06

Aeration Number - NAe

RD Impellers RDC Impellers AH Hydrofoils

 EQUATIONS

Superficial Gas Velocity (VG) – Average upward velocity of gas sparged into the tank.

QG
VG =
ATank
where : QG = actual gas flow rate (ACFM)
Atank = cross-sectional area of tank (ft2)

Aeration number (NAe) – Dimensionless number used in determining Pg/Po ratio and flood
factor. The Aeration number includes the effects of gassing rate, impeller rotational speed,
and impeller diameter.
QG
N Ae =
ND 3
where : QG = actual gas flow rate (ACFM)
N = impeller rotational speed (rpm)
D = impeller diameter (ft)

Gassed Power (Pg) – Power drawn by agitator when gas is introduced into the vessel. The
gas-liquid mixture surrounding the impeller has a lower specific gravity than the fluid alone,
and therefore the mixer draws less power.

Ungassed Power (Po) – power drawn by agitator when no gas is introduced into the vessel
(blending of fluid/slurry only).
SG ´ N P ´ D 5 ´ N 3
Po =
6.12 ´10 7

where : SG = specific gravity of the liquid

NP = impeller power number
D = impeller diameter (feet)
N = rotational speed (rpm)

 Gas Factor (Pg/Po) – Ratio of power draw in the gassed condition to power draw ungassed

Froude number (NFr) – Dimensionless number used in determining the flood factor. The
Froude number is the ratio of inertial forces to gravitational forces (for the impeller).
N 2D
N Fr =
g

where : N = impeller rotational speed (rpm)

D = impeller diameter (ft)
g = gravitational constant (ft/sec²)

Gas Expansion Horsepower (Pge) – The power of the gas sparged into the vessel.
V
Pge = VG ´
4000

where : VG = gas velocity (fpm)

V = equivalent batch volume (US gallons)

Flooding Factor – A value helping to quantify the level of gas dispersion in the vessel. In
theory, a flood factor of 1.0 represents the transition point where the system transforms from
Flooded to Minimal Dispersion. If the application also requires blending of the fluid and/or
suspension of solids there must be enough extra mixing energy to meet these requirements.
This normally means that a flooding factor > 2.0 is often required on these multi-phase
applications.
Pg N Fr
Flooding Factor = ´
Pge N Ae

where : Pg = gassed power (hp)

Pge = gas expansion horsepower (hp)
NFr = Froude number
NAe = Aeration number

 Hold-Up – Hold-up of the gas in the liquid is defined as:

Vg DZ
h= =
V Z

where : Vg = volume of gas in liquid (US gallons)

V = batch liquid volume (US gallons)
Z = ungassed liquid depth
DZ = increase in liquid level with gassing

For estimating holdup in an air-water system the following equation can be used:

h = 3.21(BHP / V )
0.47
(V )
g
0.65

where : BHP = impeller brake horspower (hp)

V = batch liquid volume (US gallons)
Vg = superficial gas velocity (ft/sec)

Gas Sparging Devices

Numerous devices are used to inject gas into a vessel including, single or multiple pipes,
sparge rings, plates and inverted cones. The sparging device affects the initial dispersion of
the gas, influencing the mass transfer rate i.e. a sparge ring with numerous small outlet
holes provides better initial dispersion than three open pipes delivering the same amount of
gas. In addition, the sparging device also affects the shaft and impeller loading of the mixer;
the better the initial dispersion, the less shock loading on the mixer.

Independent of the sparge type, it is normally preferable to introduce the gas below the
impeller at a circumference of 0.8 to 1.2 of the impeller diameter. When a central sparge
pipe is used, a disk type impeller (RD or RDC) is mandatory to ensure the gas is forced into
the high shear/high flow areas of the impeller for good dispersion.

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 Impeller Design
The following pages describe the most commonly available mixing impellers, the function of each
design and where the individual styles are most appropriately applied. The order of presentation is
generally from the highest power number (generally the highest shear) to the lowest power number
(generally the highest flow).

RD

This vertical flat blade, radial flow, disc-type

turbine is available as both a 4 and 6 blade
design, with the 6 bladed version being the
most common. The style is commonly referred
to as the Rushton impeller. This high shear
device is normally employed on gas dispersion
applications.

RDC

This impeller is similar to the Rushton turbine except

curved blades are substituted for the
vertical flat blades resulting in a lower power
number. Although it is more expensive than
the Rushton it is able to handle more gas
before flooding and does not experience as
great a power drop-off due to gas loading.
However at elevated power levels it produces
similar mass transfer as the Rushton design.

RBT

The Vertical Blade Turbine can be the impeller

of choice when very high torque is required for
blending applications at the expense of flow
efficiency. Other uses for this impeller include
high shear applications other than gas dispersion,
ie. Liquid-liquid emulsions, solids scrubbing or
where low level mixing requirements need an
impeller located close to the tank bottom.

RSB

The Swept Back or Retreat Curve Turbine is

the most flow efficient radial flow impeller. It is
used in flow sensitive (maximum pumping
desired) applications when pumping in the
radial direction is required. Typical applications
include plug flow break-up, heat transfer, low
level blending and low level solid suspension.

PBT

The Pitched Blade Turbine is more flow efficient

than the radial style impellers and produces more
fluid shear than the hydrofoil impellers. It is the
impeller of choice when both flow velocity and
fluid shear is required and/or when very high
mixing intensity is required when the use of a
hydrofoil would result in too high a tip speed or
operating speed. The most common configuration
is 4 blades pitched at 45º with the next most
common types being either 3 or 4 blades pitched
at 32º. The 32º variety can handle slightly higher
viscosity and is useful in low level mixing operations.
This style of impeller is the least expensive axial
flow impeller.

HP

The HP impeller is more flow efficient than a Pitched

Blade Turbine and therefore imparts less shear into
the fluid. The 4HP45 power number of 1.0 lies exactly
in the middle between the 4PBT45 and the 3AL39
which is indicative of its flow and shear characteristics.
It is normally used on small to medium size mixers as
a cost effective hydrofoil and where applicable should be
looked at first. In addition, the HP should be considered on
taller tank applications because the HP can invest the
same or greater torque into a fluid at lower speeds than
a AL impeller normally allowing longer shaft lengths.

AH Hydrofoil

The AH design is characterized by a very wide

blade and is the most flow efficient impeller
available for higher viscosity mixing (2500 to
75,000 cps). The AH is the impeller of choice
for coarse gas dispersion applications when
bottom flow velocities are also required, ie. gas
dispersion with solid suspension. The two most
common configurations are 3 blades mounted on
a 39º hub and 4 blades mounted on a 45º hub.
The 3 blade version is used for high viscosity
blending while the 4 blade design is for gas
dispersion. This style of hydrofoil is sometimes
referred to as a “high solidity” design.

AM Hydrofoil

The AM impeller (Np=0.35-0.40) with its slightly

wider blade than the AL design is useful on
applications where viscosities of 2000-5000 cps.
are encountered or when a small amount of gas
handling capability is required. They are commonly
applied to solid suspension applications which
have a relatively high percent solids (35-55)
particularly when solid size is small which sets
up an apparent viscosity in the slurry. This style
of hydrofoil is sometimes referred to as a “mid
solidity” design.

AL Hydrofoil

This style of hydrofoil is the most flow

efficient impeller for low viscosity (up to
2500 cps) blending applications. It is also
used on solid suspension mixing problems
where a relatively low percent solids will
be encountered (free settling applications).
The two most common configurations are 3
blades mounted on either a 45̊ hub or a 39̊
hub. This design has the narrowest blades
and therefore sometimes referred to as a
“low solidity” hydrofoil.

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 Baffle Sizing
Baffles are required in almost all mixing operations. The following chart shows the relationship of
baffle width to fluid viscosity and should be used as a guide for proper baffle selection in round tanks
with any combination of mixing impellers. The normal recommendation is for 4 baffles located at 90o -
more than 4 baffles gives relatively little increase in HP draw and virtually no change in the desired
flow pattern in the tank. Three baffles located at 120o, while not our normal recommendation, have
been used successfully provided the baffles are wider than normal - see chart below.

Without baffles, it is impossible to load the impellers properly in low viscosity mixtures because of
swirling and insufficient top to bottom movement which results in very poor mixing.

1/12 CHART IS FOR FOUR BAFFLE S

PER TANK. IF THREE BAFFLES
ARE TO BE USE D, W IDTHS
SHOULD BE 20% GREATER.
1/18

1/24

1/48

0 5000 10000 15000 20000

VISCOSITY (CPS)

The reason for a decreasing need for baffles, as the viscosity increases, is that high viscosity liquids
offer fluid flow resistance which produces less swirl and more vertical flow for the same power input as
equal amounts of low viscosity liquids.

Off-Wall Location

Ideally, baffles are to be mounted off the tank wall a distance equal to 1/6 of the baffle width. This is
necessary to minimize stagnant areas on the back side of the baffle, ensuring complete mixing in the
shortest possible time. It is possible to mount the baffles directly against the tank wall on low viscosity
(1-500 cps) applications and still have acceptable results. However, on heat transfer applications the
baffles should always be mounted off the tank wall.

In the higher viscosity ranges, it is apparent that the off-wall clearance of 1/6 baffle width can be quite
small. Therefore in cases where the fluid viscosity is 10,000 cps or greater the baffles should be
mounted 1 to 1.5" off the wall.

Baffle Height

Normally, baffles run the full straight side of the tank. For surface draw-down of light solids or gas
induction from the surface, the baffles should end 10-12" below the fluid surface. When baffles end
below the surface, an extended keyway should be provided for the upper impeller to allow for
adjustment that may be required to optimize surface vortexing.

Solid suspension applications which require low level mixing (impeller located relatively close to the
tank bottom) should have baffles terminate at a point level with the top of the impeller. This is to
induce a slight swirl to ensure the particles are in constant motion in the tank bottom.

Tanks with ASME or Semi-Ellipsoidal dished bottoms should have the baffles extend to the lower
tangent line of the tank.

Tanks with deep cone bottoms (cone angle over 20º) should have baffles extend into the cone as
shown in the sketch below. The baffle width should be 2/3 the width of the main baffles on the tank
straight sides. The distance “x” is ½ the impeller diameter.

Deep dished (spherical) tanks should have baffles extend into the bottom head to ensure good mixing
results in this region. In addition, if low level mixing is required in a semi-elliptical head these tanks
should also have the baffles extend into the lower head. Ideally, the baffle shape should conform to
head profile, however, straight baffles have been used with acceptable results. The baffle in this
portion of the tank should have the same geometry as for a cone bottom tank.

Baffles in Tanks Equipped with Coils

Helical coils installed in a tank for heat exchange purposes normally offer a very limited baffling effect
and therefore it is necessary to install baffles. The normal practice is to install coils with 1.5 to 2 tube
diameter spacing between each coil. With this spacing, baffles with standard geometry should be
mounted between the tank wall and the coils - the baffle is often used for coil support.

When two rows of coils are installed in a tank, standard baffles should be used as described above
and no baffle between the coil rows. Support for the inside row of coils can be arms extending from
the baffles but their area should be kept to a minimum.

Vertical tube bundles are sometimes used in tanks and in these cases, the tube bundle side area
should be considered as baffles. In most cases with vertical tube bundles, no further baffling is
required.

Tanks without Baffles

Occasionally an application will be encountered where baffles cannot be tolerated. In these cases it is
possible to achieve acceptable results by mounting the mixer off the tank centre to load the impeller(s)
and reduce swirl.

On tanks up to five feet in diameter, mounting the mixer 1/6 of the tank diameter off-centre will
normally give reasonable mixing. On larger tanks, 1/4 the tank diameter offset should be used.

Off-centre mounting causes larger than normal fluid forces on the mixer shaft and your selection
should be checked by the factory for proper shaft selection.

Baffles in Square or Rectangular Tanks

Baffles are normally NOT required in these tanks provided the application falls into one of the following
categories:

• Blending application with a mixing intensity level requirement of Mild or Moderate.

• Two or more mixers mounted in the same tank.
• Blending application with a viscosity of 250 cps or greater.

All other applications should have a minimum of 2 baffles @ 1800 - mounted on the short walls for
rectangular tanks.

Fluid Forces Acting on the Baffles

To determine the baffle thickness, a conservative method is to design the baffles assuming the full
torque developed is concentrated at a point directly opposite the impeller. The actual forces are
distributed over the entire length of the baffle with the highest concentration in the impeller region,
however, satisfactory data has never been developed to show the exact force distribution.

The following formula can be used to calculate maximum baffle point loading per baffle in a tank
equipped with 4 baffles:

56,800 × HP
FB = [lbs ]
2 N (T - B - 2 BC )
Where: HP = Motor Nameplate Horsepower
N = Impeller Speed
T = Tank Diameter (in.)
B = Baffle Width (in.)
Bc = Baffle Wall Clearance (in.)

With flat baffles and assuming that the force is applied midway between 2 baffle supports, the required
baffle thickness can be calculated as follows:

3FB L
BT =
2× B× S
Where : BT = Baffle Thickness (in.)
FB = Force on One Baffle - From Equation 1 (lbs.)
L = Spacing Between Baffle Supports (in.)
B = Baffle Width (in.)
S = Allowable Bending Stress for Steel = 5000 psi.

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Scale-Up

One of the most common uses of scale-up technology is to accurately predict mixer requirements in
the plant size vessel based on lab or pilot testing. In addition, smaller scale existing applications can
be used as a basis for mixer sizing in larger volumes. There are two ways to use scale-up to
determine the mixer size required for the new volume, these are:

1. Knowing the type of mixing duty (simple blending, dilute solid suspension, etc.) and details of
the process, the appropriate scale-up exponent is picked from the following table and then
applied to the scale-up equation.

2. Lab and bench mixing tests are completed and the scale-up exponent is calculated from the
test results. This exponent is then applied to the standard scale-up equation.

Common processes with established scale-up exponents are as follows:

Equal Blend Time

This is an unusual requirement and tends to predict the need for extremely large mixers in larger
vessels. Some fast chemical reactions with slower undesirable side reactions do require rapid blend
times which will limit the maximum volume for these applications which a reasonable sized mixer can
handle.

Vortex Action

This type of scale-up is called for when the critical mixing action is the formation of a surface vortex for
gas or dry solids induction. This also predicts very large mixers for larger volumes, in other words, it is
relatively easy to create a vortex in a small vessel and becomes significantly harder as the working
volume increases.

Dispersion

This is a common requirement for shear dependent applications. Gas-liquid dispersions and liquid-
liquid dispersions are common examples. Some heat transfer and chemical reactions also fall into this
category. These processes typically scale-up as equal power per unit volume.

Free Settling Solids

This scale-up rule applies provided the solids being suspended in the fluid have an unrestricted
settling rate - refer to TG3, Page 3.04 for details on Hindered vs. Free Settling applications. Free
settling generally occurs when the concentration of solids by weight is less than 25-30%. Larger
vessels require slightly more torque per unit volume and slightly less power per unit volume than
smaller vessels.

Equal Flow Velocity

This is a common requirement for processes where fluid velocities in a large tank are desired to be the
same as in the smaller tank. Most viscous blending applications can be scaled up this way, keeping in
mind that the blend time will increase approximately in proportion to the tank diameters. Most hindered
settling (>35% solids) applications also scale-up by this rule. Larger vessels require the same torque
per unit volume as smaller vessels.

TORQUE/VOLUME SCALE-UP POWER/VOLUME SCALE-UP

LOG-LOG PLOT LOG-LOG PLOT

X=2/3
X=2/3

X=1/6
X=1/3
TQ/V

X=0
P/V

X=2/9

X=-1/12
X=1/3

X=0
X=-1/3

VOLUME VOLUME

Typical Scale-Up Exponents

Torque/Volume Power/Volume
Application Exponent, x Application Exponent, x

Equal Blend Time 2/3 Equal Blend Time 2/3

Vortex Action 1/3 Vortex Action 1/6
Dispersion 2/9 Dispersion 0
Free Settling Solids 1/6 Free Settling Solids -1/12
Equal Flow Velocity 0 Equal Flow Velocity -1/3

 Scale-Up Exponents

x x
æ TQ ö æ TQ ö æ V2 ö æ P ö æ P ö æ V2 ö
çç ÷÷ = çç ÷÷ çç ÷÷ ç ÷ = ç ÷ çç ÷÷
è V ø 2 è V ø1 è V1 ø è V ø 2 è V ø1 è V1 ø

Both Torque per unit Volume and Power per unit Volume have been successfully used as scale-up
techniques. Torque per unit Volume tends to be constant for scale-up of Equal Flow Velocity
applications, common to many blending and hindered settling solid suspension mixing problems.
Power per unit Volume tends to be constant when the process requirement is dispersion, typically gas
dispersion. Torque per unit Volume is normally the preferred method as it is less sensitive to
geometric similarity and it predicts gearbox size directly.

Although the Torque per unit Volume method is less sensitive to geometric changes, it is very
desirable to hold geometric ratios as constant as possible. In particular these ratios are:

• D/T - Impeller Diameter / Tank Diameter

• Z/T - Liquid Height / Tank Diameter
• C/T - Impeller Diameter Bottom Clearance / Tank Diameter

In addition to maintaining geometric similarity, the same impeller style should be used throughout the
scale-up process.

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 Shaft Design
The process requirements determine the overall mixer size and configuration, ie. HP, RPM, number
and style of impeller(s) etc.; the next step is to design an appropriately sized shaft system. The
absorbed Horsepower of the impeller(s) creates torsional and bending stresses on the mixing shaft.
The torsional stress is due to the transmitted torque (BHP at the speed of rotation) and the bending
stress is due to the fluid hydraulic forces acting on the impeller(s).

Pure Torsional Stress

If a mixer shaft and impeller assembly had no fluid hydraulic forces acting at the impeller we would
only be concerned with torsional stress which is the torque transmitted by the shaft divided by its Polar
Section Modulus. The formula for Pure Torsional Stress is:

HP × 63025
T RPM é lbs ù
t= Q= êë in2 úû
Z' pd 3
16
Where: HP is motor HP
RPM is impeller speed
d is shaft diameter [in.]

Pure Bending Stress

If we were interested in determining the stress in the shaft due only to the unbalanced hydraulic forces
acting on the mixing impellers (ignoring torsional stress) it would be a matter of determining the
magnitude of these hydraulic forces and where along the shaft they were acting (impeller location).

The hydraulic forces, created by the action between the fluid and the impeller, produce side loads on
the shaft causing this tensile or bending stress. The fluid hydraulic force acting at an impeller is
random in both direction and magnitude, we therefore must calculate the maximum possible hydraulic
load to determine the shaft stress. The equation for hydraulic loading at an impeller is:

24000 ( HP ) (CF )
FH = [lbs.]
RPM ( D)
Where: HP is Impeller Power
CF is a Condition Factor based on impeller style and application (Typ. 1 to 3)
RPM is impeller speed
D is impeller diameter [in.]

After the hydraulic force is found at the impeller(s), the total Bending Moment can be calculated by
using the following:

M = {FH1 ( L1 )} + {FH 2 ( L2 )} + .....{FH N ( LN )} [in - lbs ]

Where: FH1, FH2 ... FHn are Fluid Hydraulic Forces at each Impeller [lbs.]
L1, L2 ... Ln are the distances from the lower gearbox bearing to the impeller [in.]

Finally the Pure Bending Stress can be calculated by dividing the total bending moment (M) by the
shaft rectangular section modulus.

M M é lbs ù
s= = êë in 2 úû
Z pd 3
32
Where: M is the Bending Moment calculated above [in.lbs.]
d is shaft diameter [in.]

Combined Stresses

When a mixer is operating the shaft is experiencing both bending and torsional stresses, therefore the
final step in shaft design is to calculate the combined stresses in the shaft. The combined torsional
stress can be found by using the following equation:

æ æ s ö2 ö é lbs ù
t max = ç ÷ +t ÷
ç
çè 2 ø
( )2
÷ êë in 2 úû
è ø
And the combined bending stress can be found by using:

æs ö æ æ s ö2 ö
s max = ç ÷+ ç ç ÷ + (t )2 ÷ é lbs ù
è2ø çè 2 ø ÷ êë in 2 úû
è ø

Critical Speed

If a shaft and impeller assembly were struck with a hammer, the assembly would begin to vibrate. The
vibratory mode with the lowest frequency is defined as the first natural frequency of the system, the
next highest is the second natural frequency and so on. Critical Speed is defined as the mixer
rotational speed (RPM) which coincides with its first natural frequency (Hz).

Rotating a mixer assembly at a rate equal to its natural frequency is like hitting it with a hammer.
However, unlike a hammer which provides a momentary influx of energy, the mixer motor continues to
pump energy into the vibrating assembly causing it to oscillate at higher and higher amplitudes until
failure occurs. We therefore must calculate the first natural frequency of each mixer assembly to
ensure we are not operating near this critical point.

The following equation can be used to determine the first natural frequency (NC) of a mixer with a
uniform solid shaft.

æd2 ö E
N C = 146.4çç 2 ÷÷
è L ø æç L + a ö÷ × æçW + 4.13We ö÷
B
è L ø è L ø

Where:
3 3
æL ö æL ö
We = W1 + W2 ç 2 ÷ + ... + WN ç N ÷
è Lø è L ø

And: d is the shaft diameter (in)

L shaft length from lower gearbox bearing (in)
L2 ,... LN is the distance from the lower gearbox bearing to the impeller (in)
a is the gearbox bearing span (in)
W1, W2, ... WN are impeller weights (lbs)
WB is the shaft weight (lbs/in3)
E is the Modulus of Elasticity (lbs/in2), ie. E=30,000,000 psi for steel.

Note: All calculations for critical speed assume that the mixer is rigidly supported.

Deflection

When a mixer is supplied with a shaft seal for closed tank applications or when tank internals
(heating coils, draft tube, limit ring, etc.) are in relatively close proximity of the mixer wet end, it is
necessary to check the shaft deflection due to hydraulic forces at the impeller(s).

The following equations can be used to check shaft deflection in the seal area or at the bottom of a
uniform solid shaft:

Deflection at seal:
æ FH L2 ö
Dy = çç ÷÷ × (2 La + 3LX - X 2 )
è 6EI ø
Deflection at end of shaft (X=L)

æ FH L2 ö pd 4
Dy = çç ÷÷ × (a + L ) where, I =
è 3EI ø 64

And: L shaft length from lower gearbox bearing (in)

a is the gearbox bearing span (in)
FH is the hydraulic force acting on the impeller (lbs)
E is the Modulus of Elasticity (lbs/in2), ie. E=30,000,000 psi for steel
d is the shaft diameter (in)
Îy is shaft deflection at point of interest (TIR is two times Îy)

Mixer Support Design Loads

The mixer support structure is to be designed so that dynamic angular deflection of drive is limited to
0.25 degrees in any direction.

Static Weight = Sum of Component Weights [lbs]

HP × 63025 × 2
Dynamic Torque = [In - lbs]
N
NI
Bending Moment = å (FH x × Lx × 2 ) [In - lbs ]
x =1

Where: D is Impeller Dia. in [In.]

N is Impeller Speed [RPM]
NI is the Number of Impellers
HP is Nameplate Horse Power
LX is distance from impeller to mounting surface [In.]
FHX is the fluid hydraulic force at each impeller (see Pg. 8.01) [lbs.]

Open Tank Mixer Support Structures

For purposes of use during preliminary investigations, information on practical support construction for
mixers mounted above open tanks is outlined here. Suggested beam sizes are rather conservative,
and apply for use with the highest output torque capacity of each drive – and at the longest agitator
shaft overhangs practical for each size. For maximum economy in a specific installation, it is
recommended that the Processor or Engineering Contractor apply his own beam support design
standards to the specific mixer that will be utilized.

Some degree of cross bracing between main beams always represents a sound engineering
approach. The user is encouraged to apply more sophisticated designs of cross bracing – particularly
with the larger tanks where cost of supports can become substantial. It is normal to apply floor plate
or grating between the main support beams which provides walkway access while providing additional
rigidity in the support structure. This information is intended as a guideline and does not relieve the
user of completely analysing the entire mounting system for each mixing application.

“BB” Dimension (inches)

Drive Size

HRF’s ST-10 ST-11 ST-12 MB-53 MB-54 MB-55 MB-56 MB-57 MB-58 MB-59 LH-9 LH-10

11 10 12 14 12 13 15 17 21 23 23 19 19

 Tank Diameter (inches)
Drive Size Beam Function
120 180 240 300 360

Main Support 6C10.5 8WF24 10WF33 12WF45 12WF79

HRF’s Drive Support 4C7.25 5C9.0 7C9.8 8C11.5 8C11.5

Cross Bracing 4C7.25 5C9.0 7C9.8 8C11.5 8C11.5

Main Support 6WF20 10WF25 10WF60 12WF72 12WF120

ST-10 Drive Support 4C7.25 7C9.8 7C9.8 8C11.5 8C11.5

Cross Bracing 4C7.25 7C9.8 7C9.8 8C11.5 8C11.5

Main Support 6WF25 10WF29 10WF60 12WF79 12WF133

ST-11
ST-12 Drive Support 4C7.25 7C9.8 7C9.8 8C11.5 8C11.5
MB-53
Cross Bracing 4C7.25 7C9.8 7C9.8 8C11.5 8C11.5

Main Support 8WF20 10WF33 12WF53 12WF92 14WF119

MB-54 Drive Support 5WF16 8C11.5 8C11.5 8C11.5 9C13.4

Cross Bracing 5C6.7 8C11.5 8C11.5 8C11.5 9C13.4

Main Support 8WF31 10WF45 12WF58 14WF87 14WF142

MB-55
Drive Support 5WF16 8C11.5 8C11.5 9C13.4 9C13.4
MB-56
Cross Bracing 5C9.0 8C11.5 8C11.5 9C13.4 9C13.4

Main Support 8WF35 10WF49 12WF72 14WF103 14WF167

MB-57 Drive Support 6WF15.5 6WF15.5 8WF31 10WF33 10WF33

Cross Bracing 6C13 6C13 8C11.5 10C15.3 10C15.3

Main Support 8WF40 10WF60 14WF68 14WF127 14WF202

MB-58
Drive Support 6WF15.5 6WF15.5 10WF33 10WF33 10WF33
MB-59
Cross Bracing 6C13 6C13 10C15.3 10C15.3 10C15.3

Main Support 10WF45 12WF58 14WF95 14WF167 14WF264

LH-9 Drive Support 8WF31 8WF31 10WF33 10WF33 10WF33

Cross Bracing 8C11.5 8C18.75 10C15.3 10C15.3 10C15.3

Main Support 10WF45 12WF58 14WF95 14WF167 14WF264

LH-10 Drive Support 8WF31 8WF31 10WF33 10WF33 10WF33

Cross Bracing 8C11.5 8C18.75 10C15.3 10C15.3 10C15.3