Mixing Process

• Mixing is an important Unit Operation (physical process) widely used in manufacturing.

• Heterogeneous constituents (solid, liquid or gas) are mixed / blended with an intent to
get homogenous mixture.
• Blending is a gentle mixing of solids with solids and in mixing solids are homogenized
with liquids.
• Mixing depends upon nature of constituents
i. solids (free-flowing / cohesive / adhesive) ,
ii. Liquids (low to high viscous, Newtonian to non- Newtonian) or
iii. Gases (compressed gas, liquefied gas, mixture of gas, inflammable gas, oxidizer,
inert gas, toxic & non-toxic)
ENGINEERS SELECT RIGHT EQUIPMENT FOR EFFICIENT
AND ECONOMICAL MIXING

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 Difference in Blending and Mixing

Blending is a mixing of powder of same

chemical but different sizes.
Blending is a relatively gentle process
as compared to mixing.
Blending is a process of solid-solid
mixing or mixing of bulk solids with
.
small quantity of liquid
Mixing is fine combination of powders
of different chemistries.
 Mixing is a perfect mixture of two
different particles and whole mixture
have uniform composition everywhere.
In practice a perfect mixture cannot be
obtained.
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 Classification of Mixing on the Bases of Phases
Single-phase blending tends to involve low-shear, high-flow mixers to cause
liquid engulfment, while multi-phase mixing generally requires the use of
high-shear.
• Liquid-liquid mixing
• Gas-gas mixing
• Solid-solid mixing
• Solid-liquid mixing
• Liquid-gas mixing
Solids-solids mixing is usually performed in batches
because continuous dry-mixing of bulk solids is more
complex due to segregation of particles, capacity
and uniformity.
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 Mixing of Liquids
• Liquid Mixing in Comparison to Solids have significant differences in mixing processes,
• Liquid mixing depends upon the creation of Flow Currents, which transfers the unmixed
material to the mixing zone adjacent to the impeller.
• In heavy pastes or masses of particulate solids, no such currents are possible and mixing is
accomplished by some other means.
• More power is required in mixing solids and pastes than on mixing liquids.
Liquid–solid mixing:
Liquid–solid mixing is typically done to suspend coarse free-flowing solids for
fine agglomeration, e.g. mixing sugar, flour or powdered milk into water.
Liquid–gas mixing:
• Liquids and gases are typically mixed to allow mass transfer by absorption.
• A tank and impeller are used to ensure that the gas bubbles remain in contact with the
liquid for longer time to minimize wastage of expensive gases like pure oxygen
which diffuses slowly in liquids.
 Gas–solid mixing
• Gas–solid mixing is conducted to transport
powders or particulate solids from one place
to another, or to mix gaseous reactants pass
through a solid catalyst particles or Fluidized
bed coal combustion.
• Multiphase mixing occurs when solids, liquids
and gases are combined in one step e.g. a
catalytic chemical reaction, in which liquid
and gaseous pass through solid catalysts, (e.g.
hydrogenation or in fermentation, where solid
microbes and the gases).
Basic Nomenclature
• For liquid mixing, the nomenclature is rather standardized:
• Impeller Diameter, "D" is measured for industrial mixers as the
maximum diameter swept around the axis of rotation.
• Rotational Speed, "N" is usually measured in revolutions per
minute(RPM) or revolutions per second(RPS). This variable refers to
the rotational speed of the impeller as this number can differ along
points of the drive train.
• Tank Diameter, "T" The inside diameter of a cylindrical vessel. Most
mixing vessels receiving industrial mixers will be cylindrical.
• Power, "P" Is the energy input into a system usually by an electric
motor or a pneumatic motor
• Impeller Pumping Capacity, "Q" The resulting fluid motion from
impeller rotation
Convective is used for

Characteristics of Mixing constituents

 Mechanisms of Mixing
Three primary mechanisms of mixing: Convective; Diffusive and Shear Mixing;

Convective blending involves gross movement of particles through the mixer either by
force action from a paddle or by gentle tumbling under rotational effects.

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 Mechanisms of Mixing
Convective mixing Mechanism is analogous to bulk transport in fluid mixing
which occur by diffusion due to random motion of particles within a
particulate bed by changing relative position with time.

Convective Mixing:
• In this type of mixing, the circular motion is caused by the rotational
motion of the mixer vessel, an agitating impeller or gas flow.
• Convective mixing is mainly a macroscopic phenomena of mixing of
bulk powder materials.
• Rate of mixing in Convective mixing is high.

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 Shear of Mixing
A shear mixer disperses, or transports, one phase or ingredient into a main continuous
phase, with which it would normally be immiscible.

Shear mixing occurs due to velocity exchange due to compression and

extension of powdered particles because of the mixers.
i. Shears are induced by the momentum exchange between the particles
having different velocities.
ii. Maximum velocity exists around the impeller blade and minimum
velocity occurs near the vessel walls.
iii. Interchange of the particles between layers cause mixing.
iv. Shear affects enhance semi microscopic level of mixing between the
particulate matter.

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Mechanisms of Diffusive Mixing
 Mixing is caused by the random
motion of the particles, also known
as random walk phenomena.
 Diffusive mixing is essentially a
microscopic homogenization.
 In diffusive mixing the particles roll
down a sloping surface.
 The rate of mixing by this
phenomena is however low, as
compared to the Shear and
Convective Mixing.

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Classification of Mixing with time
Diffusive mixing caused by the distribution of particles over a
freshly developed surfaces and shear mixing due to slipping
or sliding of particles within the mixture.
σ is standard deviation for mixing

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 Types of Mixer
Types of Mixers for Industrial Applications

Industrial mixers are designed to mix or blend materials

to form a homogeneous end product, such mixers work at
different process temperatures and operating pressures.

•Paddle Mixers. Paddle mixers are a type of

agitator used in the mixing, blending and
conditioning of dry friable materials, sledges,
and slurries.
•Static Mixer. ...
•Drum Mixer. ...
•Food Mixer. ...
•Blender. ...
•Homogenizer. ...
•Emulsifier. 13
 Mixers for Non-Cohesive Solids

Mixers for dry powders includes machines that are also

used for heavy pastes and some machines are restricted to
free-flowing powders.
Mixing is by slow-speed agitation of the mass with an
impeller, by tumbling, or by centrifugal smearing and
impact.
Powder and pastes ingredients:
The main difference is that powdered ingredients often blend nicely but
retain some texture, and paste ingredients can range in texture from
chunky to sticky in nature.)

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 Types of Mixer
Mixers for Non-Cohesive Solids
Screw Mixing:
i) Internal Screw Mixer:
 Mainly consists of a vertical tank containing a
helical conveyor that elevates and circulates the
material.
ii) Ribbon Blender:
Two counteracting ribbons are mounted on the
same shaft,
one moves the particles slowly in one direction
and other moves quickly in the other direction.
These units may operate batch wise or
continuous.

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 Mixers for Non-Cohesive Solids
Tumbling Mixers:
Consist of 2 main components, ball
mills and tumbling drums.
 Used to handle dense slurries and
heavy solids.
Filled from the top and Charged up
to 50 to 60 percent of the capacity.
Rotated about a horizontal axis for
5 to 20 minutes.
Contains internal sprays for
introducing small amounts of liquid
into the mixture.

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Problems in Tumbling Mixers:

Components are not blended in

complete random manner.
Un-blending forces, electrostatic forces
can not be ignored in case of dry solids.
When the mixing time is long, tumbling
may give rise to agglomeration, un-mixing
& segregation.

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Mixers for Non-Cohesive Solids

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 Mixers for Non-Cohesive Solids
Impact Wheel Mixers:
Combination of centrifugal, smearing and
impact force is used in impact wheel structures.
Premix of dry ingredients is fed continuously
near the center of high speed spinning disk that
throws the material outwards.
Intense shearing force acting on the powders
during the movement over the disk surface for
thorough blending of the ingredients.

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 Mixers for Cohesive Solids

Need for heavy duty mixers:

Mixing of cohesive solids ( e.g. pastes, plastic materials and rubber) is
considered most problematic,.
High viscosity of cohesive materials need more powerful mixing equipment ,
 For cohesive materials multiple mixing currents like shear, fold, stretch and
compress are applied.
 To mix cohesive solids, power consumption is high because to generate
multiple currents,

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 Mixers for Cohesive Solids

Change-Can Mixers (Pony Mixer):

Blends viscous liquids or light pastes.
Food processing and paint manufacturing.
Movable agitated can/vessel 5-100 gal. in size.
Rotating agitator contains several vertical blades
near the vessel wall.
The ‘Container’ is driven by a turn-table opposite in
direction to the agitator.
 Also known as Pony mixers.

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 Kneader Mixers for Cohesive Solids
• Mixes deformable or plastic solids.
• Squashing the mass flat, folding it over and squashing it once more.
• Most kneading machines tear the mass apart and shear it between a moving
blade and stationary surface.
• Considerable energy is required as the material is stiff and rubbery hence large
power requirement.

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Two-arm Kneader Mixer:
Used for pastes, slurries and light plastic masses.
Typical application; shredding of cotton linters etc.
Disperser Mixer:
 Draws more power than kneader mixer.
 Used for adding coloring agents
and additives into a stiff material.

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 DESIGN OF A MIXING SYSTEM
Quality and characteristics of mixer plays a major role in the operation
control quality of the final product,

To design of a mixing system the fallowing parameters are to be considered;

 Quantizes and characteristics of the ingredients to be mixed,
Operating arrangement and power requirements of mixers which depend
on the degree of mixing ( coarse, intermediate or fine) ;
 Size of the tank and size of the impeller (Impeller's diameter to be one-third of
the tank's diameter.)
 Geometric configuration of impeller.
 CHARACTERIZATION OF MIXERS
Two major characteristics of mixing devices that provide a basis for comparative
evaluations include:
•Efficiency of a mixing device
•Intensity of mixing
•Power required per unit quantity of the mixture.

Impeller Reynolds Number correlates horsepower

required to rotate impeller for a specific flow rate and
to determine the size of the impeller compared to the
mixing vessel diameter.
 Mixer Effectiveness

Performance of industrial mixer is measured by:

Mixing time required,
Power consumption by mixer,
Properties of obtained products.
Performance depends upon the problem/requirement:
Sometimes rapid mixing is required,
Some times very high degree of uniformity of the product,
In some cases power consumption might be an objective.

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 Power Requirements
 Mixing may be accomplished either by convective, diffusive or by, sheared modes or
by collectively impacts.
Energy supplied to the mixer is mainly useful for mixing to impart momentum, however
a part of energy may be utilized to recombine and re-divide the particulate matter.
Mixers can work more efficiently for the fully loaded according the capacity.
To achieve desired degree of uniformity in lesser time, more efficient utilization of
energy supplied will be required.
The power needed to mix pastes and cohesive ingredients will be greater than a mixer
used for non-cohesive materials.
The wastage of energy must be minimized by proper routine and preventive
maintenance of the mixers.

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 Statistical Method to Measure Mixing Effectiveness (For Paste)
 Statistical methods are employed to determine
Mixer performance,
 Samples are collected at different time from the
different locations of the mixer to determine
quantitative mixing effectiveness.

Calculation of Standard Deviation:

 Standard Deviation is calculated to
determine mixing effectiveness and
quality of mixing.

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If:
 ‘μ’ – Overall average fraction of tracer in the mix.
‘N’ – Number of samples taken from various location of the mix.
‘xi’ – Fraction of tracer in each sample.
 – Averaged value of fractions of tracers .

Calculation of Standard Deviation:

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Importance calculating of Standard Deviation:

Value of standard deviation is a relative value of measuring extent of mixing.

Where xi = number of fraction of component A in each sample and
= average value of measured number of fraction

When N (number of samples) are large then will be equal to μ.

If mixing is not complete, then standard deviation will be high, xi and ‘xi’ vary
significantly from ‘μ’,
 For perfect mixing, ‘xi’ will be equal to which will ultimately resemble to ‘μ’
and ‘s’ will approach to zero.
 The index that improves mixing performance is the ratio of “s” to σo.
 Standard deviation at zero mixing σo.

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 MIXING EQUIPMENT SELECTION
Criteria:
1. Powder bed should not be filled for more than 60%
2. Particles should be subjected to movement in three
directions
3. Shearing force should be sufficient to prevent
aggregation.
4. There should be no centrifugal effect
5. Forces should not cause breakage of the particles.
6. The mixing process should be stopped abruptly.

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 Mixing Index:

In contrast to standard deviation, mixing index specifies the extent of mixing.
Better the mixing, lesser will be the ‘s’ and greater will be mixing index i.e.
mixing efficiency is high.

 is the standard deviation at zero mixing,

(means two distinct layers of tracer and material, hence the mixing is about to start
xi = 0 for one layer in which xi = 1. Under these conditions the standard deviation will be
σ0.)
 maximum deviation in absence of mixing.

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Characteristics of Mixing Index:

In any batch process, mixing index is unity at the start and it increases as
the mixing proceeds.
Theoretically mixing index must approach infinity but it does not, because
of the following reasons,
 Ideal Mixing can never be achieved,
Analytical methods to measure ‘xi’ are not precise (human error may exist)
Typically mixing index falls in the range of 10 and 150, depending upon the type of
mixer, nature of material and precision of the analytical methods.

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MIXING : Theory and calculations

)
Mixing Rate:
Rate of change of mixing (mixing
rate) expressed in terms of mixing
Index ‘IP’,
“IP” varies with the kind of mixer and
nature of material to be mixed.
Example: In a two arm mixer dry powdery
clay mixes more rapidly than a wet clay.
Mixing rate highly depends on
nature of materials

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 Difference between mixing of Pasty mass and a Granular Mass
Pasty Mass Granular Mass
Weight fraction/weight percent Number fraction/number percent
Continuously increasing mixing index Subsequent increase and decrease in the trend for mixing
index (right so, due to the maximum flow ability of granular
particles as compared to a thick viscous mass)

e.g: sugar in honey e.g: sand in sugar, whiteners in granular detergent particles

Standard deviation of tracer element at zero mixing is taken Mixing at a particular time can not be judged accurately by
as reference because the mixing index is continuously taking standard deviation at zero mixing as a reference, since
increasing with time. the trend shows great variations. Therefore estimation of
mixing index at desirable time is most favorable.

Curve for standard deviation starts from one. Because even Curve starts from zero, because at zero mixing, value of ‘n’
at zero mixing, there exists a value for standard deviation. will approach zero & standard deviation at zero can’t be
accurately calculated.

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Mixing process - steps
• In the solid-solid mixing operations , four steps are involves. These are:

1. Expansion of the bed of solids

2. Application of 3-dimensional shear forces to the powder bed.
3. Mix long enough to permit true randomization of particles.
4. Maintain randomization.

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39
 Statistical evaluation
Objectives:
• To compare the efficiency of two or more mixing operations and
mixing equipment.
• To follow the mixing process with time.
• To optimize processing parameters
• To monitor the mechanism of mixing in a specific equipment.
Sample size:
Depends upon the productivity, time, production stages from raw
material to final product.
Number of samples:
• Required – 30 Sample collection:

• Ideal – 100 • At different intervals when the blend

• Economical sampling – 20
Sampling methods:
• Non destructive
• destructive
is in motion.
• After blending is completed
Sample utilization:
• Scooping sampling
• Thief probing

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 Statistical Method to Measure Mixing Effectiveness
(Granular Particles)
Mixing index at zero mixing:

The standard deviation for complete / effective mixing ‘σe’ is the used as
a reference with mixing of granular solids.
The standard deviation for zero mixing ‘σo’ is used as a reference with
mixing of pastes.
If ‘n’ is set equals to 1 then both equations become identical.
When n = 1 then xi = 1 or xi = 0 which is the same as in completely
unmixed material.
Mixing index (Is.0) of granular solid at zero
mixing can be expressed mathematically:
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Rate of Mixing in Granular Solids:
 Rate of transfer is directly proportional to driving force,
same is true in mixing.
The mixing index “ Is” is a measure of rate of mixing till
equilibrium is established.
For granular solids, ‘Is’ i.e. mixing index at any time
 For granular solids driving force at any moment will be
 ‘(1 – Is)’ because mixing index at equilibrium will be 1.
Mixing time (i.e. rate of change of ‘Is’) is proportional to
‘(1 – Is)’.
 To determine mixing time, Mixing index (Is.0)
i. Integrate the correlation between time zero to “t”
ii. Time to achieve desired degree of mixing, provided k
is known and unbending forces are not active.
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Mixing indices

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Degree of mixing

• Ideal mixing or perfect mixing:

• Acceptable mixing:
1. Random mixing
2. Ordered mixing
• Mechanical means of ordered mixing
• Adhesion means of ordered mixing
• Coating means of ordered mixing

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Adhesion means of ordered mixing:

Coating means of ordered mixing:

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Classification of equipment for solid mixing
• Based on flow properties:
1.Free flowing solids:
e.g.: V cone blend , Double cone blender
2.Cohesive solids:
e.g.: Sigma blender, Planetary mixer
• Based on scale of mixing:
1.Batch type(small scale):
e.g.: Mortar and pestle, V cone blender, Double cone
blender, Ribbon blender, Sigma blender, Planetary paddle,
Fluidized mixer
2.Continuous type(large scale):
e.g.: barrel type, zig-ag type

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 Mixing Apparatus for fluids
• A Container and
• A Mixing Device or Impeller

• Mixing devices are classified on the

bases shape and pitch ,
• In general 3 main types,
• Propellers
• Turbines
• Paddles

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 Propellers
• Consists of number of blades, generally 3 bladed ;
• Blades may be right or left handed;
• Multiple propellers are used for deep tank.
• Size of propeller is small (up to 0.5 meters) depending
upon the size of the tank.
• Propellers can rotate up to 8000 rpm and produce
longitudinal movement.

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 Turbines
• A turbine consists of
i. A circular disc with a number of short blades.
ii. Blades may be straight or curved.
iii. The diameter of the turbine ranges from 30-
50% of the diameter of the vessel.
iv. Turbines rotates from 50 to 200rpm.
• Flat blade turbines produce radial and tangential
flow but as the speed increases radial flow
dominates.
• Pitched blade turbine produces axial flow.
• In the close vicinity of the impeller, high
turbulence, rapid currents, and intense shear is
observed.
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 Paddles
• A paddle consists of a central hub with
long flat blades.
• Two blades or four blades are common.
(dished or hemispherical shaped)
• Paddles rotates at a low speed of 100 rpm
• Paddles push the liquid radially and
tangentially.

• In deep tanks multiple paddles are installed with a single shaft.

• At very low speeds no baffles are needed but at high speeds baffles
are necessary to avoid splashing.

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Flow pattern during mixing
1. Tangential or circular flow:
• Tangential to circular flow occur around the
impeller shaft.
• Creates a vortex in the liquid.

2.Radial component:
• Radial flow occurs towards the walls of the
container
• Mixture falls towards the bottom and
rotate as the mass beneath the impeller

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3. Axial component or
longitudinal or
vertical:
• Flow occurs parallel to the
impeller shaft.
• Inadequate longitudinal
component causes the liquid and
solid to rotate in layers without
mixing.
• Adequate longitudinal pattern is
best to generate strong vertical
currents.
Impeller type
TableFlow component
Propellers
Turbines
not to Axial
Axial or tangential or both
Paddles do
Radial and tangential
Paddles with pitch Radial, tangential and axial
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Factors influencing mixing of liquids in tanks
 Material related factors-
• Properties of liquids: physical properties of materials to be
mixed. e.g.: Density, Viscosity and miscibility.
 Equipment related factors-
• Shape of impeller:
e.g. straight, vertical, curved, or pitched.
• Position of impeller:
Central, off-center, side entry, vertical or inclined etc.,
• Shape and size of the container:
i. cylindrical or any other geometry.
ii. With or without baffles.
iii. Cost of equipment and its maintenance provisions.
 Operation related factors-
• Speed of rotation of the impeller.
• Time required for mixing.
• Batch size.

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 Equipment for Liquid mixing
1 . Jet mixer
i. Air Jet mixer
ii. Liquid Jet mixers
2 . Flow mixer or line mixer or pipe mixer

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 Mixing of immiscible Liquids
To Manufacture Emulsions,
The equipment used to prepare emulsions are known as emulsifier or
homogenizer.
In 1st stage coarse emulsion is prepared by using one of the following
process:-
• Wedge wood
• Mechanical blender
• Hand homogenizer
In 2nd stage coarse emulsions are further homogenized to get fine emulsion
using:-
• Silverson emulsifier
• Colloidal mill
• Rapisonic homogenizer
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