lMirinq ol Fluids 285

Chapter eight

Mixing offluids
Levenspiel l consider.ed when two fluids are nlixed rogelher,the molecularbehavior of the dispefsed lluid falls betweentwo extremes. If molecules are completely tiee 1o movc about, the dispelsedfluid behaves as a microfluid and exhibitsro flrid segregation. At the opposileextreme,the dispersedfluid remaiDsas clumps coitai ng a large nu ber of lnoleculesand is termeda n1acrclluid.Fufihermore. as the macfofluid is transfbrmedto a nicrofluid by physical mixilg processes (e.9.,turbulelceor noleculat diffusion),the degreeaDdscale of segregalion(i.e., thc averageof lie seglegaled clumps) decrease. An importantnlixiig opelatiollinvolvcsbringing djflerent lnoleculai. speciestogether to obtain a chemicalreaction.Thc compoDents may be miscible liquids,immiscible liquids,solid particles and a liquid.a gasand a liquid,a gnsand solidpadicles. or two gases. In somecases, temperaturcditlerencesexisl betweenan equipmcnt surface and thc bulk fluicl, o[ betweenthe suspended partic]esand the continuous phasc lluid. Thc same mcchanisms fhilt enhance mass lransi-er by reducingthe film thicknessare used to promotc heat translerby jnc.easingthe tempcratlre gradientir the tlim. Thcse mechanisms are bulk flow, eddy diffusion, ard moleculardilTusion.The pedbrnance of equipmentin which heat tLansfeloccurs is expressed in terms of tbrced conveclive heal tansfer coefficients. This chapler revie\ls the various types of impellers, the flow patterns gerleraledby these agitatols, corelation of the dimensionless (i.e.,Reynoldsnumber,Froudenurnber, parameters and power number). scale-upof lnixers, hea! lransfercoef{icicltts of.iacketedagilated vessels,and tl'ie time required lor heating or cooling these vessels.

MIXING AND AGITATION OT FLUIDS

N4anyoperationsdependto a great extent on eifective mixi[g of fluids. Mixing ref-ers to any opelation uscd to charrgea norr-urlilbfm systeminto a ulliform onc (i.e., the ralldom d;stribution of two or nToleirlitially sepalated phascs): agirarion impljesforcilg a lluid by Dechanical mcens to llow in a circulatoly of other pattetn insidc a vessel.Mi\ing is an integrai pallt of cheDical or physical processes

ng Processes 286 ChemicalEnglnee

such as blending, dissolving, dispersion,suspension,enltlsification, heat transfer. and cheJnicalreactions. as the nixing of two call be considerecl Dispersion characteristics and liquids, or liquids and gases, immiscible licluids, solids or more into a pseudo-honogeneotsmass.Snall drops a.e createdto provide oontact bctween immiscible liquids. These liquids a.e lnixed for specific purposes,namely solvont extraction. removal or additior of The terlns dispeftion heat, and to affect massftansferratesh reactors. Dispersion is a general and emulsion are often used interchangeably. term that implies dislribution, whereasemulsion is a special case of dispersio[. Dispersion is a two-phase mixnue in which drops may coalcsce.The mate al present in a larger quaniity is referred to as the continuousphaseand thc material prcselltin a smaller quantity is m;xturc ol very phase. An emulsionis a Lwo-phase cajled the dispersed The stability of occll.s. fine drops in which littlc or no coalescence on surface ion activity, which is a function of an emulsion clepends particle size. Colnmon dispersionsare water ard hydtocatbons,and combiled wilh oryanicliquids.Table8-1 solulions acidicor alkaliDe purposes for agitaling Iluids Coker[2]. the prircipal summarizes AGITATION EQUIPMENT Various types of vesselsand tanks of differing geometricalshapes and $izes are used for mixing fluids. The top of the vessel may be open or sealed.the vesselbottom is nornally not l'lal

Table 8-t tor agitating fluids Characteristics

L B l e n d i n go f 1 w o m i s c i b l cc , f i n i s c l b l el i q u i d s . 2 . D i s s o l v i n ss o l i d si n l i q u i d r .
Dispersnrga gas in a lntrid ds fine bubbles (e.g., oryscn f.on air in a suspension ol micfoorgaDisB1br fenneotationor lor aclilrled sludge treatmen0. Agitation ol the lluid !o increasebear tfaDsferbclwccn lhe llltid and a coil

i . Suspensionof finc solid pr jcles in a lrquid, such as in lhe caralyric hydrogcnalion of a liquid wlrere solid catilysl and hydrogen bubbles arc dispcrscd jn the liqrrid. ( e . g . .i s o n e o f d r o p l c l so f o n e i n m i $ c i b l el i . l u i d i n a n o r h e r 6. Dispcrsion proccss of liquid exrfactio,r). bcrerogeneous feaciion huid

but rounded to eliminate sharyco.nersot regionsilrto which the fluid curents would not penetrate; dishedends ate most common.The liquid depth is approximately equalto the dianeter of tle tank. An impelleris molLnted on an overhung (i.e.,a shaftsuppotedlrom sh,Lft, above). The shaftis motordriven;this is solEtimesdirectlvconnected lo lhe :harl. brrri. rrr,'re oflen connecled.lh,',ugh c speed-.eciucing gearbox. OtherattachmeDts includeinlet and ortlet lines,coils.iackels. and wells ior thermometers. Iiigure 8-l showsa typical standard tank

I I
Figure 8-1. Siafdard tank contiguraiion.

I
H

EngineeingPfocesses 288 Chemical

configuration. The geometric proporlions of the agitation system, a typical standarddesign are given in Table 8-2. which are considered These relative proporlions lorm the basis o{ dle najor corelations of agitation p(-Ifornlancefrom various studres. There are cases where WDa = 1/8 and J/D r = l/10 fol some agitator correlatiols. Usually,4 baffles are used aod the clearance betweenthe baffles and the wall is about q.l-0.15 J. This ensuresthat the liquid does not form siagnantpocketsbetween the balfle and the wali. The rumber of impellel blades varies lrom 4 to 16, but is Senerally between 6 and 8. Mixilg by agitation of iiquids normally involves the ffansfer of momenlum fton ao impelle. lo the liqllid. In some cases,mixing is achievedby gas injectioll or circulation via a pump loop. An jrnpeller, which is mounted or a shaft ddven by an elcctric ilotor, is divided into two operation categories: iD which the Where monlentltlnis t.ansferredby shearingstresscs, This caiegory transfcr is perpendicularto the direction of flow. d i c ca n d c o n e . r g i t r t o r s . i n c l u d e 'l h e f o t s { i n g The momeltun is translerred by l1orma] stresses,in which the transferis parallel to thc direction of flow. This categoly includes r h ep u d d l e p r n i \ e ra g i l r t o r s . . rof'eller. nd lrrrho

Table 8-2 proportions tor a standaad agilalionsystem Geometric

Do I Dr3

Dr. wl D,r 5

J1 DI 12 L1 De4

B = R = DA = H Dr = E = J= L = W =

numbef of blxdcs on lmpeiler number oi b:rftles agitator dianleter liquid heicht irnk diamcler heigh! of lhe agiiator frcm thc botton ol fte tank baffle width agitalor blade lenglh agirator blde width

but rounded to eliminatesh$p comersor tegionsiDto which the fluid currentswould not penetrate; dishedends are most common,The liquid depthis approximately equal to the clianetelof the fank. Ar irnpeller is rnounted on an ove rungshaft,(i.e.,a shaftsupported fiom abqve). The shai is motordriven;this is sometimes directlvconnected lo the \hrft. bur is moreolreacunnected.lluough ; .peedreducing jDclude gearbox. Otherattachments inlet andoutletiines,coils.iackets. a n dw e l l s . r e8 - t s n o u .a l ) p r c i rsl t r n d u d f o rr h e r m o m e r H f ir g.u trnk

-+lrfe"m"

Figure a-1. Standard tank configuration_

Agjtation plays an essential roLein the success of many chenical prccesses! and thercis a wide range of cornmercially available impellers that can provide the oplinun degree ol agitalionfbr any process. The problem arisesin selectingthe bestil11pelief for the requitedpr.ocess. Equipment mentfacturers often provide expert guidance.bul it is benelicial for designers andengineers to acquire fund4mental kilowledge of varioustypes of impeller's. The process objectiveof an impeller is the primary factor that detenninesits selection.These objectives, summalizedin Table 8-1, togetherwith physical propertiessuch as viscosib'pla),an importantrole in the selection of jftpellersin lamimr, transiiional. and turbulent operations.In genetal, impellers can be classiliedinto two main groups. Impellers wilh a small blade area,which rotale at high speeds. Theseinclude iu.bines and m4,ire propellers. Impellers with a large blade arca, which rolate at low speeds. Theseinclude anchors,paddles, and helical sdewsThe lelter inrpelle.sare very effeclivefor high-viscosity liquids and dependon a large bladearca to pruduceliquid rnovemenllhrougholrt the vessel.Since they are low-shearimpellers, tJreyare useful for nixing shearthickeningliquids.Figure8 2 showsa typical gateanchof agitator. ADchoragitatorsope.atevely closeto the vesselwall with a radial clearaace eqlLal to 0.0275DA- The shearing actionof the irnchof past produces blades the vesselwall a coltinual interchange of liquid lretweer the bulk liquid and lhe ljquid film betweenthe bladesand the wall. Fol heat traNfer appiications, anchorsare fitted with wall scrape.s to preventthe blLildupof a slagnanlfilm betweenthe anchor and the vesselwall. The anchorinrpelleris a good blendingand heat transl'er device when the fluid \,iscosityis between5.000 and -50,000 cP (5 and 50 Pas).Belo\,\'5,000 cq there is rot enoughviscousdrag at the tank wall to promoiepuolping.resultingin a swirling condition. At viscosities greater than 50.000cP (50 Pits),blendingand heat t.ansfei capabilitiesdecrease ?}spumping capacily declites and the impeller "slips" in the fluid. Helical scrcwsoperate in the laminarrar,ge at nor]nallyhigh impelle. to vessel dialneler ratio (DA/Dr) with a ladial clexrance equal to 0.0375DA. The impeller usuallyoccupiesone-third1()one half of rtre vesseldiameter. They functiorrby punping liquid frorn lhe bot|oln of a lank to the liquid sufnce. The liquid returnsto the bottom ot the

290Chemicl Engineering Processes

Figure 8-2. Gale anchor agitator. (SourcerHo and, F. A. and Bragg, R. Fluid Flow lor ChemicalEngineers, 2nd ed., Edwad Arnotd, tgg'.)

tank to fill the spacecreated\I/hen fresh liquid is punped to the surface. Figurc 8-3 showsthe flow patternin a baffledheiical screw tatrk.Baffles set away flom the tanl(wall createturbulence and,thus. enhance the eltrainmentof liquid io contactwith the tank wall. These are not required if the helical screw is placed in an off-centered positionbecause the system becomes self-baffling. Theseimpellersare usetul in heat translerapplicationwhen it is essential that rhe fluid closestto the wall rnovesat high velocities. Turbulentinpellcrs are classif'iecl as axial or radial flow impellers. Axial flow impellers cause the tank fluid to flow parailei to the jmpeller'slotation axis. Radialflow impellerscausethe tank fluid to

\_/

Figure 8-3. Flowpafternin a bafitedheiicalscrewsyslem.(Source: Holand, E A. and Bragg, R. Fluid Ftow lor ChenricalEngjneers, 2rd ect., eAwari

flow perpendicularto the irnpelier's totation axis. Small blade. hieh speeri Jm p r l l e r . t r e \ e d l n r n i \ l o w t u m e L L i r r t m i..,,,itr liquids f i g u r e . l 4 n t J 8 - 5 . r e . l e c t' e l ) . s h . r ud l e \ i \ , t h r b l r d e l u r b i n (l , u d manl1e piope]ler type agitzttols.Figure 8 6 shows flat blade turbines used to produce radial flow patternspetpendicula. to the vessel wall. In contasr, Figure 8-7 depicasma ne-type propellerswith axial flow

292 Chemical Engineering Prccesses

Figufe 8"4. Six tlat blade lurbine.(Source: Ho and, F A. anclBrcgg, R. Ftuid Flow for ChemicalEngineers, 2nd ed., Edwad Arnotd, 1995.)

Figure 8-5. Marine propeller (Source: Hoqand,F-A. and Bragg, R. Fluid Ftow for ChemicalEngineers, zrd ed., EdwardArnotd, 1gg'.)

Mixing ofFluids 293

(-( )' \\ )

t)

r \\l// ,' \ -

!1^r

Figure 8-6. Radial flow patiern prodLrced by a flat blade iurbine. fsourcel Halland, E A. and Bngg, R. Fluid Flow for Chernical Engineers,2rd ed., Edwatu Anold. 1995.)

r-=\

II
. \l

4'

?)l

Figure 8-7, Axial llow pattern produced by a marine prcpetteL (Source: Holand, E A- and Bragg, R. Fluid Flow ior Chemical Engineerc,2nd ed.. Edward Amoki, 1995.)

294 Chemical Engi.eering Processes

patterns.Both of these types of impellers are suitable to mix liquids with dynamic viscositiesbetween l0 alld 50 Pas. Severalmetl.]ods of selectingan impelier are available[3,4]. Figure 8 8 sl.rows one method based on liqlrid viscosity and tank volume, and Table 8-3 illustrates another basedon liquicl viscosity alone. Axial ilo$, devices such as l gh efiiciency (HE) impellers ancl pitched blade tlrbines give better perfoinance than conventional pitched blade turbines. They are best suited to provide the ess(]ntial flow patternsin a tank that keepthe solids suspended. High-efiiciency impellers cffectively convefi lnechanical energy to verticai flow

101

loo

101

102

10" 10"
x

E x l r u d eR r ,o l lM i l l , e t c . Anchor, Hel i c o lRi b bo n

to"
l0z 1 nr ;

104 103
J

10u

102
.l

iY,'J:'.-tV\
loz io3
/< l0-

P r o p e l lre \el

Pr o p e l lre { 42 0r p m } , Tu rbin e 1010"

-7

rol

V e s s e lV o l ume( V ) , 9 s ollon
Figure 8-8. lmpeller selecIlo.. (Saurce:penny, W. R. "cuide to touble free mixets," Chem. E^9., 77(12), 171, 1970.)

lvliting of Fluids 295

taDte 6-J

Impellerselection guide Type of impeller

Range oI liquid, CP
t02 2 x tol l 0 u, 1 0 4 lou-3x lOa 10'? 3 x loj roj lo5 3xior 3xld i0"-2xi0"

Viscosity, kg/m - sec

r0r-2 lo3 t0' l0-r 3 x 10' loj-3xior
! ioo l0l

3 3xl0' lor 2 x 101

S.urte: HalLa.l, F A., atu Chdprrr, t: 5: Liqlii lvlixingand Pro.ossing iI Stified T.Dks. Reinhold, N.r' tut+, 1966

required to overcome fhe elTects of gravity on solids iD suspension. They also plovide the same levels of solids suspensionat rcduced capital and opelating costs. FLOW PATTERJ\ In fluid .rgifation, the direction as well as the mngnitude of the veloc;ty is c tical. The dilections of the veiocity veciors rhroughout an agitatedvesselare.eferred to as the flov patteln. Since the velocity disi bulion is constantin the viscous and turbulenl ranges,the flow pattem in an agitated vessel is fixed. During the mixing of fluids, it is essential to avoid solid body rotation aDd a latge cerrral su*ace voltex. When solid body roution occlus, adequatemixing is not achievedbecausethe fiuid rotates as if it were a single ass as shown in Figure fl-ge. Centrifugal lbrce of the fluid cnusesa cenfal surlace vortex fo be thrown outward by the impeller. Entrainrrent of ai. rcsu1lsif the vortex reachesar irnpeller, reslrlting jn rcduced mixing of the fluids. This !'ituation can be avefted by insralling balfles or the vesselwalls, which impede rotaliotal flow without interfering with radial or longitudinal flow. Effective baffling is attainedby installjng vertical stdps peryendiculalto the wall of fhe tank. Witi dre exception of large tanks, four baffles are adequateto prevent swi.ling and vorLexformation. For ptopellers, the width of the baffle should be less ore eighteenth the diameter of the tanki fol

296Chem icalEngrneer ng Processes

(a) Axialor radialimpeilers Figure 8-9.Agitalorflow patterns. withoutbafiles produce vortex.(b) Ofi-center location reduces lhe vortex.(c) Axial ;mpeller with baifles.(d) Radialimpeller with baffles.(Source; Walas, S. M., Chemical ProcessEquiprnent-Selection and Design,Bulterworths Seriesin Chemical Engineering, 1988.)

turbines,less one-twelfththe tank diatneter. Figure 8-9 shows the variousflow pattertrs of radial and axial impellers. Reducingvortex lbrmation ll1ayalso be aohieved by placing an impeller in an oif-centerposition.This createsan unbalanced flow pattern,reducingor eliminatilg the swirl and therebyincreasing or naximizing the power consumption. The exact position is critical, sincetoo far or too little off-center in olredirectionor the other will causegreaterswirling, erratic vortexing,and dangerously high shaft stesses. Changes in viscosityandtank sizealsoaffectthe flow paftem in suchvesseis. Off-cenlermountingol radial or axial flow impellers is readily employedas a substitute for baffledtank iostallations. It is coilmon practicewith propelie.s, b.lt lesswith turbiie agitators. Offcerter nlounting can also be useful for a turbine operatedin the rnedirnn viscosityrangeand with non-Newtonian lluids wherebaffles causestagnatioo with little swirl of the fluid. Off cenier n:lountir1gs havebeenquite effective in the suspetrsion of paperpulp-Figure8-10 illu$trates positionibr ptopellers, an angularotT-center wl'iichis eflectivewithoui using ballles.

Fig!re 8n0. Flow paltern ot prcpe lerc in an eccenlricaig e and off-ceniered

296 Chemical Engineering Processes

Once swirling stops, the spccil'jc flow pattcrn in the tank depends or the type of impeller. Paddlc agitalors and tlat-blade tLrrbines pronote good radial flos'in the planc of the in1peller wiih the flow dividillg the wa11 to fblm two separare (Figure 8 6). circuliition parterns portion One tlows down along the wall and back ro thc center of the impellcl' fron below, and the other flows up toward the surface and back to the inrpeller fiom above. Propclle. agitators drjve the liqlrid down to lhe bottom of tlte tank. whcrc the stream spreadsradiall1,in all dircctionstowatd tlie wall, flows upwa along tl.tewall, and retums to ihc suction of the propellet lion the rop. The earlier Figure 3-7 shows lhe flow patte.n ol a propeller agitator.Propellersa.e etnployed when beavy solid particlesare suspcnded. Table 8 4 shows flow patternszlnd applicationsol sone cornmercially availableilnpellers- Generally,the axial 1'lowpatlern is mosl suitable lor llow sensjtive operation such as blending. heat transfer, alrd solids suspension! while the radial llow patrern is ideiLlfor dispe$ion opcrationsthat require highet shearlevels thao are provided by axial flow impcllers.Myers el al. [5] hale described e selection of ilnpellcrs wi!h applications. Fllftlrer dettils on sclcctionare provided by Uhl and Gray f6l, cates et a1.f7l, Hicks et al. l8l and Dickey [9]. POWER REQUIREMENT FOR AGITATION The flow mechanisnr in a ni,\ing tank is very conplex. Va.ious techniques, includirg computarioil4l fluid dynamics(CFD) and computationirl iluid miring (CFM) tools, are enployed together with cxperimenlal date to eslablishintpfovelnei]tsin mixing \.vithincreesedyield. Estimating tl'ie power consumptiotl for any agitator is essential fot clesign. Cenerally,the desiredrequirements 1br-thesystemto be ixed will categorize the type of i1npellerto be used. Laboratory tests on the system can estabiishtle ilppropriatespeecl tbf the maintenancoot' isotropicturbulence in the nixing vessel. Therefore. estimaring fhe power consumplioll for a large-scaiemixing operation must inclLrde scale-upconside.ations. These requirementsmay bc detemlined ftom the Narier-Stokes equation ol analyzecl by a dimensiolalanalysis of the mixing opeiadon. The powerconsunedby an agitalordepends on ils dinensionsand the physical properties ol lhe fluids being mixed (i.e., density and viscosity). Since there is a possillility of a gasliquid sur-facebeing

Table 8-4 lmpellersand flow patterns

!4qjnFfu'b95dipldi'

Dffi;I l;da'e6o

4!;@'brtrbkhe

fd=3 o

'{'dN"q,hD4*&d

ffi

t"-l

ffi
rlijl

4 4,
S.!rce: Mrers, K., .t .1., Asrd,t,n Jdr ,'!..esi Rrpn.luced with pernisi.n' of tch.rtE lhe Chemical lrlsineer. Oct. 10, 1996.

300ChemicalEnginee ng Processes

distorted,as in the fomation of a vorlex, g.avity forces must also be considered. Consider a stired tank vessel havitrga Newtonian liquid of density p and viscosityp is agitaaed by an impellerof diameterDA, rotatitrg at a rctational speedN. Irt the tank diarneterbe Dr, the impeller width W, and the liquid depthH. The power P requiredfor agitationof a

single-phase liquid canbe expr-essed as: P = f(p', pb,N', go,Di, Df, wc, Hf

'

(sr)

Therc are nine variablesand threeprimary dimensions,and therefore by Buckinghan's theorem,Equation8,1 can be expressed by (8-3) dimensionless groups. Employingdimensiotalanalysis; Equation8-l in terms of the thlee basic dimensions (massM, length L, atrd time T) yields: Power = ML2T 3. Substitution ot the dimensions into Equation8-1 gives, ML2r-3 = f{O4L 3)",(Ml--r1r;t, r, (LT*"f, L., Lr, Lc, Lhl (8-2)

Equatingthe exponents of M, L, and T or both sidesof Equatioo 8-2 gives M: L: T: 1=a+b 2= -3a-b+d+e+f+g+h -3 =-b c-2d

(8-3) (8 4) (8-5)

From Equation7-3 (8-6) Substituting Equation8-6 irto Equarior 8-4 gives 2=-3(l-b) b+d+e+f+g+h (8-7)

5=2b+d+e+f+g+h From Equation8-5

b=3

c-2d, or

c=3-b-2d From Equation 9-7 e=5-2b -d f g-h

(8-8)

(8-9)

Substitutirg a, c, and e on the right side.of Equatipn 8-1 yields f = f(Ot o, pb, N3-b 2d, gd, D5 2b-d-r-c-h, D+, Wc, H n) {r-ro) Rearrangingand grouping the exponentsyields,

p = xlorjol f--u-l't g-l'[!,)'( * )-t'-" f Il

(8-1r)

u )"f r ffq,)'r*ff -P = =-ll "j "t'l o,ot tpNl6 Jltri,^ l tD^ JJ c') Jl%Jlo^
The dimensionless parameters are: The Power nu.b.r. N" = .lg:. gL - drmen.ronal gravitation cx oln s l r n t

r.fT.tt, :z.,ro tDr secI kg ' rn41 ' '""2 PMi The Revnolds no-b".- No" = tl .N,D, The Froude number. Nr, =

302Chemical Engineering Pro@sses

Substituting thesedimensionless numbers into Equation8 12 yields,

= oo, *{^..: ^* (+l(#)'(r+)'}

SIMILARITY

( 8 -1 3 )

Equalityoi i l groups in Equation 8-13 assures similarity between systens of dilferent sizes.The types of similarity are geometdc, kineinatic, and dynamic. The last thrcetermsof Equation 8,13 represent the conditions tor geometic simil(rrity, whrch require that all correspondingdimensionsitr systemsof djfferent sizes have the same ratio to each other.For geometficsimilarity, Equation8 13 becomes
Np = KNR: NFrd

(8-14)

The constant K and lhe exponellls Ll and d must be determined for the llarticular type ol agitator, its size aDd locatiol in lhe tank. the dirrensionsof tlle tank. and the depft of thc liquid. Kinc Ntit- li//rilddal,cxists bot$ccl1two srsteJls ul dilfereal sizcs *be]] the_\ rfe gcontctficallysinrilararid \lhen the rlitios (]1 \elocities between oor]lsfondi[g ]toir1l!in one systenr arc cquitl to thosein the other. D|nLonic sinlilLlitj, exists betweel two systems when, in addition to being geometdcally and kinematically similar, the mtios of forces between consponding points in one system are equal to fhose in the othel. The value of NR" determineswhetherthe flow is lrr;ti:ll| r:r lrtrbLrlrnt and is a significant group alfecting the power.consumption. The Frordc number N",, representingthe ralio ol-iI1ertial to gravitalional lorccs, is only significant when the liquid in the tank swhls to such an extent that a deep vortex is formed and the wave or surface effects become impoflant. In an unbaffled vessel, a balance between the inertial and gravitational forces detemtines the shape of any vortex. The Po$c| nurnbe| N,, may be consideledas a,i|:i! rr,il-ljri1]li 1r'
i l r ' .1 - : : , ! il : , . : : r r - ,

Experimeutaldata on powet consumption are generallyplotted as a l'u[ction of the PowernumberNp versus ReynoldsnumberNR.,that is by rearangirgEquation 8-14.

o=$4=r<u;3

(8ls)

For a fully baffled tank, b = {l and O = l.ir,.A generalized plot of Equation9-15 is shownin Figure8 11.The power corelation indicates three rangesof liquid motion: laninar (viscous),transition,and tuabulent.The lamiiar or viscousrangeoccursbelow a Reynoldsnumber of 10. The expected result of the Power number being inversely proportional to the Reynolds numberis alsoconfirmedby experimental data.The Froudeeffectsare unimportantand a logarithmicplot of the .ela6on betweenPower nunber and Reynoldsnunber gives a slope of -1 in this range.FLdlyturbulenL lgilatiori occursabovea Reynolds number of 10,00i).The rangebetweentheselimits can be descrjbed as the tralsition flow becauseflow patter[s change dependingon the Reynolds number.Figure 8-12 shows tlte Power number versus Reynoldsnumberplot for the unbaffledsystem. Both Figures8-11 and 8 12 are identical to point C where Np. = 300. As the Reynolds
rurl,tent I

AeM -

Figure 8-1i. Power curve for the standardtank conf iguration.(Source.' Holland,F A. and Bragg, F- Fluid Flow for Chemical Engineers, 2nd ed, EdwardAmold, 1995.)

304Chemical Engineering Processes

l._vi,.ou. rong.
I

rurburni-.l 'onq. I

to2

I I

1Or

too

1o!

to2

105

1o'l

6e" * Figure 8-12. Powercurvefor the standard tank conflguration withoutbaffles. (Source: Holland, F A. and Bragg, R. Fluid Flow for Chemical Engineers, 2nd ed., Edward Amold, 1995.)

numberfor mixing increases beyondpoint C in the unbaffledsystem, vortexingincreases and the Powernumberfalls sharply.Fier|r 8,13
!hon'! th. |.,,r.'r) llur:tbei:L liirrtio11r)i tiic Re\jnolCs l1LrrlbeI f-or shexr'tiliiuli|r: llLriii,,.The ful1 line gives the Newtonian Power number obtained by Rushton et al. l10l for a flat-blade turbine system,while the dashedline shows Metzner and Otto's L11l plot for shearthinning liquids. Figure 8 13 illustrates that at no point is the shear thinning power curve higher than the Newtonian powgr curve. Therefote, the use of the Newtonian power curye to determine the power will give a colseNative value when used for shearthinning liquids. Figule 8-]rt shows Power nLlmbercorrelatiorlslbr various t],pes of agitators.In the fully turbulent flow, the curve becomeshorizontai ancl the Power numberN" js indepcldsntof the Reynolcls nu]nber. Rushton et al. uOl performedextensivelneasLlrements of the power requirements for geometrically similar systems and found that for baffled tanks, the Froude number plays no part in deternining the power reqliremelts, as vortices do not form in such systems. For unbaffled systems,the Froude number plays a part above NReof about

l ixing of Fluids305

-----

Linr ot Rurhto, cortidr dd Ey.r.tt Linc of lldu|llr d|d Otlo

.' = -!!d14

BeN-.....-

Figure 8-13. Deviation powercurvefor shearthinningliquids. from Newlonian (Source:Holland,F A. and Brcgg, R. Fluid Flow ior ChemicalEngineers, 2nd ed., EdwardAhold, 1995.)

300. They reportedNp = 6.3 in the lurbulent range 01 10,000.After extensivecuNe fitting of their experinentaldata,a single curve was obtainedfor any particularunbaffledconliguration.If @ is plotted as a futrction of NRewhere O is defined as
(D=N-

lbr NRe< 300

NP

)/uJ ,rr[1" t.strn.

for N.. > 300

(8-16)

where a and b are constantsfor any configuration (Figure 8-14). Dickey alrd Fenic F2l observed that the impeller characteiistics have significatrtinfluenceon the Power numbercofielation.

306Chemicl Engineeinq Proesses

d=Np it F.o.NFe33oO ,Np o'ii;#Giniah

NFa'roo rrR=o

ReynordsN!mb.r (NRe)

p ,= D i 1 .P r o p e l l e F R=0 aj2.1, b- 18, B=3 2 , P r o p e l l e r sp ,=Di R=4 J = 0 , 1f t B=3 3 . P r o p e l e r sp , =20 R=0 a=1.7i b=18; B=3 4 . P r o p e l l ep B= ,2D; R=4 J=0.17t B=3 5. Flatblade d sclurbine, R;0;a:110i b:40.00 6 Flatblade discrurbine, R:4'J=017i B=6

7. CuNedblsde disclurblne, R=4; ! =0.11" B-6 8 AtrN-headdisciurbine, R:4iJ:o1T B=6 9. Pllched tlrbine blade R=4;!=0.1r; B:8 R=4 J:0.1r' B:2

R=4i J-0.17 8=6 12.Diffuser ing shrouded lurbinos slEtor nnShaving 20 blades, B=6.

Figure8-14.Powe.number versus Reynolds number co elation for common impellers./Sour.cei Ruchtonet al.,Chem. Eng. Ptog., 46, No. 8, 495, 1950. Repinted with permission of AlChE. Copyright @ 1950. A tights resetved.)

Two chafacteristics of Figure 8-14 are: 1. At low NRe< 1.0, Np * l/Nr", independentof the presence of baffles. 2. At high Reynolds, at which most mixing operations arc performed, the Power Dumberis constant,that is, Np - P/pN3D5 = constant, Rushton et al. uol investigated the effect of varying the tanL geometdcal ratios and the corrolatiol of the Power number with Reynoldsnumber.At high Reynoldsnurnber,it was inferred that,

Mixing ofFluids 307

. iD is relatively unchanged when Dr/DA is varied from 2 to 7 for propel]er-agitaLed turbine- al1d baflled systems. . O is unchanged when ItDa is varied flom 2 to 4. . O is unalteredwhen E/DA is chargediiom 0.7 to 1.6. . O changesto O * (J/DA)0'3 when J/Dr is changedlrom 0.05 to 0.17. . iD dependson the numbe. of bladesin the turbine impeller as: 6-18/6)08ttU.6un,1 O-(Bi6)0i if B > 6 (where B = number of impec l l bla.lc.r. . If off centeredand inclined propellerswithout baffles or sideentedrg propellerswithout bafflesare used,no vortex forms and the O versusNo" curve for the coffespordingbaflled tank can be usedto estimatethe power requircmetrls. These conclusionsare speculative ard experimental curves must be generatedif more than one geometricalratio differs from the standard value. The power consurned by an agitakrrat vadousrotationalspeeds and (e.g.,\'i$.orlr: dlld ,jeitil!) for a system's physical properlies geometry can be determinedfiom the Power number correlation.The procedureinvolves: . CaicLr]ntin: tlre trle:rolds nunrher N,a.for rnixing. Rcadingthi Pore. nunbcf :\lp1io 1hc xpplrpilat.ccurli. and
ciLlculnljng fhc po\!c! P :li\.n h!

p=Nr,.pN.iDi bcNR")/b] or p=opN3D5\.N[1."

(8-r7)
(8-18)

Equaliors 8-17 artl 8-18 al.ethe power consunedby the agitator. Additional power is requiredto overcomeelectricalaDdmechanical (e.g.,85olc) losses. A contingency of notor loadingas a percentage is addedwhen selecting the motor Equation8 17 can also be rearranged to detemrine impeller diameterwhen it is desiredto load an agitator impellei to a given power level. The torquedeliveredto the fluid by an impeller fuom its speedand power drarl,is delerminedby:
D \r ^Nr2rr5

2rN

2n

(8-19)

308Chemlcal Ensineenns P@cesses

The primary pumping capacityof an impeller is determinedby the impeller diameter,the Pumpinguumber,and the rotatioral speed.The Prmping nLrrnber No is dcfired by [13]
n, Q"

"Q

NDi

(8-20)

The lumping number is used to determinethe pumping rate Qp of rn impeller. where Qe = eflective purnpirg capacity,inr/sec N = impeller rotational jjpeed,sec I De = impeller diamcter. nl Hicks et al. [8] developed a correlation involving the Pumping number and impeller Reynolds number for severalratios of impeller diemeter to tank diameter (Do/Dr) for pitched-bladeturbines. From this correlation,Q" can be detemined, and thus the bulk fluid velocity from the cross-sectionalarea of the tank. The procedure for determining the pammetersis iterative becausethe impeller diameter DA and rotational speedN appearin both dimensionless palameters(i.e., N^" and Nq). Figure8- 15 showsploTs ol'Pumping nurnbe| N, andPowet nuulber Np as lunctions of Reynol.l\ numbcr lr{*" for a pitched-bladeturbine and high-efficiency impeller. Hicks et al. [8] further introduced the scaleof agitation,So, as a measure for determiningagitationintensity in pitahed-bladeimpellers. The scaleof agitation is based on a characteristic velocity, n defined by -r= Q" wherc v = charactedsticvelocity, m/sec Av = cross-sectional area of the tank, m2 The charactedsticvelocity can be expressed as:

(8-21)

"-''...,^i+]

(8-22)

Figure8-15.Power number and Pumping nurnber as tunctions of Reynolds numberfor a pitched-blade turbine and high-efficiency impellet.(Soutce: Bakker,A-, and Gates L. E., "ProperlyChoose Mechanical Agitatorc for Viscous Liquids,"Chem.Eng. Prog.,pp. 25 34, 1995.)

In geometrically similarsystems, the characteristic velocitybecomes

v - N^ND^

(8-23)

Thus, during geometricscale-up, the characteristic velocity is held constart by holditrg NaNDA constant.Qp is determinedfrom the Pumping number and Figure 8-15. SA is a linear function of the characteristic velocity and is determined by S^=128''' (8 24)

Accordingly,a value of Sa equal to I represents a low level and l0 shows a high level of agitationintensity. The 1 10 range of agiaation intedsity accounts for about 9570or more of all turbine, agitationapplications, enablingit to be suited for a wide range of process operations. Gateset al. [l4] gaveguidelines on how to relate proues\ So to specific irpplicaLions

Engineering Processes 310chemical

NIIXING Tih{E CORRELATION

The mixing ard agitation. A distinctionwas madeearlierbetween jntermingling third term in liquid mixing is blending.This lefers to the of miscible fluids lo produce some degrce of uniformity A criteion fol good mixing may only be visual. For example,it could be a particularcolor liom two differentcolor liquids,or the color charge of an acid-baseindicator tiat determinesthe Iiquid blerding times. of blendirg i. agitatedvesselsis usually in terms of Charactedzation mixing time. This is the timc requifed to achieve some specified degree of unilormity at'ter introduction of a tracer' Table 8-5 gives various techniqueslbr determiningblending tinie. measLlres a differelt degreeof unjformity, therelbre' Each techniclue the time required for blending may dilfer from one method to the other. The correlatioDof blending tlne as delived ftom dimensional Uhl and Gray [6] summarized analysisis applicableto all techniques. mally of the experime.rtsand correlations on blending and mixing similar systems, times.For a given tank and impelleror geometrically the mixing time js predicted to vary ilvelsely with the stirrer speed, Figurc8-16 showsplots as confiuled in variousstudies [15,16,17,181. of mixing time (tN) against th|r Reynolds number N"" for several a tu.binc with DA/Dr - l/3 and Dt/H = 1, As an example, systems. the value of Nt is 36, for N*. > 103,comparedwith a predicted value of 38. Table 8-5 Methods tor determining blending time Technique
Grab sample Dye inlroduction Conductivity cell

Tracer
An,v malerinl that can Dyed fiuid. Concentradorof srlt

Blend time reached when

Samplesdo not vary more than 1X9. from frnal concenfiatioD. Uniform color is atiained. Measurcd conductivitythdt reprc is within sents concertration 1XE of frral concentmlion. Neuiralizationis complele as determinedby color change
" Chem Eng,

indicator Acid G,r base). Acid-basc

Sow?: Dickq, D.5.,

'Dnncnsk\ol rnol,-sit.ftt lluid |gitoti.rt !l\t"

E
= =

f i E Y N o L DN SUrvlB FE , r v F .- , D l p l !

times in agitaledvessels.Dashed,ifes represent Figuie 8-16, IVixing unbaffledtanks; solid lines representsa balfled iauk. (Source:Mccabe, 4th ed., Mccraw-Hi of ChemicalEngineering, W. L., et al., Unit Operalions Book Company,New Yotk, 19a5.)

a mixing time corelation for Prochazka and Landau[19] developed tank in the standard Ruslrton turbine impeller in a baffled a single for N^. > 104: configuration

=,'.,ri,:i!.1'',,,,i:..l x, '1!..
\D.j 1
For a propeller,the mixing time is given by:
. . . t0 i

{8.-tj)

NL=.r+slLl l"*[L'l
\D",1 1X.J
For a pitched-blade turbine,the nixing time is:

(8-26)

xr=-t,-'il|l iij

r,,.i - l \i
\

rq 17\

Processes 312Chemical Engineeing

where 4 = initial value of the degreeof inhomogeneity, which vades of 2 is recommended between 1 and 3: a valLre = X" final integral mean value of the local degreeof inhomogeneity and is defined as:

- c^ cttr _f l ' "- L c"-c' l

where C(t) = instantaneous concentration = Ct initial concenfation C^ = final concentation

(8-28)

X" = 0.05 for most configurations. Moo Younget al. [20] corelated their mixing results from

Nt =KNi"

(8-29)

where K = 36 and a = 0 for turbinesin baffled tanks for 1,000< NRe < l0'. Sanoand Usui [2ll developed an expre\sion lor mi\ing limes bv tracer iniection for turbinesas:

Ll Nr=:.el

.-t.\0,

. {.51

{Dr /

ifLl
\Dri

nJrT

(8-30)

where np is the number of blades.Gray [22] found the mixing times of helical ribbon impellers to be of the form

Nt=30

(8-31)

where N is tlle rotational speedof the helical dbbon impeller, and t is the batch mixing time. Fasanoet al. [23] expressedthe blend time for turbulence conditions in a standardbaffled tank (i.e., NR" > 10,000) as:

4.065

(8-32)

"..[3;)'(?l'

Mxingof Fluids 313

where a and b are the t11ixillgrate constants.Table 8 6 shows values of a and b for different il]rpetler types. The constantsare lor suface addition, however,blend times for similar fluids are relatively insensitive to addition location. Equation 8-32 is limited to the following: . Newtonian fluids of nearly the same viscosity and density as the bulk fluid. . Additions of 5oloor less, of the fluid volume. . Additions made to a vessel already undergoing agitaaion(blend times of sfatified fluids can be considerablylonger). using a standard The estimatedblend time for 9570 uliformity (tb.95ez) double flight helical ribbon impeller with (PilDA = l, W/DA = 0 1, and DA/Dr = 0.96) is given bY = 15 For N,." ( 100: tb,951i, i:

(8-33)

For anchor impelleru of standardgeometry (w/DA = 0.1, De/Dr = = 1.0), the estimatedtb fbr 100 < Nq" < 10,000 is 0.98, and Mr given by = exp(12.9Nil;135) tb,es% \rhere DA Dr H N = = = = impeller diametel m lank diameter,m impeller oI helix height, m impeller rolational speed,sec I

(8-34)

Table 8-6 for fully turbulent Mixing rate constants flow regimes(NF.> 10,000) lmpellertype
Six-biadeddlsc Four-bladed45" pitched Three-bladedhigh eff iciencl
sautcc: FosolL et ol. []31, 142 6), Atgtst 199'1. ,1Lfiane.l t peltet Geaheh

1.06 I.[J L 0.641 4.2'12

uoasts Liquid )sitdtion,

2.1'1 2.31) 2.19 1.61

Chan.Eh&,

Processes 314Chemical Eng ineering

P' = pitch of a helical ibbon impeller, m W = blade width, m both Equations8-33 and 8-34 and Bakkel and Gates[23] compared inferl'ed that at a Reynolds number of 100, it will take an anchor uniformity as a impeller more than 13 times as long to acbieve95o/o helical ribbon impeller operating at the same speed.These impellers require cooling to remove the excassheat due to their high power relates to tanks operatilg input. The mixing time that was considered in closedsystems(e.g., batch reactors).In a continuousfeed taDk,the mixing time is generally shorter than in a closed tank.

Example 8-1 Calculate the power for agitation of a liquid of density 950 kg/m3 and viscosity 250 cP given the following configuration: number of blades B = 6, agitator diameter 0.61 m, and speed at 90 rym. Othef flat turbine geometrical ratios tue shown in Figure 7-1. A disc-mounted is used, Solution f o r m i x i n gi s The Reynolds number

^, - pNDi
N = the numbel of revolutions per sec is (90/60) = 1.5 rev/sec.
,) t (e .61 soxr.5)(o lks

250x 10 Nt" = 2,121

1--'-'

I
m-l Kgl
-."* |

t-*-

Using curve6 in Figure8-14,the Powernumberis N p = 5 0 . T h e power for urixing is theoretical

Mixing of Fluids315 f r-^ -^,,1 I p = NppNrD= i 5.0 z 950 x | . 5| x 0 . 6 t5 { "E.rF'i.m5} Lm' sec' J

= 1,353.9 w 9 = 1.35kW (1.82hp) ( N B :I k W - 1 . 3 4 1 bp)

Example8-2 Calculatethe theoreticalpower for a six-blade,flat-blade turbine without balfles, but with the standardtank conJigurationshown in Table 8-2. Use the samedata as in Example 8-1. Solution Since the tank is unbaffled,the Froudenumberis a factor and its effectis calculated lrom ,'

.,

N2Do g

(1s')(061)
9.81

tt lrev
t

m I lsec2 m I

;Pl

-- 0. t4 Nn" =2,121 The constants a and b for an unbaffledtant R = 0, ar.e a = 1.0 and b = 40. Using curve 5 in Figure 8,14, the Power numberis Np = 2.0 N'P - , w b e r em a - logloNRe b

Processes Engineeirq 316Chemi@l

1.0 - lo9to2,1zl = 0.0582 40 = 1.1212 Nfl,= 0.14{ 0582 power P = N" pN3D5oNfl, Therefore, t{.r') - 2.0 x950rl.5J z 0 . u , '^ , . , 2 1 2 [ ]m" e . sec\
= 601-24 w = 0 . 6 t k w ( 0 . 8 1h p ) Studies on various turbine agitatols have shown that geometric rutios that vary from the standarddesign can causedifferent effects on the Power number N" in dle turbulert regions [24] . Fof the flat, six-bladeopen turbire, Np - (wiDA)ru . For the flat, six-bladeopen tulbine, vnr-yingDA/Dr from 0.25 to 0.5 has no eflect on Np. . When two six blade open tulbines are installedol1the sameshaft and the spacing between the two inpellers (vedical distance betweenthe bottom edgesof the two turbines) is at least equal to DA, the total power is 1.9 times a single 1lat-bladeimpellei (45') turbines,the power is about For two six-bladepitched-blade impeller. 1.9 times that of a single pitched-blade . A bafIled, ve{ical squaretank or a horizontalcylindrical tank has the samePower number as a vefiical cylindrical tank

SCALE-IJP OF MXING

SYSTEMS

for agitation is only a part The calculation of power requirements of the mixer design.In any mixing prcblem, there are severaldefined objectives such as the time required for blending two immiscible jacket per unit volume of liquids, ratesof heat tlansfer from a heated the agitatedliquid, and massfansfer rute from gas bubblesdispersed by agitation in a liquid. For all these objectives,the processresults are to achievethe optimum mixing and unilbrm blending

Mixing of Fluids 317

The process results aIe related to variables charactedzing mixing, namely geonetlic dimensions,stiller. speed(rpn), agitator powel.,and physical properties of the Jluid (e.g., density, viscosity, and surface tension) or theit dimensionsless combinations(e_g.,the Reynotds number, Floude number, alld Weber number, pNrDi/o). Sometimes, empiricai relationships aro established to relate process results ard agrtation parameters. Often, however, such r.elationships are nonexistent- Labolatory scales of equifment using the same matedals as on a large scale are then experimcnted$ith, and the desired process result is obtained. The laboratory system can then be scaled-up to predict the conditions o11the ]argel systen. For some scalc-up ptoblems, generalizedconelalions as shown in Figures8 ll, 8-i2, 8 13, and 8-14 are available for scale-up. However, there is oluch diversity in d1epfocess to be scaled-up,and as such no single method cal1succcsslully handle all types ol scale,up problenrs. Va ous methods ol scale-uphavc been proposed:all based oi geomctric sinilality between thc laboratory equipment and the ful1 scalepla0t. It is t1otalways possib]eto have the large and small vessels geometrically sinilar, although it is pefhaps the simplest to attain. If geoineftic similarity is achievable,dynamic and kinematic similarity cannot often be predicted at the sanle time. For these reasons,experience andjudgmeit are relicd on with aspects to scale-up. Thc main objectives in a fluid agitation process are [25]: . Equivalentliquid motion (e.g.,liquid blending where the liquid motion or coresponding velocities are :rpproximatelythe same in both cases). . Equivalent suspensiotiof solids, where rhe levels of suspension aie identical. . Eqllivalenl rates of mass transfcr,\/here nass ffansfer is occur:rirg between a liquid and a solid phase, between liquid liquid phases, or between gas and liquid phascs, and the rates are identical. A scale ratio R is used for scale up fiom the st4nd.trdconfiguation a5sho\dn i n l a b l e 8 - 1 .l h c p r o c e d u r i e .: l. Determire thc scale-LrP ratio R, assumiugthat rhe oiginirl lesscl is a standard cylinder with Dr, = H1. The volun-re Vr is
-h2

V',4 =""rl

.g, = TUir

(8-35)

Engineering Processes 318Chemical

The ratio of the volumes is then

v,
vt

ro1,l+
nD! l4

D+'
Di,

(8-36)

The scale-upmtio R is

*= P"=flbll Drr Vtr

\. ./

(8-37)

Using the value of R, calculatethe new dimensioltsfor all geometric sizes.That is, Do, = RDa1, J, = RJ,, $y', = ft\i,r, Ez = REr, Lz = RLr, Hz = RHr or H, o- Do: -Dr: r -w: "-Do, wr Hr J . z- E : Jr Er

2. The selectedscale-uprule is applied to determine the agitator speedN2 from the equation:

.',=.-,(+l=.-,(+)"

(8-3 8)

. where n = 1 lbr equal liquid motion . n = 3/4 for equal suspension of solids . n = 2/3 for equal rates of masshansler (correspondingequivalent power per unit volume, which resultsin equivalgntintefacial area per unit volume) The value of n is based on theoreticaland ernpirical considerations ard depetrdson the type of agitation problem. 3. Knowing the value of N2, the requiredpower can be determined using Equation 8-17 and the generalizedPower number coraelation.

Mixing ofFluids 319

Otherpossibleways of scalingup are constant tip speed ur(7rNDA), and a constart ratio of circulatingcapacityto head Q/h. S i n c eP * N ' D l a n dV - D i r h e n
p -

- N'D'^

-^

(8-39)

For scale-upfrom system I to system2 involving geometrically similar tanks and sameliquid properlies, thp followirig equatiorscan be applied: = N2D42 N1Da1 For a constaDt tip speed, N" Nr D^, De.z

(8-40)

For a constant ratio of cjrculatitrg capacity to head, Q/h,

N r 3n 2 - Nr3 n2

(8-4r)

Example 8-3 Scraperblades set to rotate at 35 rpm are used for a pilot platrt addition of liquid ingredients into a body washploduct.What should the speedof the bladesbe io a full-scale plant, if rhe pilot aud the full-scale plants are geometricallysimilar in design?Assumescaleup is basedon constanttip speed, diameterof the pilot plant scraper bladesis 0.6 m, and diarneterof the full-scale plant scmperblades is8ft. Solution The diameterof the full scaleplant scraperblades= 8.0 x 0.3048 = 2.4384m (2.4 m). Assumingconstanttip speed, N, - D^, N, D(8-42)

320Chemical EnsiieeinsPrccesses

where Nt = N2 = Dat = Dlz = N. -=

scraperspeedof pilot plant scraperspeedof full-scale plant diameter of pilot plant scraperblades diameter of full-scale pla[t scraperblades

Nr Der Do,

_ (3sxo.6)
(2.4) = 8.75 rym

Example 8-4 During liquid makeupproduction,color pigmeflts(i.e., solid having identical particle size) are added to the product via a mixer. In the pilot plant, this mixer runs at 6,700 rpm and has a diameter head of 0.035m. Full-scaleproductionis geon.retrically similar and has a mixer headdiameterof 0.12 rn. Determinethc speedof the full-scaleproduction mixer head.What additionaliflfonnation is requiredfor the motor to drive this mixer? Assume lhat power curves are available for this mixer design, alld the scale-upbasis is constantpower/unit volume. Solution Fol constanrpower per unit volume, Equation 8-39 is applied: P/V * N3D2a or NiDir = N;Dir. Therefore,

Do, N, ' = N, ' \ID o , l"'

J
whereN, = 6,700rym D.rr-0035m = 0.12m D,qz r n ols r2/l N, | :r::: I ' =6.700 \0.12l

Mixing of Fluids 321

Nz = 2,946.7rpm Nz = 2,950rpm The power requiredfor mixing is P = NppNrDl, whercthe Power number(Np) is a llnction of the Reynolds number[i.e., Np = f(Nr")]:
^r.rn2 P.

The plant must be providedwith the viscosityof the productand its densitl after addilion o f r h ep i g m e n t s .

Example 8-5 A turbineagitatorwilh six llat bladesand a disk hasa diameter of 0.203m. It is usedin a tank with a diamete.of 0.61 m and height of 0.61 m. The width is W = 0.0405m. Four baffles are used wirh a width of 0.051rn. The turbineopentesar 2'75rym in a liquid having a densityof 909kg/m3and viscosityof 0.02 Pas. Calculatethe kW power of the turbine and kWrn3 of volume. Scale up this systemto a vesselwhosevolumeis four times as large,for the caseof equal masstransfermte. Solulion The Reynolds number for mixing is NR..The numberof revolutions = 4.58 rev/sec. per sec,N = 275160 ,, pND':" p (90q)(4.58t(0.20312 I kq rev , ..r.. I

''-

0.02 = 8,s78.1 Nt" = 8,600

lmr sec

te

Pro@sses 322ChemilEnsineering

Using curve 6 in Figure 8-14, the Power number N" = 6.0. The power of the turbine P = trtoPN3Dl:

.m5 P= (6.0,(e0qx4.581(0.2011 l+.trf. l seclmI = 0.1806kw (0.24hp) Drr = 0.61: Vr - rtD+r/4. The tankdiameter tank\,olume The original /.\rn 6r 13 4 Vr = 0 178m3 The power per unit volume is P/V P v 0.1806 0.178 =1.014kWm3 For the scale-upof the system,the scale-upratio R is

f,

;17=
I

nD3-" la D+,

";
(8-37)

R= rLlr =
\vr /
Vz = 4Vr where

Dt,

Drr

vz=4(0.178) = 0.712 m3 R = ( 4 ) l= 1 . s 8 7
I

Mixing ofFluids 323

The dimensions of the largeragitatorand tank are: = 0.322 Da2= RDol = 1.58? x 0.203 m D.., = RDr, = 1.587 x 0.61= 0.968m For equal masstransfer rate n = 2/3
-2

n,=N,f]l' '
\ R/

(8-r8l
2

=4.5srI )j
\1.587/ = 3.37 rev/sec The Reynolds number N*" is

.,

- PN:Di:

(c09 )(3.37)(0.122 )- fkp rev , ..r""'l 0.02 t<g I fm' sec = 15,880.9 Nn = 16'000
Using curve 6 in Figure 8-14, NP = 6.0- Powerrequiredby the agitaloris P2 = NlpNtDi,

p,=(6.0xe0ex3.37f .{+. (0.322)5

Pz = '722.5'7 W = 0.723kw (0.97hp)

,'

t e v 3,m.l . I secLm" |

Proesses 324chemical Ensineering

T h e p o w e rp e r u n i t \ o l u m eP / V i ( : P2 _ O-'.723 v2 0;712 = 1.015kwm3 MIXING TIME SCALE-UP uniformil)in r balch r}e rime lbr oblarniDg concenrahon Predicting mixing operatior can be basedon model theory.Using the appropriate groupsof the pertinentvadables,a rclationshipcan be dimensionless systems developed betweenmixing times in the model and large-scale for geometricallysimilar equipment. systems to occur Considerthe mixing in both small and large-scale as S and L respectively. Using the in the turbulentregion, designated Norwood and Metzner's cofielation [26], the mixing time for both systemsls

rr(Nrolr.;'2/'rvopvz t"(N"oL)'?/3*vooK

Hg'.Dt3

Hll'.D't

(8,43)

rule of equalmixing times,andrearTanglns Applyingthe scale-up Equation 8-43,yields

2

/N, )l \NsJ

=fs*)tf o*ltf "* )tfg")t

\Drr/ [DorJ \Do"J lHrJ

3411

(8-44)

Assuming geometricsimiladty,
Ht=

Hs

Po"
D,rs

(8-4s)

D'"= D^. Drs D,rs

(8-46)

Mxingof Fluids 325

Substituting Equatiors 8-45 and 8-46 into Equation8-44 gives

/rr 23411 \; /n \,/n \;/n \,/n \,

lll'1" =1"+l'l+l"l+l'l:* Do,

\Ns J
.2

\Do. _/ \Dor./ \
I

./ [ Do, J

l'

B_411

fo-16 ful'= \Ns / lDo"J

OI
I

[N,) - (oo,);

l\l

lD*l

(8-48)

The exponenttr for the mixing time scale-up rule is 0.25. The power P of the agitatorfor both large and small systems is
DD

pnt-i[
where

p$1"

(8-49)

r, _ 1u, 1r1 oo,)5

r. lNrJlo*.J

(8-50)

Substituting Equation8-48 into Equatiotr8-50 yields

e- = l ^ / 'o^. l l ' " 1 )o"rl^. )t

P. \Dos./ \DosJ
of

(8-51)

P,-l -f Do, lt" P, Do,J

(8-52)

Engineering Processes 326Chemical

The power per unit volume P/v for both large and small-scale syslemsls:

=L.f!Ir)'

Ps \ Drr-./

(8-s3)

Substituting Equations 8 46 and 8 52 into Equction8-53 gives

, \5.75 .3 (P/v)'- - lD* I ID^s l (P/v), lD*J lr*l

-1D"" I
\Dos./

\2.15

(8 s4)

Table 8-7 summarizescorrelations for the effec1sof equipment size on the rotational speed needed for the same mixing time by va.ious investigators. The relationshipsin Table 8-7 show that the rotational speed to obtain the same batch mixing time is changedby a small power of the increasein linear equiprnent dimensionas equipnlentsize is changed.Equation 8 49 shows that greater power is required for a large-scalesystem comparedto a smaller system. Often, the power required for a larger system may be prohibitive, thus modification of the scale-uprule is needed(e.g., t. = 10ts or tL = 100ts)to obtain a lower power requirement.Il should be noted that relaxation of mixing time rcquirementsmay not pose other problems.For by a chemical reaction in a example,if the mixing is accompanied for mixing CSTR,assuming that the Norwood Metznef 126lcorrelation that the mixing time in time (t) is sti1l applicable,it must be ensured the larger scale(tL = 10tsor tL = 100ts)is lessthan 57oof lhe average residence time of the liquids in the reactor,otherwisethe conversion

s
b o
ll^iog 29!:n _5 i :1,

q) E

E*-g:a
<a!

x
5

E
!t

E
o {,
t! lrl
0,

_?: z< nN
><
"i-

i-a
AN

:r;N

d@
Ji

.;2 rl

o3

o>

-;
;]

;>

o o

gPEP
(E

6NNN

o
=
(lt
N

E
'= !J

E i
: r'1

E
o 0

a n F
'!

tt o

z
o o o

".

s
z
EIE8

ID

328ChemilEngineering Pro@sses

The power per unit volume P/V for both large- and small-scale systems ts:

p- InDt"
Ps/Vs -

_l;r]"

v;

=L.(P^l'
Ps \ Drr- ,/

(8-53)

SubstitutingEquations 8-46 and 8-52into Equation 8-53 gives

(P/v), _ I oo, -

.)ttt

p/vt

tD*l
\2.75

(oo. )'

lD* l

I Dor l I D"s,/

(8-s4)

Table 8-7 summaLizescorrelatiols for the effects of equipment size on the rotational speed needed for the same mixirg time by varioLlsinvestigators. The rclationships in Table 8-7 show that the rotational speed to obtain the same batch mixing time is changedby a small powel of the increasein lioeal equipn'ient dimension as equipmentsize is changed.Equation 8-49 shows that grcater power is required for a large-scalesystem cornparedto a smaller systen. Often, the power required fol a larger system may be prohibitive, thus modifiaation of the scale-uprule is needed (e.g., tt = 10ts or tL = l00ts) to obtain a lower power requiremert. It should be noted that relaxation of mixing time requirementsmay not pose other problems. For exarnple,if the mixing is accompaniedby a chemical reaction irr a CSTR, assuming that the Norwood-Metzner [26] correlationfor mixing time (t) is still applicable,it must be ensurcdthat the mixing time in the larger scale(tL - 10ts or tL = 100ts)is lessthan 57o of the average residencetime of the liquids in the reactor,otherwise the conversion

Mixlng ofFluids329 scale-up chart only applies to systems of sinilar geometry. When the geonetry is diiTerent,special and specilic analysesof the system Samant aDd Ng l28l coDpared various scaleup rules for agitated reactors,They suggssted dlat a scale-uprule of power per unit volume and conslaDtaverage residence time (wherethe power pcl unit volurne llnd averagercsidencetime cannot be incrcased)is the most suited in many operatiorls.Ilowever, lhis still may not improve or prese e the peformance of the systems.Therefbre, adequrte considerationmus! be given to a tradeolTbetweenperformanceand operatingtonsfaints.

REFERENCES 1. Levenspiel,O., Chenical ReactionEngineering,3rd ed., John. Wiley & Sons,New York 1999. 2. Keyode Coker, A., Modeling oJ Chenical kineticsa cl rcdctor design Gulf Pnblishing Conpatry Ney' Delhi 2001. 3. Penny, W. R., "Guideto tioublefreemixers,"Chem. Eng.,77 (12), r'7t, t9'70. 4. Holland,F. A. andChapman, F.5., Liquid MiJiilxg .tnd Processiirg in Stired Tunks, Reinhold,New York, 1966. 5. Myers, K. J., Reeder, M., andBakker, A., "Agitating for success," T'heChemicalEngifleer, pp. 3942, 1996. 6. Uhl, V W. and Gray, J. B., Eds. Miting Theory and Prdctice, Volume 1, AcademicPressInc., New York, 1966. 7. Gates,L. E-, Henley,T. L., and Fenic,J. G., "How to selectthe optimum turbine agttatot,"Chem.Eng.,p. 110,Dec. 8, 1975. 8. Hicks, R. W., Morton, J. R., md Fenic, J. c., "How to design agitators fbr desiredprocess response," Chen1. Eng., p. lO2, Aptll 26. 19'76. " Cfrem. 9. Dickey, D. S., "Succeedat stirred tank reactor design, Eng.,pp. 22-31,Dec. 1991. 10. Rushton,J. H., Costich,E. W., and Everett,H. J., "Power characteristics of mixing inpellers," Cltem Eng. Prog,46.395, 1950. ll. Metzner,A. B. and Otto, R. E., "Agitation of non-Newtonian fi'rj.ds," AIChEJ,3,pp. 3-10, 1957.

Engineering Processes 330chemical

for fluid analysis 12. Dickey, S. D. and Fenic,J. G, "Dimensional agitation systens," Clrcm. Eng., Jan 5, 1976. impeller W. R., "Advanced A., and Penny, J. B., Bakker, 13. Fasano, En|,l0(8), pp. 110-116, Chen.. geometry liquid agitation," boosts August 1994. 14. Gates, L. E., Hicks, R. W., and Dickey, D. S., "Application guidelines for turbine agitators," Chem Eng., 83, pp. 165 170' Dec. 6, 1976. 15. Cutter,L. A., AlChEI, 12, 35, 1966. 16. Moo-Young,M., Tichar,K., and Dullion,F. A L.' AIChEJ' 18, 1'18, 19'12. 17. van de Vusse,J. G., "Mixing by agitationof miscibleliquids," Chem.Eng. Scl.,4, 178, 1955. 18. Fox, E. A., and Gex, V E., "Single phaseblendingof liquids''' ArchEJ, 2, 539, 1956. J. and Landau,J., Coll CzechChen] Cummun,26: 19. Prochazka, 2 9 6 1 ,1 9 6 1 . F. A L.' "The blend20. Moo-Young, M., Tichar, K., and Takahashi, of some inpelleis ;n batch mixing''' A/Cftt"r, irg efTiciencies 18(1),pp. 178 182, 1912. 21. Sano,Y and Usui, H., "Interclationsamongmixing time, power flow rate numberin bafflcd mixing vessels," numbeL and discharge l. Chem.Eng., Japan,18:47-52,1985. Chen. Eng.Progr, Jiquids," 22. Gray, J.8., "Batchmixing of viscous 59,No. 3, p. 59, 1963. Agitators choosemechalrical 23. Bakker,A. and Gatcs,L. E.. "Proper'ly Dec. 1995. Pro7., for viscous liqri,tJs,"Chen. En1. R. R., lE.C Proc.Des, R. L., Fondy,P L., andCorpsteir. 24. Bates, 1 9 6 3 . 2,310, R. R, and Dickey, D.S., "How to 25. Rautzen,R. R.. Corpstein. Chen. Eng, Oct use scale-upmethodsfor lurbinc agitators," 25, 19'.16. 26. Norwood, K. W. and Metzner,A. B., "Flow patternsand nixing rates in agilatedvessels,"AlClE"/, 6,432, 1960. K. D. and Ng, Ka, M., "Developmentof liquid-phase 28. Samant, simulationand scaie-up."AIChII' agitatedreactolsrsynthesis. N o v e m b e1 r999 V o l . 4 5 ^N o . 1 1 ,p p . 2 3 7 1 2 3 9 1 ,

[rl,ing o i F t u i d s3 3 1

PROBLEMS
8.1 A tank 1.2m in dianreler.nd 2m high is nllcd to a depll of 1.2n with a latex h a l i n g a v j s c o s i i y o f 1 0 P a n d a d e n s i t y o f 8 0 0 k g / n r r . T h e l a i k i s n o t b a f f l e d .A lhree bl.de 360 nn-diamerer propeller is iistalled in inc tank 360nn fron the bottoD. The piich is l:l (!ilch equals diameter).Tle notor !!ailablc dcvelops 8 k W . l s r l r e n o t o r a d e q u a t et o d r i v e l h i s a g i t a t o r a t a s p e e d o f 8 0 0 r / n i n ? in Prob. 8.1 nay 8 , 2 W h a t i s r h e n a x i n u m s p e da l w h i c h a g i l a t o r o f l h e t a n k d o s c r i b e d of I P andthe sane density? b y o n eh a ! i n g a v i s c o s i t y be driveniflle liquid is replaced 8.3 what power is .equired lor the nixing opc.ation ofProb. 81 ifa propeller360 nn i n d i a m e t e r h r r n i r g a t 1 5 r / s i s n s c d a n d i f f o u r b a l e s , e a c n 1 2 0m m w i d e , a r e 8 . , 1 T h e p r o l c l l c r i n P r o b . 8 . 1 i s r e p l a c c dw i t h a s i x b l a d e l u r b i f l e 4 0 0 m m i n d i a m e t e r . poweFlaw liquid having an aPparedl and the fluid to be agitatedis a pseudoplastic shouldthe lurbhe v i s c o s i l yo f l 5 P s h e n t l e v e l o c i t yg l a d i e n l i s 1 0 s - . A t w h a t s p e e d rotate to dclircr I kW/nr olliquid? For this 1luid, = 0.75 and p= 950 ke/mr. 8.5 A mixing rine of29 s was nre.sured for a 4.5_ft baflled lank with a 1.5_llsix_blade t u r b i i e a n d a l i q u i d d e p t h o 1 4 . 8 f t . T n e i u r b i n e s p e E dw a s 7 5 r / m i n , a n d t h e t ' l u i d h a s a v i s c o s i t yo f I c P a n d a d e n s i l y o f 6 5 l b / f . . E s l i ' n a t c t h e m i x i n g t i n e s i f . n i n p e l l e r o n e q u a r t e r o r o n e - h a l f t h e l a n k d i a n e t e r s e r e u s e d w i t l t n e s p e e d sc h o s e n ro give tle same power per unit volume. ch size that t g 8.6 A pilot-plaut re.clor, a scalemodel of a production unit. is of c h a r g e dt o l h e p i l o t - p l a n t r c a c t o r i s e q u i v a l e n it o 5 0 0 g o f t h e s a m e n d t e r i . l c h a r g e d ro the production unii. lhc produclion unil is 2 m in dianeter and 2 n deep and conrainsasix-bladetrrbineagilato.0.6mindiametcr'lheoPtinunr.gilatorspeed i n r h e p i l o t - p l a n r r e a c t o r i s l b u n d b y e x p e r i n e n t t o b e 3 3 0 r / n i n . ( a , )w h ! t a r e l h e s i g n i l i c a n ld i s e n s i o n s o f l h e p i l o t p l a n l r e a c t o ! ? ( r ) l f t h e . e a c t i o n d a s s h a s t h e p r o p e r t i c so f w a t e r d t 7 0 " C a n d t h e p o { e r i n D u t p e r u n i t v o l u n e i s t o b e c o n s t a l t , a r w ! . 1 s l e e d s h o u l d l h c i n r p e l l e rt u r n i n t l e h r e e r e a c t o r ?( c ) A t $ h d t s p e e ds h o t l d it rurn ifrhe mixing tine is lo be lept coDstamt? f d l A t w h a l s p e e ds h o n l d i t t u n i f l h e R c y n o l d s n t r n b e r i s h e l d c o t s t a n t ? f 4 w l i c h b . s i s w o u l d y o u r e c o m m c n df o r sclleup? why? turbine h.s been used 8.7 A stifed tank reactor3 ft in dilneter will a l2_i., flat_blade is consideled 6i1ical. I o r a b a l c h r e a c l i o n i n w h i c h t h e b l e n d i n et i n e o f a d d c d r e a g e n t s S . t i s f a c t o r yr c l t s w e r e o b t a i n e dw i t n a s t i t r c r s p e do f 4 0 0 r / n i n . T h e s a m er e a c l i o n is 1o be carried oul in a tank 7 t in dianeler. for which a 3 I slandard lurbine is a r a i l a b l e . f d . /W h a l c o r d i l i o n s i n o u l d g i v e t h e s . n e b l e n d i n gl i m e i n t h e h r g e r t . n k ? ( b l w h a l w o u l d b e l h c p e r c e n t . g ec h a i g e i i t h e p o w c r p e r u n i t v o l u n e ? D e n s i l y p = 6 0 l b / f t r r v i s c o s i l y1 1- 5 c l . 8 . 8 . A s i x - b l a d ed i s k t L , r b i r e / D a = 3 f f ) i s u s e d t o d i s p e s e h y d r o e e n g a s i n t o d s l u r . y reaclor containing netlyl linolcateai 90'C aid 60lbjtii.': gange wilh I percent 50ltr, p/ = 4 g/cnn). The reactordianeter is 9 ft suspended c a t a l y s t p a r t i c l e s/ D , a n d i h e d e ! l h i s l 2 f i . T h e g a sf l o w r a t ei s 1 8 0 0 s i d f t l / n i n l, h e o i l v i s c o s i t iys l 6 c ? . n d t h e d e n s i t y i s 0 . 8 . 1 g / c n i i l 9 0 ' c . T h e r e a c t o r i s f u l l y b a f f l e d .( a ) w h a t l g i t a l o r s p e c d i s n e e d e d t o g i v e 5 h p / 1 0 0 0g a l d u r i n g l h e r e . c l i o n ? f 4 W h a t i s t h e p o w e r consudption wilh gas flow on and rvitl gas flow off?

332 Chemicl Engineeins P@esses

E . 9 . F o . t h e c o n d i t i o n so f P r o b . 8 . 8 ,e s t i n a t e t h e p o w e r r e q u i r e df o r c o n p l e t e s u s p e n s i o n of rhe calalyst. 8 . 1 0 -A 1 5 p e r c e n ts l u r . y o f 2 0 - t o - 2 8 - m e s h limestoDe ir waie. is ro be kept itr suspension in a 20-fFdiameter tank using a six-bladels twbine, (d) If Da./Dt=U3, an,J WDa= 0.2, w h a t s i i n e r s p e e di s r c q u i r e d ?@ , C a l c u l a t er h e s t i r r e r s p e e d and power requi.enenr if Da/Dt = 0.4. 8 . 1 1 .A f o a c t i o n i n w h i c h t h e p r o d u c t f o r m s r f y s t a l l i n e s o l i d h a s b e e n s t u d i e d i n a p 1+t-diamete ri l o L p l a l t r e a c t o re q ! i p p e d w i L h d 4 i n . s i x - b l a d er u r b i n e w i t h c u r v e d b l a d e s .A i s t i f f e r s p e e d s l e s st h a ! 6 0 0 r / m i n . a s o l i d d e p o s i rs o m e t i f t e sf o r m s o n t h i b o i t o m , a n d t b i s c o n d i t i o n n u s t b e a v o i d e di ! t h e c o n m e r c i o l r e a c t o r .D e n s i t y o f t h c l i q u i d i s 7 0 l b / f p ; v i s c o s i t yi s 3 c P . ( a ) W h a t i s i h e p o w e r c o n s u n p t i o n i n r h E s m a l l r e a c t o r , a n d w h a t i s r e c o n m e n d e df o r a n 8 0 0 0 - g a 1 reactor if geomerrical s i m i l a r i t yi s p r e s e r v e d ? @ , H o w m u c h n i g h t t h e r e q u i r e dp o w e r b e l o w e r e db y l s i n g a differenl tyDe of agilator or different geomel.y? (C:Ha) is to be dispemed 8 . 1 2 .G a s e o u se L h y l e n e i n w a t e r i n a t u r b i n e - a g i r a r ev de s s e l at l l r c a n d a ! a b s o l u t e p r e s s u r eo f 3 a t n r . T h e v e s s e l i s 3 m i n d i a m e t e r w i t h a m a x i m u m l i q t r i d d e l t h o f 3 n r . F o r a f l o w r a t e o f 1 0 0 0n r / h o f e u r y l e n e n , easuied a t p r o c e s sc o n d i t i o n s ,s p e c i l yf d t h e d i a m e t e ra r d s p e e do f l h e t u r b i n e i m p e l l e r ,( b , t h p o w e r d r a w n b y t h e a g i t d t o . ,( c ) t h o m a x i m u m v o l t r n e o f w a t e r a l l o w a b l e ,a n d ( d ) r h e n t e n t w h i c h w a t e r i s v a p o r i z e db y t h e e l h y l e n el e a v i n g t h e l i q u i d s u r f a c e . A s s u m er h a t n o n c o f t h e e t h y i e n e dissolves i n t h e w a t e r a n d t h a i t h e e t h y l e n el e a v i n g is saturated with warer. E.l3.For a flow rate ol250nr/h in the vesscl d e s f f i b e d i n P r o b . 8 . 1 2 ,e s t i m a t er h e g a s h o l d u p , m e a n b u b b l e d i a m e t e r ,a n d i n i e r f a c i a a l reaper unlt voiume.