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ChE 702
Liquid Mixing
Fundamentals
Piero M. Armenante
2008©
Instructional Objectives of
This Section
By the end of this section you will be
able to:
Identify the geometric, physical and
dynamic variables of importance for the
analysis of mixing in a stirred tank
Assess the relative importance of those
variables
Quantify the power dissipation, pumping
effects, and blend time in a mixing vessel
vx=0
Increasing
Viscosity
xy
xy
Piero M. Armenante ChE702 9
Dynamic Viscosities of
Various Fluids
Fluid Viscosity
(centipoise, cP)
Gases ~ 0.001
Organics <1
Water ~1
Kerosene ~10
Lubricants ~100
Piero M. Armenante ChE702 10
Dynamic Viscosities of
Various Fluids
Fluid Viscosity
(centipoise, cP)
Glycerol ~1000
Corn Syrup ~10,000
Molasses ~100,000
Molten Polyethylene ~1,000,000
D
vtip R 2 N N D
2
Piero M. Armenante ChE702 22
Power Dissipation in Low
Viscosity Liquids in Stirred
Tanks
Instructional Objectives of
This Section
By the end of this section you will be
able to:
Calculate Re, Fr in stirred tanks
Distinguish agitation regimes
Calculate the power dissipated by an
impeller from available power numbers
Calculate the power dissipation as a
function of operating variables
v
v(t)
t
Piero M. Armenante ChE702 26
Turbulent Flow
(A play on Jonathan Swift's "Great fleas have little fleas upon their backs to bite 'em,
And little fleas have lesser fleas, and so ad infinitum." (1733))
Controller
Probe
Slip Ring
Tachometer Interface
Strain Gages
Vessel
Computer
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 41
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:
Piero M. Armenante ChE702 46
Impeller Reynolds Number
As usual, a physical interpretation can
be associated with the impeller
Reynolds number, Re. Accordingly:
Inertial forces
Re
Viscous forces
T H C w B
f Re, Fr , , , , , , n, nB , impeller type
D D D D T
i.e.:
P Re, Fr , geometric ratios,
NP f
N D
3 5
impeller type
Piero M. Armenante ChE702 50
Geometrical Similarity
Two systems are geometrically
similar if all corresponding
dimensional ratios are the same in
both systems
1.5 H
Cb 1.5 Cb
D 1.5 D
T 1.5 T
f Re, Fr
P
NP
N D
3 5
f Re
P
NP
N D
3 5
La
10
m
in
a
r
i o n al Turbulent
s i t
Tran
1
1 10 100 1000 10000 100000
Reynolds Number, Re
i.e.: P N 3 D5
Piero M. Armenante ChE702 60
Power Curve:
Turbulent Flow Regime
In the turbulent flow region the
power dissipated by an impeller is
given by:
P k ' N D NPT N D
3 5 3 5
After Bates et al., Ind. Eng. Chem. Proc. Des. Devel. 1963
Piero M. Armenante ChE702 65
Power Number Curves for 45° Pitched-Blade
Turbines (4-Blades) and HE-3 Impeller
A Re
NP BC
Re 1000 Re
where A, B, and C are coefficients that
depend on the type of impeller.
After John Smith, Unpublished Data
4
Ne
0
0.2 0.25 0.3 0.35 0.4
D/T
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 74
Effect of D/T Ratio on Power Number for
Pitched-Blade Turbines
6-PBT; C /D=0.24 4-PBT; C /D=0.84
3 6-PBT; C /D=0.10 4-PBT; C /D=0.54
6-PBT; C /T=0.25 4-PBT; C /T=0.28
6-PBT; C /T=0.05 4-PBT; C /T=0.19
2
Ne
0
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55
D/T
Armenante et al., Ind. Eng. Chem. Res., 1999.
Piero M. Armenante ChE702 75
Effect of Impeller Clearance on
Power Number for Disc Turbines
6
4
Ne
3
D/T=0.352; H/T=1
2 D/T=0.264; H/T=1
D/T=0.352; H/T=2
D/T=0.264; H/T=2
1 Regression Curve
0
0 1 2 3 4 5 6
Cb1/D
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 76
Effect of Impeller Clearance on
Power Number for Disc Turbines
A correlation between the Power
Number and the impeller clearance off
the impeller bottom, Cb1, is:
Cb1
NP 4.93 3.44exp 5.38
D
C '1 w b
4.93 3.44exp 5.38
D 2D
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 77
Effect of Cb on Power Number
for Disc Turbines
6
5
Po
4
D/T
0.217
3 0.261
0.348
2
0 0.05 0.1 0.15 0.2 0.25
Cb /T
Armenante and Uehara Nagamine, Chem. Eng. Sci., 1998.
Piero M. Armenante ChE702 78
Effect of Cb on Power Number
for Flat-Blade Turbines
3
2.8 D/T
0.217
0.261
0.348
2.6
Po
2.4
2.2
2
0 0.05 0.1 0.15 0.2 0.25
Cb /T
Armenante and Uehara Nagamine, Chem. Eng. Sci., 1998.
Piero M. Armenante ChE702 79
Effect of Impeller Clearance on Power
Number for Pitched-Blade Turbines
3 6-PBT; D/T=0.264; H/T=1
6-PBT; D/T=0.264; H/T=2
4-PBT; D/T=0.343; H/T=1
4-PBT; D/T=0.507; H/T=1
2
Ne
0
0 1 2 3 4 5 6
Cb1/D
Armenante et al., Ind. Eng. Chem. Res., 1999.
Piero M. Armenante ChE702 80
Effect of Cb on Power Number
for Pitched-Blade Turbines
3
D/T
0.217
0.261
0.348
Po
1
0 0.05 0.1 0.15 0.2 0.25
Cb /T
Armenante and Uehara Nagamine, Chem. Eng. Sci., 1998.
Piero M. Armenante ChE702 81
Effect of Cb on Power Number
for HE-3 Impellers
0.5 D/T=0.348; T=0.292 m
D/T=0.391; T=0.292 m
D/T=0.304; T=0.584 m
D/T=0.348; T=0.584 m
0.45 D/T=0.391; T=0.584 m
0.4
Po
0.35
0.3
0.25
0 0.05 0.1 0.15 0.2 0.25
Cb /T
Armenante and Uehara Nagamine, Chem. Eng. Sci., 1998.
Piero M. Armenante ChE702 82
Power Dissipation in
Multiple Impeller Systems
2 S23
H
2
S13
H S12
1 S 1 Cb2
Cb2
D Cb1 D Cb1
T T
Double DT Triple DT
System System
6
Ne
4
D/T=0.264
2 H/T=1
S/D=1.5
0
0 0.2 0.4 0.6 0.8 1 1.2
Cb1/D
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 86
Power Dissipation in Double
Disc Turbine Systems
10
6
Ne
4
D/T=0.264
2 H/T=1
Cb1/D=1
0
0 0.5 1 1.5 2
S/D
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 87
Power Dissipation in Double
Disc Turbine Systems
10
S/D=3
8 H/T=2
Cb1/D=1
6
Ne
4
Impeller Location
2 1 Total
2 Single Std.
0
0.1 0.2 0.3 0.4
D/T
Armenante and Chang, Ind. Eng. Chem. Res., 1998.
Piero M. Armenante ChE702 88
Power Dissipation in Double
Disc Turbine Systems
Ne tot /Ne Single Std. = Ptot /PSingle Std.
2
air entrainment
1.8
1.6
S/D
1.4 0.667
1
1.333 4
1.2 D/T=0.264 1.5
H/T=1 S/D
1.667
0.667
D/T=0.264
3 1
Ne 2/Ne 1 = P2 /P1
1 H/T=1
0 0.5 1 1.5 2 2.5 1.33
(a) Cb1/D 1.5
1.667
2
air entrainment
0
0 0.5 1 1.5 2 2.5
(b) Cb1/D
2
air entrainment
1.8
D/T=0.264
H/T=1
1.6
Cb1 /D
1.4 0.167
0.333
0.5 4
1.2 0.667 Cb1 /D
1 0.167
1 3 0.333
Ne 2/Ne 1 = P2 /P1
0 0.5 1 1.5 2 2.5 0.5
(a) S/D 0.667
1
2
1
D/T=0.264
H/T=1 air entrainment
0
0 0.5 1 1.5 2 2.5
(b) S/D
8 3
2 S12 /D
D/T=0.264 0.67 2.5
H/T=2 1 4
S13/D=5 1.5
1
0 0.5 1 1.5 2
(b) Cb1/D
Pi /P tot (%)
40
30
20
10
0
0 1 2 3 4 5
(a) S12/D
70 D/T=0.264
H/T=2
60
S13/D=5 Cb1/D=0.5
50
Pi /P tot (%) 40
30
20
10
0
0 1 2 3 4 5
(b) S12/D
70
60 Cb1/D=1
50
Pi /P tot (%)
40
30
20 Impeller Location
10 1 2 3
0
0 1 2 3 4 5
(c) S12/D
3
Ne
1 D/T=0.264
H/T=1 5
S/D=1.5 Impeller Location
0 1 Total
4 2 Single Std.
0 0.2 0.4 0.6 0.8 1 1.2
Cb1/D
(a)
3
Ne
2
1 D/T=0.264
H/T=1
Cb1/D=1
0
0 0.5 1 1.5 2
(b) S/D
2.2
S/D
2 0.667
1
1.8 1.5
1.6
1.4
2
1.2 D/T=0.264
H/T=1 air entrainment D/T=0.264
H/T=1
1
Ne 2/Ne 1 = P2 /P1
0 0.5 1 1.5 2 2.5
(a) Cb1/D
1
S/D
0.667
1
air entrainment 1.5
0
0 0.5 1 1.5 2 2.5
(b) Cb1/D
2.2
air entrainment
2
D/T=0.264
1.8 H/T=1
1.6
1.4
Cb1 /D
0.333 0.667 2
1.2 0.5 1
Cb1 /D
1 0.333 0.667
Ne 2/Ne 1 = P2 /P1
0 0.5 1 1.5 2 2.5 0.5 1
(a) S/D
D/T=0.264
H/T=1
0
0 0.5 1 1.5 2 2.5
(b) S/D
Baffled Tank
10
Unbaffled Tank
1
1 10 100 1000 10000 100000
Reynolds Number, Re
P
V
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
Piero M. Armenante ChE702 103
Power per Unit Volume
Substituting for P and V gives:
P NP N D 3 5
V / 4T H
2
P NP 3 2 D D
2
V /4
N D
T H
P / V small scale N 3
D 2
small scale
P / V small scale N 3
D
2
small scale
N 3
D2 large scale
N 3 D2
small scale
3 tip
V ND
v tip
2
V
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
Blade
Disc
Control
Volume
Mixing Vessel Beam Expander and
Transmitting Lens
y
Photodetectors Transmitting Optical
Train
and Frequency Shifters
x
z
Traversing
Apparatus
Q
NQ
N D3
should be maximized.
Piero M. Armenante ChE702 146
Relationship Between Power
and Flow
For a fixed impeller geometry it is:
Q
NQ N D
3
NQ 1
1
P NP N D
3 5
NP N D 2
i.e.:
Q 2 NQ 1
2
P NP vtip
Piero M. Armenante ChE702 147
NQ/NP for Various Impellers
in Baffled Tanks
Impeller NQ/NP
Disc Turbine 0.14-0.17
45 Pitched-Blade Turbine (4 blades) 0.4-0.6
45 Pitched-Blade Turbine (6 blades) 0.5-0.7
Marine Propeller 1.1-1.6
Lightnin A310 1.8-2.3
Chemineer HE-3 1.6-1.9
P 1 P
5 3
Q NQ
4
NQ D 3
4
NP N NP
5
P NP N NP 4
4
3
N N D
Q Q
To increase Q at constant P one can
lower N while increasing D. This
approach increases the capital cost
(proportional to the torque =P/2N).
Piero M. Armenante ChE702 154
Optimization Strategies to
Maximize Pumping Efficiency
The preceding analysis is valid if NP
and NQ are constant. This is correct if
the flow is fully turbulent.
Changing the D/T ratio usually has
little influence on NP and NQ provided
that it is not too small or large (0.25<
D/T <0.7) [Too large a D/T ratio
chokes the recirculation flow].
Sensor
CFinal
t
Piero M. Armenante ChE702 166
Concentration Fluctuations at
Sensor and Experimental Blend
Time
C
C90%
CFinal
t t90%
Piero M. Armenante ChE702 167
Concentration Fluctuations at
Sensor and Experimental Blend
Time
C
C95%
CFinal
t t95%
Piero M. Armenante ChE702 168
Equations for the
Determination of Blend Time
Here, two approaches/equations for the
determination of the blend time will be
presented:
Approach 1: Fasano, Bakker, and
Penney’s approach
Approach 2: Grenville’s approach
Approach 1
0.8
0.6
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-1
0 1 2 3 4 5 6 7 8 9 10
t (s)
0.8
0.6
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-1
0 1 2 3 4 5 6 7 8 9 10
t (s)
0.8
0.6 exp(-kt)
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-exp(-kt)
-1
0 1 2 3 4 5 6 7 8 9 10
t (s)
0.8
0.6 exp(-kt)
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-exp(-kt)
-1
0 1 2 3 4 5 6 7 8 9 10
t (s)
tU ln1 U / k ln1 U
tU ' ln1 U ' / k ln1 U '
99% 1 99.9999% 3
k T H
f , ,impeller type
N D D
k/N =constant
100
fRe=tU/tU (turbulent)
10
0.1
10 100 1000 10000 100000 1E+006
Re
Piero M. Armenante ChE702 200
Effect of Viscosity Ratio on
Blend Time
f* is the correction factor to account
for viscosity effect, when the viscosity
of the added fluid is greater than that
of the liquid in the tank.
In order to calculate f* the viscosity
ratio:
added liquid
*
liquid in the tank
must be determined first.
Piero M. Armenante ChE702 201
Effect of Viscosity Ratio on
Blend Time
tU N constant
This implies that blend time experiments
can be conducted in small scale
equipment to determine the above
constant, and that this equation can be used
for scale-up purposes
1
N D large scale
P / V small scale N D 3 2
small scale
N 3
D2 N D
large scale
3 2
small scale
2
Dsmall scale 3
Q
NQ 3
Q NQ N D 3
ND
it follows that:
V V
tcirc
Q NQ N D3
Piero M. Armenante ChE702 214
Blend Time and Circulation
Time
The relationship between tU and tcirc
can be obtained recalling that:
tU N constant
Then:
tU N NQ D 3
t circ V V
NQ N D 3
Piero M. Armenante ChE702 215
Blend Time and Circulation
Time
Finally:
NQ D
2
D D
3
NQ
tU 4
t circ / 4T H
2
T H
For a given system, and for a pre-
assigned level of uniformity, U, all the
factors on the right-hand side are
fixed. Hence tU/tcirc is constant
Piero M. Armenante ChE702 216
Blend Time and Circulation
Time
Example: Disk turbine in a standard
mixing system
NQ=0.8
D/T=D/H=1/3
If U=99% (=47) t99=5.3tcirc
If U=95% (=0.6547=30.5)
t95=3.5tcirc
Approach 2
For example:
t 99 ln1 0.99
1.537
t 95 ln1 0.95
Piero M. Armenante ChE702 224
Blend Time Equation in
Turbulent Regime: Approach 2
For mixing in turbulent regime
(Re>~10,000) the Grenville equation
becomes:
1.74 ln1 U T H
1.5 0.5
tU N
D D
1/ 3
Po
0.33 < D/T < 0.50
C/T = 0.33
0.50 < H/T 1
Po = Impeller Power Number
Piero M. Armenante ChE702 225
Blend Time for Turbulent Regime
with H/T=1, T/D=3: Approach 2
Impeller Equation
Disc Turbine t99 N=51
Flat-Blade Turbine t99 N=62
(4 blades)
45 Pitched-Blade Turbine t99 N=81
(4 blades)
Marine Propeller t99 N=127
Chemineer HE3 t99 N=132
Piero M. Armenante ChE702 226
Impeller Efficiency in Turbulent
Regime: Approach 2
From:
1.74 ln1 U T H
1.5 0.5
tU N
D D
1/ 3
Po
and: P Po N D3 5 3
Po N D 5
V / 4T H 2
T 3
it is: 1 1
1 T
2
3 3
tU T 3
D
Piero M. Armenante ChE702 227
Impeller Efficiency in Turbulent
Regime: Approach 2
From the previous equation for turbulent
regime, it is:
all impellers of the same diameter are
equally energy efficient (i.e., achieve the
same tU at the same power input/mass)
shorter tU are achieved with larger
impellers at the same power input/mass
blend time is independent of fluid
properties
when scaling at constant power
input/mass and similar geometry blend
time increases with the scale factor
raised to 2/3
Piero M. Armenante ChE702 228
Blend Time Equation in Transitional
Regime: Approach 2
tU N
Po Re D
2/3
From:
11,181ln1 U T
2
tU N
Po Re D
2/3
and: P Po N D 3
Po N D 5 3 5
V / 4T H
2
T 3
it is: 2 2
1 T
2
3 3
tU T 3
D
Piero M. Armenante ChE702 231
Impeller Efficiency in Transitional
Regime: Approach 2
From the previous equation for the
transitional regime, it is:
all impellers of the same diameter are equally
energy efficient (i.e., achieve the same tU at the
same power input/mass)
shorter tU are achieved with larger impellers at
the same power input/mass
blend time is proportional to viscosity and
inversely proportional to density
when scaling at constant power input/mass
and similar geometry blend time decreases with
the scale factor raised to 2/3 (however do not
forget that that Re increases with scale, and larger
system may no longer be in the transitional
regime)
Piero M. Armenante ChE702 232
Conclusions: Power, Flow and
Blend Times in Mixing Tanks
Under turbulent conditions, the power dissipated by
an impeller depends on:
agitation speed (PN3)
impeller size (PD5)
type of impeller (PNP)
density of the fluid (Pρ)
Axial impellers and radial impellers generate
different circulation patterns
In general, axial impellers generate more flow per
unit of power dissipated than radial impellers
Blend time is inversely proportional to the impeller
agitation speed and is not generally significantly
affected by scale