Chapter 16: Blending and Agitation Rules of Thumb for Chemical Engineers, 5th Edition by Stephen Hall

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Problem Statement: Calculate the blend time for a mixer with one or two impellers

Inputs Fluid Mixing purpose Degree of agitation Fluid density Fluid viscosity

SI Units

US Units

ro mu

kg/m3 kg/m-s

1000 0.001

lb/ft3 lb/ft-s

62.43 0.000672

Tank Geometry T Diameter H Filled Height Impeller Lowest impeller Type Diameter Projected blade height Distance to mounting flange Distance to lower bearing Distance off bottom Second impeller Type Diameter Projected blade height Distance to mounting flange Speed

m m

1.5 1.8

ft ft

4.92126 5.905512

D1 W1 L1 L' C

m m m m m

0.45 0.1 1.6 1.3 0.7

ft ft ft ft ft

1.476378 0.328084 5.249344 4.265092 2.296588

D2 W2 L2 N Baffles B

m m m rps 5

ft ft ft rps

0 0 0 5

Number of baffles Baffle width Space between baffle and wall

m m

4 0.15 0.03

ft ft

4 0.492126 0.098425

Data Lookup and Calculations Nre Reynolds number gc Conversion factor NQ Pumping number Q Pumping capacity NP Power number - lower impeller

m3/s

11,250,000 1 0.8 0.3645 5

ft3/s

11248372 32.17 0.8 12.8722 6

Power

11533.00781

ft-lbf/s hp

10209.19 18.56216 0 0 10209.19 18.56216

NP P P

Power number - upper impeller Power Total power (assume additive)

W W

0 0 11533.00781

ft-lbf/s ft-lbf/s hp

Mixing zone calculation, Np^(1/3) * Nre Mixing zone Theta95 Mixing time, 95% uniformity Desired mixing uniformity Adjusted mixing time Volume Turnovers, 95% uniformity s

19237229.4 Turbulent 8 99% 12.1 3.180862562 0.90 ft3

20439649 Turbulent 7 99% 11.4 112.3311 0.85

s m3

Problem Statement: Calculate power and blend time for a helical ribbon impeller working in the laminar flow range

Inputs Fluid ro mu Mixing purpose Fluid density Fluid viscosity kg/m3 kg/m-s

SI Units Blend 1000 100

US Units

lb/ft3 lb/ft-s

62.43 67.20882

Tank Geometry T Diameter H Filled Height Helical Ribbon Geometry D Diameter h Overall height of impeller p Pitch (height of one turn) w Blade width nb Number of blades N gc Speed Conversion factor

m m

3 3.5

ft ft

9.84252 11.48294

m m m m

2.85 3.5 0.5 0.285 2 0.1 1

ft ft ft ft

9.350394 11.48294 1.64042 0.935039 2 0.1 32.17

rps

rps

Calculations c wall clearance clearance % of tank diameter Kp P Power factor for helical ribbon Power

0.075 2.5% 807.1066 18683.81

ft

0.246063

ft-lb/s hp

807.1066 13784.65 25.063 109.5456

Theta

Blend time

109.5456

Problem Statement: Estimate the settling velocity of solids in liquid

Inputs Solids ps dn Liquid p u v Descriptive density nominal diameter solids concentration in slurry density dynamic viscosity kinematic viscosity kg/m3 mm wt % kg/m3 Pa-s cSt

SI Units Spheres 1,100 1.0 55% 1,000 0.0010 1.0

US Units Spheres 68.53 0.039 55% 62.30 1.0 1.0

lb/ft3 in wt % lb/ft3 cP cSt

Other g

gravitational acceleration

m/s2

9.80

ft/s2

32.17

Calculations and Results s specific gravity, solids A formula coefficient A B formula coefficient B S* dimensionless particle parameter W* dimensionless settling velocity terminal settling velocity correction factor ws settling velocity

cm/s

1.10 0.79 4.61 7.83 0.72 2.26 1.85 4.19

ft/min

1.10 0.79 4.61 7.83 0.72 4.46 1.85 8.25

Data Coefficients for Equation Crushed Natural Sediment Well-Rounded Spheres Correction for Solids Concentration

A 0.995 0.954 0.89 0.794 Solids% 0

B 5.211 5.121 4.974 4.606 Factor 0.75

2 5 10 15 20 25 30 35 40 45 50

0.8 0.84 0.91 1 1.1 1.2 1.3 1.42 1.55 1.7 1.85

Result

Problem Statement: Calculate the ungassed and gassed power required in an agitated vessel designed for gas dispersion

Inputs Geometry and Parameters T Tank diameter D Impeller diameter Impeller speed NP Power number Liquid H pL uL Gas Gas flow rate, actual Other g gc

SI Units m m rpm 1.30 0.52 42 5.0 ft ft rpm

US Units 4.27 1.71 42 5.0

Liquid height Density, liquid Viscosity, liquid

m kg/m3 Pa-s

3.77 1,000 0.0010

ft lb/ft3 lb/ft-s

12.37 62.3 0.00067

am3/h

14

acfm

Gravitational acceleration Conversion factor

m/s2 m/s2

9.81 1.00

ft/s2 ft/s2

32.17 32.17

Calculations A Tank cross-section V Volume v Superficial gas velocity QG N NFl NFr D/T Gas flow rate, actual Impeller speed Gas Flow Number Impeller Froude Number Impeller ratio

m2 m3 m/s m3/s rps

1.33 5.00 0.003 0.004 0.70 0.040 0.03 0.40

ft2 ft3 ft/s ft3/s rps

14.29 176.7 0.010 0.14 0.70 0.040 0.03 0.40

Gas Dispersion Regime

No discernable action Flooding

No discernable action Flooding

RPD Nre

Gas Flow number at transition RPD at transition Relative Power Demand Reynolds Number

0.04 0.86 0.85

0.04 0.86 0.85

P pG

Power, ungassed Power, gassed

W W

65 56

hp hp

0.09 0.07

Data

Results

N Regenerate Power 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460

Regime 49 No discernable actionFlooding 152 360 713 1,255 2,025 3,067 Recirculating 4,421 Recirculating 6,131 Recirculating 8,237 Recirculating 10,782 Recirculating 13,808 Recirculating 17,358 Recirculating 21,472 Recirculating 26,194 Recirculating 31,565 Recirculating 37,628 Recirculating 44,425 Recirculating 51,998 Recirculating 60,388 Recirculating 69,639 Recirculating 79,792 Recirculating

No discernable action

100,000

10,000 Ungassed Power, W

1,000

100

10 10 100 Impeller Speed, rpm

1000

Problem Statement: Calculate shaft diameter, torque, and first critical speed, for up to 3 identical impellers on one shaft. Assume that power is equally distributed among the impellers.

Inputs Impellers D Diameter Number of impellers Np Power Number fH Hydraulic service factor Shaft Np Speed L Shaft length from bottom bearing Sb Bearing span, Sb Distance between impellers Modulus of elasticity Shaft density Allowable shear stress Allowable tensile stress Mixture ro Density of mixed liquid P Power, total Intermediate Calculations Geometry and Power - impeller-specific Shaft length, top impeller Shaft length, middle impeller Shaft length, bottom impeller Power per impeller Weight of blades, per impeller hydrofoil 4-blade PBT

SI Units m 0.457 1 6.0 1.0 5.00 1.30 0.30 1.97E+11 8,027 4.10E+07 6.90E+07 1,000 11,533 in

US Units

rps m m m N/m2 kg/m3 N/m2 N/m2 kg/m3 W

rpm in in in psi lb/in3 psi psi lb/in3 hp

m m m W kg kg

NA NA 1.30 11,533 5.56 4.30

in in in hp lb lb

Calculations Torque Bending moment (maximum) Shaft diameter Based on shear Based on tensile Selected shaft diameter Weight of hub

N-m N-m

477 314

in-lbf in-lbf

m mm m mm mm

0.04 41.39 0.04 40.26 50

in mm in mm in

Read from chart Total weight for each impeller with hub hydrofoil W 4-blade PBT Equivalent weight, not including shaft We hydrofoil 4-blade PBT Natural frequency - First Critical Speed hydrofoil 4-blade PBT

kg

9.0

lb

kg kg

14.56 13.30

lb lb

kg kg

14.56 13.30

lb lb

rps rps

9.09 9.39

rpm rpm

Data Conversion factors for blade weight formula hydrofoil 4-blade PBT

0.14 0.084

350

140

300

120

250

100

Mass of Hub, lbm

Mass of Hub, kg

200

80

Hydrofoil 150
4-Blade PBT

60

100

40

50

20

0 0 2 4 6 8

0 0

50

20

0 0 2 4 6 8

0 0

Shaft Diameter, in

Sh

llers on one

US Units 18.0 1 6.0 1.0 300.0 51.0 12.0 2.86E+07 0.29 6,000 10,000 0.036 15.48

NA NA 51.0 15.48 12.3 9.5

3,252 2,778

1.54 39.04 1.53 38.90 2.0

20.0

32.27 29.50

32.27 29.50

559.95 578.47

Results

0.5 0.3

140

120

100

Mass of Hub, kg

80

Hydrofoil 60
4-Blade PBT

40

20

0 0 50 100 150 200

20

0 0 50 100 150 200

Shaft Diameter, mm