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DESIGNING A MIXER

PRELIMINARY PRE LIMINARY Deciding on and choosing the size of a type of a mixer consists in finding the optimum parameters for the implementation of the desired procedure. Frequently, optimization is limited by constraints such as costs, bulk or physical limits. This approach consists in choosing a certain number of parameters: Type of agitators and position - Radial discharge rotors - Axial discharge rotors - Mix discharge rotors - Angled discharge rotors - Dispersion/emulsification rotors Geometry of the tank (size, shape) Rotation of the rotor (speed, rate of discharge) Length of mixing Imposed physical conditions (pressure, temperature) The people who make these choices rely on their knowledge and experience to make them and choices become additionally complex because of a certain number of factors of which the most frequent follow: The nature and rheology of products can lead to complicated expressions of a certain number of parameters and specifically of their respective progress during the mixing process. More precisely in the case of non Newtonian liquids (when viscosity of liquids is directly related to the speed of shearing) for which is observed non linear progress of the required power and the rate of flow of circulation in respect to the rotation speed of the agitator. This is observed in rheoliquidifying liquids (fruit juice, blood), threshold or Bingham liquids (paint, varnish, mayonnaise, toothpaste), rheothickening liquids (wet grit, starch suspension, pizza dough) or thixotropic liquids (yogurt). Constraints regarding some parameters because of experience or technologic and economic reasons, such as the peripheral speed return from one type of mixer to another, shearing rate, speed of flow or pumping limit the margin of action for the calculation of the other mixing parameters. It is a limiting factor but we must consider that these constraints, in the end, lead to a more rapid result by minimizing choices.

compromise: : a dominant parameter is established and calculated In practice, choosing an agitator becomes a compromise calculated and then sufficient. . the other parameters are checked to insure they are sufficient

VMI recommends and implements the following method: Step 1 ............................................................... Identification of the type of mixing to perform

Step 2 ................................................. ................................................. Inventory of the characteristics of mixing materials

Step 3 ............................................. Identification of the global characteristics of mixing rotors

Step 4 .....................................................................Choice of the rotors

Step 5 ................................................... Calculation of the various mixing parameters (tank rotors)

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DESIGNING A MIXER
STEP 1: Identification of the type of mixing to perform Solid / liquid mixtures - Soluble powders Dissolution Homogenizing - Non soluble powders powders Placing in and/or maintaining in suspension Homogenizing Dispersion Liquid / l liquid iquid mixtures - Miscible liquid liquids s Placing in and/or maintaining in suspension Homogenizing Dilution - Immiscible liquids Emulsion rheol olo ogy of viscous mixtures Complex rhe ol Placing in and/or maintaining in suspension Dissolution Homogenizing Dispersion Heat transfer Grinding

STEP 2: Inventory of the characteristics of mixing materials Liquids Liquids Solids Solid s Gas Gas Nature Flow Pressure Solubility Nature Percentage Density Granulometric dimensions and distribution Settling speed Wettability Solubility Density Viscosity Percentage Initial and final temperature Type of discharge

rotors s STEP 3: Identification Identification of the global global characteristics haracteristics of mixing rotor Flow mainly generated (axial or radial) Importance of the pumping effect (high, medium, low) Importance of the shearing effect (high, medium, low) Capacity of generating turbulence (high, medium, low) ZI Nord - 85607 MONTAIGU Cedex - France Tel: 33 (0)2 51 45 35 35 Fax: 33 (0)2 51 06 40 84 http:\www.rayneri.fr - E-mail : comm-rayneri@vmi.fr

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DESIGNING A MIXER
STEP 4: Choice of rotors rotors You must then chose between the varieties of rotors offered by VMI the one that is the best adapted to the mixture you want to produce. Your choice should be based on the following:

Intrinsic characteristics of the rotors taking into account the preferred type of flow, knowing that frequently a compromise must be made between the type of discharge (axial, radial, turbulent) and mechanical effect generated (circulation, shearing, ), Laboratory tests, Financial criteria: example = choice in order to achieve the best Nq/Np performance to minimize installed capacity, Functional criteria: example = choice of a rotor that is the easiest to clean.

Currently VMI offers the following agitation rotors: 1. Profiled triblade 7. Centripetal 13. Break=up

2.

Two way profiled triblade

8. Deflocculator

14. Butterfly

3.

PSVB four blade

9. Sevin with inlets

15. Saw teeth

4.

PSVH four blade

10. Centrifugal

16. Anchor blade

5.

PA four blade

11. Centri=deflocculator

17. Rotor=stator

6.

Water propeller

12. Cutting

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DESIGNING A MIXER
Table I

Main Flow

Rotor Type
Water propeller (6) Profiled triblade (1) Two way profiled triblade (2) PSVB four blade (3) PA four blade (5) SEVIN with inlets (9) Centripetal (7) Centrifugal (10) Saw teeth (15) Deflocculator (8) Centri=deflocculator (11) Rotor/Stator wide slots (17a) Rotor/Stator narrow slots (17b)

Function Main Fu nction

Circulation Homogenizing liquid/liquid Dissolution, incorporation charges Dilution/Dissolution Dilution/Dissolution Dissolution/Dispersion Dilution/Dissolution Dissolution Dispersion Dispersion Dispersion Dispersion/Emulsion Dispersion/Emulsion

Power NP
0.21 to 0.28 0.34 to 0.60 0.76 to 1.22 1 to 1.95 1.8 to 2.2 0.4 to 0.55 1.6 to 2 2.5 to 4.5 0.23 to 0.42 0.34 to 0.8 1.1 to 2 2.1 to 5.9 2.3 to 6.2

Pumping NQ
0.58 to 0.68 0.84 to 0.87 1.15 to 1.2 1 to 1.73 1 to 1.73 0.75 to 0.85 1.1 to 1.3 3 to 3.8 0.19 to 0.31 0.37 to 0.44 0.67 to 0.79 0.82 to 0.9 0.55 to 0.6

Shearing Strength
Very low Very low Very low Very low Very low Medium Low Medium High High High Very high Very high

AXIAL

RADIAL

Note: NP, NQ and shearing strength are expressed for equivalent diameters
Power: N = p
P (P: agitation power; : density; N: rotation speed; d: rotor diameter) is the coefficient N 3d 5

of drag from the agitator when in the liquid and represents power usage. Pumping: N = QP (QP: pumping flow rate; N: rotation speed; d: rotor diameter) is the dimensionless
Q

N d3

expression of the pumping flow rate for the agitator. Shearing strength indicates the capacity of the rotor in breaking the friction effect exerted by two infinitesimal layers of liquid sliding against one another. Shearing is usually stated as speed of shearing & = , expressed as
s=1, a value that is very difficult to measure.
PERFORMANCE MOBILES
Pouvoir de cisaillement

V e

Trs Faible

Faible

Moyen

Fort

Trs Fort ROTOR STATOR FE

ROTOR/ STATOR FL 0,5

DISSOLUTION DISPERSION DILUTION DISSOLUTION

CENTRIPETE DEFLOCULEUSE CENTRIFUGE

DISPERSION EMULSION

QUADRIPALE

R e n d e m e n td e d b i tN q / N p

1,5

TRIPALE BIDIRECTTIONNELLE SEVIN

MAINTIEN EN SUSPENSION HOMOGENEISATION

TRIPALE PROFILEE

2,5

3 MARINE 3,5

Very Low

Low

ROTOR PERFORMANCE Shearing Strength Medium

High

Very High

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DESIGNING A MIXER

Table II
Solid / Liquid Mixtures Soluble Non Soluble Powders Powders Suspension Homogenizing High circulation capacity . . . 1 3 6 . 16 (*) Liquid / Liquid Mixtures Miscible Liquids Immiscible Liquids (*) 1 2 . Complex Rheology for Viscous Mixtures Heat Transfer

1 3 6 7

1 3 6 7

Dissolution Homogenizing Dilution

1 2 3

7 10 11

1 3 7 10 8 9 10 11 12 . (**) 13 15 17

High shearing strength

Dispersion

Emulsion

8 16

2 8 9 14 . 15 17

(*) Triblade Four blade Water propeller Centripetal (**) Deflocculator / Sevin Break=up Centri=deflocculator

efficient for high volumes at low rotation speeds efficient for low and medium volume at medium rotation speeds efficient for high volumes requiring strong circulation very efficient for dissolution because of the right compromise between circulation and shearing a Sevin insures better circulation at equivalent power input, specifically for high volumes very efficient for complex dissolutions very efficient for placing compact materials in suspension very good compromise between the centrifuge and deflocculator Centrifuge

STEP 5: Calculation Calculation of the various mixing parameters 1. rotor(s) Diameter, number and speed of one or more mixing rotor(s)

These calculations are performed taking into account as main parameters one or several criteria for a precise mixture: Criteria for mixing efficiency = peripheral speed, = recirculation rate therefore capacity of the turbine, = length of the mixing process. Criteria linked to the rheology of the product (the higher the viscosity of the product, the higher the diameter of the rotor at low speed) Economic criteria Guide for selecting the Dtool /Dtank ratio in the tank Dtool / Dtank Viscous product* Low viscosity product product*
0,1 0,15 0,2 0,25 0,3 0,5 0,9 1 0,2 0,25 0,3 0,5 0,6 0,8

Table III

Type of Rotor
Rotor/Stator

Speed (rpm) rpm)

3000 1500 1500 to 750 500 to 250 170 to 90 60 to 30 10 to 200

Propeller or Turbine Anchor or butterfly blade

*according to the number of movements

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DESIGNING A MIXER

Guide for selecting the peripheral speed speed and the recirculation rate Table IV TYPE OF MIXTURE
Maintaining in suspension, circulation: slow sedimentation product Maintaining in suspension, circulation: fast sedimentation product Liquid/liquid homogenizing Liquid/solid homogenizing Relatively equal apparent densities Low concentration dissolution: 10 to 20 % max Solid /liquid homogenizing Very different apparent densities High concentration dissolution: up to 50 % Dispersion facile Products that swell Difficult dispersion Extremely fine products Mashing

Speed in m/s
0,5 to 1,5 1,5 to 2,5 2,5 to 4 4 to 5

Recirculation volume bac/h

50 to 200 200 to 300 300 to 400 400 to 700

5 to 8 8 to 10 15 to 20

700 to 1000 800 to 1200 1000 to 1500

Guide for selecting the number of ro rotor tors tor s in the tank Table V Viscosity Pa.s
0.001 (eau) <0.1 0.1 to 10 10 to 30 30 to 60 60 to 100 100 to 1000 > 1000

No. of movements mo vements

1 movement 1 or 2 movements 2 movements minimum

Height of work (Nb of times )

8 to 3 3 to 2 2 to 1.5 1.5 to 1 1 0.8 0.65 0.5

Flow rate factor K0

1.3 1.2 1 0.8 0.6 0.5 0.35 0.2

2.

Calculation Calcul ation of the characteristic parameters of the mixer Sizes used: - D: diameter of the mixing tool (m) - N: rotation speed of the tool (t/s) : apparent density of the liquid (kg/m3) - : viscosity of the liquid (Pa.s) - NP0: Number for nominal capacity - NP: Number for corrected capacity - NQ: Number of pumping actions - KS: Metzner=Otto constant to calculate shearing - K: Consistency index (Pa.sn=1 ) = n: exponent of rheoliquidifying; K and n are determined by a measure of viscosity where = K n=1 Calculation of Reynolds number (Re) Newtonian liquids: Re = x N x D2/ Non Newtonian liquids: Reequivalent = ( x N2=n x D2)/K

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DESIGNING A MIXER
Table VI Re
1 2 3 4 5 6 7 10 20 30 40 50 70 100 150 200 250 300 500 1000 5000 10000 50000 100000

Calculation of the nominal capacity number NP0 = f(Re) Experimental values of NP0 = f(Re) (NP0 = 1 for Re = 104) Triblade Profile
/ 59 29,5 23,5 19,1 16,2 14,7 11,2 6,8 5,3 4,4 3,8 3,2 2,7 2,2 1,8 1,6 1,5 1,2 1,1 0,94 1 1,03 1,12

Water Propeller
100 60 44 36 30 26 23,2 18 10 7,6 6 5,2 4,4 3,6 2,8 2,6 2,2 1,8 1,4 1,2 1 1 0,88 0,84

PA
22,4 13,5 8,8 7,6 6,5 6,2 5,3 4,1 2,8 2,4 1,9 1,8 1,5 1,2 1,2 1,1 1,06 1, 0,95 0,95 1 1 1,06 1,1

Four blade PSVB

36,2 21 14,3 12,4 10,5 10 8,6 5,7 3,8 3,1 2,8 2,6 2 1,7 1,4 1,1 0,95 0,95 0,86 0,86 0,95 1 1 1,05

PSVH
31,5 19 12,4 11,4 9,5 9 7,6 5,2 3,2 2,7 2,2 2 1,8 1,3 1,2 1,05 0,95 0,95 0,86 0,86 0,95 1 1 1,05

Centripetal
53 31 22 18 16 12 11 9,5 6 4,7 4 3,4 2,8 2,3 2 1,8 1,7 1,7 1,5 1,2 1,05 1 0,96 0,95

Deflocculator
94 55 39 34 30 24 22 16 10 7,9 7 6 5 4 3 2,5 2,4 2,2 1,8 1,4 1 1 1 1

SEVIN with inlets

128 77 57 49 41 31 28 23 14 10,5 9 7,7 6,2 5,2 3,8 3,1 2,8 2,6 2,1 1,6 1,05 1 0,97 0,9

Calculation of Froude number (Fr) if required (appearance of a vortex) Fr = N2 x D/g (g=9,81 ms=2) A vortex will be considered formed if Fr , 3 Calculation of corrected capacity number NP - If Fr - 1 (no vortex), then NP = NP0 - if Fr , 3 (vortex), then NP = NP0 x Fry et y = (a Log Re) / b radial effect rotors: a = 1 b = 40 axial effect rotors: a = 2,1 b = 18 Calculation of absorbed pump power Pab (in W) Pabs = NP x x N3 x D5 Calculation of turbine flow rate Q (in m3/s) Q = NQ x N x D3 Calculation of drag flow rate Qe (the viscosity of the liquid is taken into account) Qe = Q x K0 (flow rate factor, see Table V) Calculation of recirculation rate TRC (in volume / hour) Directly deducted from the drag flow rate Qe and the volume V of the tank Calculation of mixing time Tm Tm = K x V/Qe where K is an experimental coefficient varying from 10 to 10000 (tests from Grenville and Co in 1992 or Nienow in 1997) If K is unknown the value for K0 can be used (Table V), and you will get: Tm = K0/TRC Calculation of peripheral speeds (VP), flow speeds (or transversal) (VF), and rising speed (VR) Peripheral Speed (in m/s) (linear speed of the extremity of the turbine) ZI Nord - 85607 MONTAIGU Cedex - France Tel: 33 (0)2 51 45 35 35 Fax: 33 (0)2 51 06 40 84 http:\www.rayneri.fr - E-mail : comm-rayneri@vmi.fr

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DESIGNING A MIXER
VP = .D.N Flow Speed (in m/s) (linear speed of the liquid in the turbine) VF = (4 x NQ x D x N)/ Rising Speed (in m/s) (linear rising speed of liquids on the side of the tank) VR = (4 x Q)/ (Dc2 = D2) = (VF x D2)/(Dc2= D2) with Dc = diameter of the tank

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DESIGNING A MIXER

MIXING LEXICON
Behaviour index

Parameter of Ostwald=Dewaeles Law, the behaviour index defines the pseudoplastic character of a liquid for n<1 or dilatant for n>1. For n=1, the apparent viscosity is independent from the speed gradient, which defines a Newtonian liquid.
Bingham

A Bingham liquid is one that flows only if shearing stress is superior to a certain threshold 0. Beyond this threshold, the product reacts like a Newtonian liquid, pseudoplastic or dilatant. Chocolate, toothpaste and drilling mud are examples of Bingham liquids. Parameter of Ostwald=Dewaeles Law the consistency index defines the consistency of a liquid. The higher the value of the index the higher the apparent viscosity, at a given speed gradient, is important
Dilatant Consistency index

A dilatant like liquid is one whose apparent viscosity increases with the speed gradient. The rheologic model of Ostwald=Dewaele defines this liquid. The dilatant characteristic will be will be even more apparent as the behaviour index increases. Aqueous clay suspensions and some slush are examples of dilatant liquids.
Dilution

Dilution is the transformation of a concentrated solution to a more diluted solution by adding a continuous phase
compatible with the solution. This operation requires an important circulation of the product.
Dispersion

Dispersion is the incorporation of a solid phase divided in a continuous liquid phase where the particles of the solid
phase are not soluble in the liquid phase.
Dissolution

Dissolution is the incorporation of a soluble solid phase in a continuous liquid phase often called solvent. This
operation requires good circulation.
Emulsion

An Emulsion is a mixture of two immiscible liquids. One liquid (the dispersed phase) is dispersed in the continuous phase. This operation requires a very high degree of shearing from the agitation rotor. The stability of the emulsion is essentially linked to the size of the droplets of the dispersed phase, their surface tension and distribution in the dispersed phased.
Endothermic

A reaction is endothermic when it absorbs heat. Dissolution of citric acid in water is endothermic.
Exothermic

A reaction is exothermic when it emits heat. Dissolution of soda in water is exothermic.

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DESIGNING A MIXER
Extraction

Extraction is made up of the dispersion or suspension of a solid phase divided in a liquid phase obtaining a very high

concentration that can reach 75% of the end product.

Froude
The Froude number is a dimensionless number (no units) comparing inertial and gravitational forces. It occurs only

when gravitational forces are sensitive and it is characterized by the forming of a vortex on the interface of the liquid.
Grinding

Grinding is an activity that reduces the sizes of solid particles, either in a liquid phase or directly in its dry state.
Homogenizing

Homogenizing is the action of homogenizing a medium. This means that the value of a characteristic quantity
(example = temperature or concentration) is identical in every part of the medium. Significant circulation of the product favours this operation. A discharge is laminar when the layers or threads of liquids slide one against the other without merging. It is characterized by a Reynolds number lower than a limit value which depends on the geometric conditions of the agitation system. The transversal motion of linear momentum is caused only by molecular momentum. The term mixture defines a system made up of several chemical species which can found in various states (solid, liquid, gaseous). To perform a mixture for which at least the dispersion phase is in liquid state, the agitation rotor creates two distinct actions: a pumping action to ensure a wide scale global mixture (macro=mixture) and a turbulent action or shearing to ensure a small scale local mixture (micro=mixture).
Newton Mixture Laminar

Newtons Law expresses the quantity of motion transferred through a given surface, represented by the formula:
d ( mV) dV =S . dt dx

Newtonian

A liquid is Newtonian when its viscosity is constant when in given temperatures and pressures. Viscosity does not depend on operational conditions (speed gradient, shearing rate, time ). All gases, water, light organic products are Newtonian liquids. A liquid is non=newtonian when its viscosity is dependent of operational conditions. Notably we can distinguish liquids for which the apparent viscosity depends on: = the speed gradient (pseudoplastic, dilatant, of Bingham) = the speed gradient and length of the application of the constraint (thixotropic, rheopectic) = the speed gradient, length of the application of the constraint and modulus of elasticity (viscoelastic).
Ostwald>Dewaele Non Newtonian

Ostwald=Dewaeles Law, also called power law, is the rheologic model used to characterize the behaviour of
pseudoplastic and dilatant liquids. It expresses the apparent viscosity as a function of gradient speed using the equation: a = m & n 1 where m and n are respectively the consistency and behaviour index of a liquid.
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DESIGNING A MIXER
Phase reversal

Phase reversal created by a very significant mechanical or thermal effect characterizes an emulsion where the
dispersed phase becomes the dispersion phase and vice versa.
Propeller

The word propeller is a generic term used to qualify an agitation rotor that generates a main axial discharge, meaning parallel to the agitation shaft. Shearing constraints are generally low. A liquid is pseudoplastic when its apparent viscosity decreases as the gradient speed increases. Ostwald=Dewaeles rheologic model defines this liquid. The pseudoplastic character will be more significant the lesser the behaviour index. Carbomer solutions and cosmetic creams are examples of pseudoplastic liquids.
Reynolds Pseudoplastic

Reynolds number is a dimensionless number (no units) that represents the relationship between inertial forces and
viscous forces. A low value of this number indicates the dominance of viscous friction: it is the laminar regime. A high value indicates the dominance of dynamic friction: it is the turbulent regime. A rheogram represents the progress curve of shearing constraint in respect to the speed gradient used. Using this diagram you can determine the rheologic behaviour of the liquid (newtonian, pseudoplastic, dilatant, thixotropic or rheopectic) and associate this behaviour to one of the existing rheologic models. A rheometer is a device which can be used to trace a rheogram. It determines the viscosity of a liquid continuously; at a constant gradient speed or within a range of gradient speed.
Rheopectic Rheometer Rheogram

contrainte de cisaillement

Bingham pseudoplastique newtonien dilatant

gradient de vitesse

A liquid is rheopectic when its apparent viscosity increases when the length of application of constraint increases. A gypsum suspension presents a rheopectic character. A suspension is the setting in motion of a non soluble divided solid phase in an internal liquid phase. Without agitation the particles, which usually have a different density from the liquid phase, depending on the situation, tend to settle or float. A liquid is thixotropic when its apparent viscosity decreases when the length of application of the constraint. Paint, ink, polymers in a solution are generally thixotropic liquids.
Thixotropic Suspension

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DESIGNING A MIXER
Turbine

A turbine is a generic term used to designate an agitation rotor that creates a main radial discharge, meaning perpendicular to the agitation axis. Shearing constraints are generally very high because the speed of flow located close to the turbine is significant compared to the speeds of surrounding liquids. A discharge is turbulent when the sizes characterizing the motion of the liquid are turbulent. Streams of liquid no longer have any individuality. It is characterized by a Reynolds number superior to a limit value which depends on the geometric conditions of the agitation system. Molecular motion is insignificant, the transversal motion of the linear momentum is ensured by the vortices. A viscoelastic liquid includes simultaneously viscous properties (distortion when submitted) and elastic properties (reverts to its initial state when constraints are removed). Several polymers are viscoelastic, like polyacrylamide solutions. A viscosimeter is a device used to determine the viscosity of a liquid in given operational conditions. Its operation is based more often than not on the measure of working torque from the setting in motion of a solid in contact with a liquid. A characteristic of non newtonian liquids. The definition of apparent viscosity is the relationship between shearing tension and the speed gradient. The definition of kinematic viscosity is the relationship between the dynamic viscosity and the density of the liquid. It is seen as the coefficient of diffusion of linear momentum. A property of a liquid, dynamic viscosity usually called viscosity, characterizes the resistance of transfer of linear momentum. It is the coefficient of proportionality between tangent shearing tension to the transverse speed and the speed gradient. At a given speed, a higher viscosity requires greater power for movement. For a given applied force, an increase in viscosity is characterized by a lower speed of movement.
Dynamic viscosity
V F plaque entrane y plaque immobile F A V y

Turbulent

Viscoelastic

Viscosimeter

Apparent viscosity

Kinematic viscosity

par dfinition :

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