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The first thing to keep in mind is proper positioning of the agitator with respect to the
vessel geometry. If not, it is like placing your General Manager in Gang Man’s position.
Performance is liable to fail.
The general thumb-rule in any mixing problem is to determine the amount of energy or
power required to perform the operation; then selecting the most efficient method of applying
this energy in terms of low a> first cost, b> operating cost & c> maintenance cost. The major
steps in selecting a mixer from the process standpoint are as follows.
1 Definition of the problem.
2 Description of materials to be mixed.
3 The mixing cycle.
4 Classification towards purpose.
A clear picture what is to be attained. E.g. to make up and hold in uniform suspension
10% slurry of hydrated lime or to dissolve 30 Kgs. of sugar in 50 liters. water in 5 minutes time.
Complete physical properties of each ingredient should be known, including sp.gr., initial
and final viscosities, easiness of miscibility, etc.
Easiest of agitating applications and normally axial turbine or hydrofoil impellers are
preferred. Jet mixing by recirculation with an ordinary pump is equally good at lower cost.
Dissolving
In dissolving, we want provision of high flow rate and low shear past the solid surface.
Unless the solid is polymeric or sticky or viscous in nature, it is an easy operation. Data
solicited are solid percentage, physical characteristics with interim changes, temp,
solubility and permissible dissolving time.
Heat exchange.
Used to speed up heat transfer by forced convection. Apparently simple but for critical
applications, following data helps.
A Tank dimensions and details of jacket and coils, preferably G.A.drawing.
B Heat transfer co-efficients.
C Specific heats and thermal conductivities.
D Temp. of batch at start and end of cycle.
E Temp. – Viscosity curve of components.
F Whether solid suspension is included.
Emulsification.
Imparting a high power to break the molecular chains and to form the oil-water emulsion
with a non-ionic surfactant. Other applications are mainly in paints & lubricants sector.
Some emulsion may be steady for years and some break within minutes. Static mixers are
preferred than agitators for high instantaneous power resulting better emulsion but
washing pump & pipeline is problematic.
Solids suspension.
It is simple physical (like mixing) operation but power consumption varies greatly on
purpose e.g. a> complete motion of solids, b> complete suspension of solids, c> complete
uniformity. Power req. is in ratio of 1: 2: 5 for said operations.
Chemical reaction.
This is normally a continuous counter- current (fluidized bed) process like solid
suspension involving water to be well mixed up with other ingredients and the
ingredients separates out by gravity separation. Usually of interest for mining people.
Gas is impregnated from bottom as small bubbles and intimately distributed throughout
the liquid usually resulting a chemical reaction. Generally curved vane impeller or
multiple turbines are preferred with high speed. Fully baffled tanks should be tall and
narrow in construction. Pressurized chamber accelerates the process. A better way is by
static mixer employing a liquid pump and a pressurized semi- permeable solid wall to
impregnate gas under pressure.
Crystallization
As like fan (for air handling) or hydel power turbines, much research has been conducted
towards agitator impeller design and it is a very wide subject with much more further scope to
research and improve. Impeller is designed mainly keeping in mind the purpose or application
and sometimes custom built.
WHERE
P= BREAK HORSE POWER (H.P.)
K= A CONSTANT VARIES GREATLY FROM 0.3 UPTO 8 AND IS DEPENDENT
MAINLY ON BLADE GEOMETRY, TANK DIMENSIONS, BAFFLES, PHYSICAL
FLUID CHARACTERISTICS, ETC. TERMED AS THE IMPELLER NUMBER.
NS= NO. OF IMPELLERS.
S.G. =SP.GR. OF THE LIQUID.
N= ROTATIONAL SPEED RPM.
D= IMPELLER DIAMETER IN METER.
Considering gear efficiency and motor margin, motor power is determined.
Q= K*N*D3.
WHERE,
Q= FLOW RATE IN CUBIC METER PER MINUTE.
K= PUMPING NUMBER MAX. 0.7 (FOR HIGH FLOW & LOW SHEAR) AND MIN.
0.01(FOR LOW FLOW & HIGH SHEAR).
N= RPM.
D= IMP. DIA IN MTRS.
The agitator price is somewhat very little in comparison to what a process would gain and
deserves from a reasonably good design.
Pilot plants do come and go but the commercial plant determines the profit percentage. It
is always suggestable to go for much in-depth of pilot plant studies before arriving at the big risk
time.
Furthermore, in case of any doubt, checks and cross checks from different agencies are
likely to be obtained and it is available at reasonable cost. Designer should have adequate
experience in the proper application you are trying to achieve.
In case you have any quarries/ suggestions, I would be glad to share our knowledge.
DATA USUALLY REQUIRED FOR PROPER DESIGN.
1 Purpose of agitation.
2 Mixing cycle.
3 Foaming tendency
4 Materials to be mixed with individual physical characters and their
quantities.
5 Tank dimensions preferably with sketch.
6 Duty hours.
7 Electrical: 1 ph. Or 3 ph., flp or not etc.
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There is no perfect design and I strive to provide you low cost agitator as per best of my
knowledge to suit your purpose and to fetch gold both for you and me.
With the above notes, please do not get agitated if I ask for your valued order with little
knowledge and no experience of my own as on 07-01-2014.