Agitation and Mixing of Liquids

What is Agitation and Mixing?

Agitation refers to the induced motion of material in a

specified way.

Mixing is random distribution, into and through one another, of

two or more initially separate phases.

Agitation = Mixing ---?

What is Agitation and Mixing?

Agitation refers to the induced motion of material in a specified

way.
Agitation refers to forcing a fluid by mechanical means to flow in
a circulatory or other pattern inside a vessel.
Mixing is random distribution, into and through one another, of two
or more initially separate phases.
Mixing usually implies the taking of two or more separate
phases, such as a fluid and a powdered solid or two fluids, and
causing them to be randomly distributed through one another.
Objective: Agitation is a process that involves mixing products to
obtain a homogeneous solution (reducing non-uniformities such as
Concentration, temperature and other properties).

Purpose of Agitation
1. Blending of two miscible liquids, such as ethyl alcohol
and water.
2. Dissolving solids in liquids, such as salt in water.
3. Dispersing a gas in a liquid as fine bubbles,
- such as oxygen from air in a suspension of
microorganisms for fermentation or for the activated
sludge process in waste treatment.
4. Suspending of fine solid particles in a liquid,
- in the catalytic hydrogenation of a liquid, solid
catalyst particles and hydrogen bubbles are dispersed
in the liquid.
5. Agitation of the fluid to increase heat transfer between
the fluid and a coil or jacket in the vessel wall.

Method for mixing

Mechanical mixing (rotating, vibrating)

Pipeline mixing( turbulent flow, static mixer)

Method for mixing/pipeline mixing

Mechanism of mixing for liquids

Liquid-liquid mixing is the formation of homogenous
system by the application of shear.
Mechanism of mixing:
The mechanism of mixing can be classified into four
classes.
1. Bulk transport
2. Turbulent
3. Laminar mixing
4. Molecular diffusion

Bulk transport:
Movement of a large portion of a material from one location
to another location in a given system.
For this rotating blades and paddles are used.
Turbulent:
Mixing due to turbulent flow, which results in random
fluctuation of the fluid velocity at any given point within the
system.
Laminar mixing:
Mixing of two dissimilar liquids through laminar flow
Molecular diffusion:
Mixing at molecular level in which molecules diffuse due to
thermal motion.

Agitated vessel for liquid-liquid mixing/mechanical

The apparatus consist a container (tank),usually
cylindrical form and a mixing device. A mixing
device is called impeller,
which is mounted with the help of shaft. The
shaft is driven by a motor.
Tank:
- Made up of stainless steel
- Top of tank may be open or closed
- Size depends on nature of agitation methods
- Diameter to Liquid height ratio = 1:1
- Tank bottom is rounded(not flat)
- Baffles(to suppress the vortex formation)
- Coils
- Jackets
- Temperature measuring device
- Mixing Device : Impeller(which supply energy =
shear force)
- Outlet

Classification of Impeller Agitators

1. Paddle Type
2. Turbine Type
3. Propeller Type

Paddles
Example

Simple Paddle

Turbines

Curved Blade

Standard 3- Blade

Size

Diameter of paddle
is 50 -80% of the
inside diameter of
vessel

Uses

Suitable for:
Suitable for:
Suitable for:
mixing low viscosity mixing viscous
Mixing heavy susps.,
liquids.
liquids, thin pastes mixing of thin liquids
Dissolution of solids.
and emulsions.

Rotation
speed
Flow type

Diameter of turbine
is 30-50% of the
inside diameter of
vessel.

Propellers

Diameter of propeller
is much smaller in
diameter than
paddles or turbines

20 - 120 r.p.m.
(low speed)

120 - 200 r.p.m.

(moderate speed)

400 1750 r.p.m.

(high speed )

Tangential & radial

Tangential & radial

Tangential & axial

Flow patterns

Flow pattern of the impeller mixers depends on:

1- liquid properties.
2- Type of impeller.
3- Size of the mixing tank.
4- Presence of baffles and agitators.
Flow
1.
2.
3.

patterns
Tangential (rotational) flow
Radial flow
Axial or longitudinal flow:

Flow patterns

1.Tangential(rotational)
flow:
The liquid follows a
circular path around the
shaft.
It is the least effective
type of flow

2.Radial flow:
The liquid discharges from the impeller at a
right angle to its shaft.
Occurs when the centrifugal force produced
by the impeller > liquid resistance to flow due
to viscosity.
Centrifugal force depends on diameter and
speed of impeller.
3. Axial or longitudinal flow:
In cylindrical tanks, radial flow gives axial
flow due to reaction at the wall of the tank.
The liquid discharges parallel to the shaft,
either from:
surface bottom or bottom surface.
Axial flow is necessary for liquid containing
suspended solids.

If rotational flow predominates a vortex.

Baffles and Vortexing

Baffled tank:
No vortex

Unbaffled tank:
Vortex

Vortex formation
The tangential flow predominates when the shaft of the impeller is
vertical & centrally located in the tank.
Vortex is created at the liquid surface when the liquid swirls around
the vessel with little or no intermingling.
As velocity is increased, the vortex is increased.
Disadvantages of vortex:
Bad mixing due to swirling of the liquid layers.
Centrifugal force will throw the suspended particles towards the wall
of tank then downward to the bottom.
Air is drawn into the mixed material which causes decomposition of
oxidizable substances and foaming of others.

Suppression of vortex
Baffles
Produce resistance in liquid flow and improve blending
prevent vortex formation and convert tangential
(rotational) flow into axial (vertical) flow
Baffles are always used in turbulent flow systems
Baffles are not used in laminar flow
Typically four baffles are used (occasionally three) in fully
baffled tanks
A gap between the baffles and the wall (25mm) is
introduced to prevent stagnation behind the baffles and
accumulation of material
Width of baffle: 1/10th or 1/12th of tank diameter
Height: Higher than liquid height

Baffles and Vortexing

Examples of Radial Flow Impellers

After Tatterson, 1991

Examples of Radial Flow Impellers

Disk Turbine (Rushton Turbine)

Flow Generated by Radial Impellers

Flow Generated by a Radial Impeller in a Stirred Tank

After Tatterson, 1991

Examples of Axial Flow Impellers

After Tatterson, 1991

Flow Generated by an Axial Impeller in a Stirred Tank

After Tatterson, 1991

Power Consumption
The power dissipated (or consumed) by the
impeller, P, is one of the most important
variables to describe the performance of an
impeller in a tank
P is a function of all the geometric and physical
variables of the system
Dimensional analysis can be used to establish a
relationship between P and the independent
variables

Experimental Determination of Power Consumption

The power dissipated by various impellers under
different conditions has been experimentally
obtained by many investigators
Power data are available in the literature (as nondimensional Power Numbers)

Experimental Determination of Power Consumption

The total power dissipation in a system is given
by:
If one needs to know Pimpeller, Ptotal and all other
power dissipation sources must be known under
the dynamic conditions in which the impeller
operates
This can be quite difficult

Experimental Determination of Power Consumption

A number of methods have been used to measure
the power dissipated by impellers including:
electric measurements
dynamometers (coupled to the motor or the
tank)
strain gages and torquemeters
calorimetric measurements

Example of Strain Gage System for Power

Measurement

Power Dissipation
For the case in which a number of geometric
variables have been defined (e.g., tank shape, tank
bottom, impeller type, baffle position, etc.) the
dependence between P and the other variables can
be written as:

Power Dissipation
Using dimensional analysis (Buckingham pi theorem)
the previous equation can be rewritten in nondimensional terms, as:

Power Number, NP (also referred to as Po or Ne)

The impeller Power Number, Np (also called Po, or
the Newton number, Ne) is a non-dimensional
variable defined as: (analogues to friction factor or
drag coefficient)

If English units are used then:

Power and Power Number

The power consumed by an impeller and the Power
Number are related to each other via the equation:

where Np is a function of the impeller type and the

geometric and dynamic characteristic of the system

Impeller Reynolds Number

The impeller Reynolds number, Re, defined as:

is a product of the non-dimensional analysis. Impeller

tip speed equals DN
Compare this Re with the Reynolds number for a
pipe:

Impeller Reynolds Number

As usual, a physical interpretation can be associated
with the impeller Reynolds number, Re.
Accordingly:

Froude Number
Another non-dimensional number arising from the
non-dimensional analysis is the Froude number, Fr,
defined as:

Froude Number
It can be shown that the Froude number has the
following physical interpretation:

Power Equation
The power equation can be rewritten as:

i.e.:

Geometrical Similarity
Two systems are geometrically similar if all
corresponding dimensional ratios are the same in both
systems

1.5 H
H
1.5 Cb

Cb
D

1.5 D

1.5 T

Geometrical Similarity
For geometrically similar systems:

Power Equation for Geometrically Similar Systems

For geometrically similar (including same type of
impeller) stirred tanks and impeller all geometric
ratios are the same
Hence, NP does not change with scale between
tanks:

Power Equation for Baffled, Geometrically Similar

Systems
When baffles are present, no vortex occurs, i.e., the
gravitational forces become unimportant, and the
Power Number becomes independent of Fr:

Typical Power Curve for Impellers in Baffled Tanks

Power Curve:
Laminar Flow Regime
For Re<10 the flow in a baffled tank is laminar
Theoretical and experimental evidence shows that:

i.e.:

Power Curve:
Laminar Flow Regime
In the laminar flow region the power dissipated
by an impeller is given by:

where k is a proportionality constant that

depends on:
type of impeller
geometry ratios for the system

Power Dissipation in the

Laminar Flow Regime
In

the laminar regime power dissipation is:

independent of the density of the liquid
directly proportional to the viscosity
strongly affected by the agitation speed (PN2)
strongly affected by the impeller diameter
(PD3)

Power Curve:
Transitional Flow Regime
For ~10<Re<~10,000 the flow regime cannot be
well characterized as either fully laminar or fully
turbulent
Depending on the type of impeller NP may decrease
with Re or decrease and then increase with Re
before entering the turbulent flow regime

Power Curve:
Turbulent Flow Regime
At high Reynolds numbers (Re>10,000) the flow in a
baffled tank is turbulent
Theoretical and experimental evidence shows that
NP is independent of Re:

i.e.:

Power Curve:
Turbulent Flow Regime
In the turbulent flow region the power dissipated by
an impeller is given by:

where k is a proportionality constant equal to NPT, the

asymptotic value of NP that depends on:
type of impeller
geometry ratios for the system

Power Dissipation in the Turbulent Flow Regime

In

turbulent regime, power dissipation is:

independent of viscosity
directly proportional to the density of the liquid
very strongly affected by the agitation speed
(PN3)
extremely sensitive to the impeller diameter
(PD5)

Sensitivity of Power Dissipation

In the turbulent regime P is very sensitive to N and
D
Examples:
a 10% increase in agitation speed, N increases
the power dissipated by 33%
a 20% increase in N increases P by 73%
a 10% increase in impeller diameter, D increases
the power dissipated by 61%
a 20% increase in D, increases P by 148%

Power Number Curves for Various Impellers

After Bates et al., Ind. Eng. Chem. Proc. Des. Devel. 1963

Power Number Curves for 45 Pitched-Blade Turbines

(4-Blades) and HE-3 Impeller

After K. Myers and R. J. Wilkens, Personal Communication

Equation for Power Number Curves

An equation for Power Number as a function of Re
has been proposed:

where A, B, and C are coefficients that depend on

the type of impeller.

After John Smith, Unpublished Data

Coefficients in Equation for Power Number Curves

Power and Torque

The power drawn by an impeller, P, and the torque,

, required by the same impeller rotating at N are
related to each other by the following equation:

Important Mixing Operating and Scale-up Parameters

Traditionally, mixing processes have been scaled

up and operated by maintaining constant one the
following parameters:
Power per unit liquid volume in the tank, P/V,
or per unit liquid mass, P/V
Torque per unit liquid volume in the tank, /V,
or per unit liquid mass, /V

Power per Unit Volume

The power dissipated by the impeller per unit liquid
volume in the tank:
is one of the most important mixing parameters used
in scale up of mixing processes
The units for P/V are W/L, kW/m3 or hp/1000 gal

Power per Unit Mass

The power dissipated by the impeller per unit liquid
mass in the tank, :

is an alternative to the use of P/V (since the only

difference is the presence of )
is also widely used for scale-up
The units for are m2/s3

Power per Unit Volume

Substituting for P and V gives:

Power per Unit Volume at Different Scales

The ratio of P/V at two different scales is:

Power per Unit Volume at Different Scales

For geometrically similar systems:

and the P/V ratio becomes:

Scale-up Based on Constant Power per Unit Volume

(P/V)
If P/V is kept constant during scale-up of
geometrically similar systems:

Tip Speed and Torque per Unit Volume

For geometrically similar systems (for which D
T) in fully turbulent regimes, or for the same
system at different agitation speeds, if the torque
per unit volume, /V, is kept constant, then:

Tip Speed and Torque per Unit Volume

Simplifying:

i.e., keeping constant the tip speed is equivalent to

keeping /V constant, provided that the geometry of
the systems is similar and the flow is fully turbulent

Flow Number (or Pumping Number) NQ

In order to make the impeller discharge flow rate
non-dimensional one can define the Flow Number,
or Pumping Number, NQ:

Relationship Between Power and Flow

For a fixed impeller geometry it is:

i.e.:

Variation of Flow and Power Dissipation

Most impellers have flow numbers in the relatively
narrow range of 0.4-0.9 (typically 0.5-0.8), i.e.,
their ability to pump is of the same order of
magnitude
The same impellers have power numbers ranging
between 0.25 and 6, a much wider range

Circulation Time
One can define the circulation time, tcirc, as:

tcirc is a measure of how long it takes the impeller to

pump the same volume of liquid as that contained in
the tank (V=Qtcirc)

Blend Time
(Mixing Time)

If a miscible tracer is added to a homogenous

liquid in an agitated tank the local concentration
(measured with a detector) fluctuates with time
The amplitude of the concentration fluctuations
will decrease with time
Eventually the tracer concentration will become
completely uniform in the tank

Blend Time
(Mixing Time)

Blend Time (also referred to as Mixing Time) is

the time it takes the tracer-liquid system to reach
a desired (and pre-defined) level of uniformity

Blend Time Facts

Blend time and the achievement of a homogeneous

state can be critical in some operations (e.g., fast
chemical reactions)
In any real mixing tank, blend time is never zero
Homogeneous phases do not mix instantaneously!

Experimental Determination of Blend Time

Tracer

Sensor

Concentration Fluctuations at Sensor and Experimental

Blend Time

C
C90%
CFinal

t
Piero M. Armenante

ChE702

t90%

Blend Time and

Non-Uniformity
The level of non-uniformity (or unmixedeness) X is
defined as:

where Co and CFinal are the initial and final tracer

concentrations in the liquid
Before the tracer addition (t=0) C=Co and X=1; for
t, C=CFinal and X=0

Piero M. Armenante

ChE702

Liquid-Liquid dispersions The Weber number (We) is the

most important variable in controlling the drop size of the
dispersed phase. The Weber number can be expressed in
many ways depending on available data and units. For our
purposes the following equation applies: - In general the
Weber number expresses the ratio between inertial
forces trying to disperse the phases, to the interfacial
forces trying to keep them distinct. At a given viscosity
ratio, the drop size therefore decreases as the Weber
number increases