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specify precisely the right system configuration to best serve the total
Sentinel
Lancer Propeller
Mixing Mechanisms
Mixing is achieved by a number of different mechanisms, as
summarised in the following table. The most important mechanism will
vary for any given application, and a given process may rely on any or
all of these mechanisms.
In order to arrive at an optimum mixer design a detailed
understanding of the various mechanisms involved and their
importance in achieving the process result is required.
Convection
Macro-mixing
Laminar shear
Micro-mixing
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Induced by pumping action of the impeller, Fluid moves through the different parts of
vessel, preventing stratification.
Caused by turbulent flow a wide range of vortices. Smallest in the impeller region where
dissipation is the highest. Separates bulk of fluid into smaller elements.
Below the scale of macro mixing fluid elements are further dispersed by laminar shearing.
Elements are stretched, distorted and folded.
Final smallest scale mixing. Diffusion of reactants takes place and is driven only by
concentration gradient. Takes place on scale smaller than any eddy size.
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Nomenclature
Where:
D = Impeller Diameter
C = Impeller off Bottom
Clearance
N = Impeller speed
Z = liquid Depth
T = Vessel Diameter
click image to enlarge
Basic Mixing Applications
By far the most common of mixing applications are those which rely upon flow to achieve the required process result.
These applications are often referred to as, 'Flow Controlled Applications', and include such applications as Blending,
Solids Suspension and Heat Transfer. Whilst it is not possible to cover all possible applications these can be assigned to
Application Classes. Some of the more common application classes are considered here.
Blending / Homogenisation of Miscible Liquids
Blending involves the mixing of two or more miscible liquids to achieve a uniform mixture throughout the entire
volume of the tank, usually within a specified period of time. It is important to note that the blending of liquids having
widely varying density and/or viscosity requires special attention and may require longer blend times to ensure the
liquids are mixed.
Typical Blending Applications
Chemical Reactions
Polymerization
Simple blending of miscible
fluids
Make-Up Tanks
Storage, Feed, or Holding
Tanks
Blend Time
Density
Volume (s)
Solids Suspension
The suspension of solid particles in a liquid is achieved by providing a flow field with sufficient velocity to lift the solids
to the required level within the tank. Careful consideration should be given to the degree to which the solids are
suspended as this has a significant effect on the required mixer power.
Principally there are five degrees
of suspension as follows:
SG of Solid
Slurry viscosity
Heat Transfer
There are many applications that either exothermic, endothermic or simply require heating or cooling. This requires
heat to be transported to or from the process fluid via a heat transfer surface usually in the form of coils or a vessel
jacket. Mixers are used to improve heat transfer by effecting the mixer side film coefficient. It should however be
recognised that this represents only part of the overall heat transfer equation and that variables not controlled by the
mixer may have a much greater influence on the overall heat transfer.
Typical Heat Transfer
Applications
Chemical Reactions
Fermentations
Polymerizations
Esterifications
Hydrogenations
medium
Density
Bulk Temperature
Blending Intensity
Mild
Non critical blending operations, Storage
or Holding Tanks, Feed Tanks, Flocculation
Long Blend Time
Surface barely in motion
Viscosity Ratio < 10
Moderate
Adequate for most mixing duties,
Make-up tanks, Reaction tanks, Blend tanks
Moderate blend Time
Surface in strong motion
Viscosity Ratio < 50
Vigorous
Critical mixing operations
Reactors
Most Heat Transfer
pH control
Rapid Blend Time Surface in rolling
boil Viscosity Ratio < 500
Violent
Special critical applications
Reactors
Critical Heat Transfer
High Shear requirements
Polymerizers
Nearly instantaneous blending
Surface boiling splashing and vortexing
Viscosity Ratio < 10,000