Mixing 101: Flow Patterns & Impellers

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Mixing Flow Patterns & Impeller Types

In our article on 4 Impeller Types and Their Applications, we provided an overview on the most common types of
impellers used in industrial mixing. Now well go into more detail about each impeller type and their influences on
the mixing process.

Our focus on impellers is due to the fact that they are the part of the mixer that does the actual mixing: as they
rotate they create fluid flow. These flow patterns are the primary considerations when designing a mixer because
creating the right flow pattern is critical to achieving the desired result.

The most common flow patterns in mixing are axial (down and up) and radial (side to side) flow. These flow
patterns also describe the generic classes of impellers: axial and radial.

1. Axial Flow Impellers

Axial (down and up) pumping is an important flow pattern because it addresses two of the most common
challenges in mixing; solid suspension and stratification. In this process both the superficial and annular
velocities can be calculated to determine and control the level of mixing. (If your axial impeller is causing swirling
or vortexing, check out our previous Mixing 101 posting Baffled by Baffles?)

Here are some of the most common axial impellers:

A. Marine-type Propellers

Viscosity: 0 5,000 cps

Commonly used on marine boats, the propellers are often used in small portable direct drive
mixer applications because theyre economical and efficient. However, in larger applications
theyre seldom used because of their price and weight.

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 B. Pitch

Viscosity: 0 50,000 cps

The pitch blade impeller is the most versatile impeller and was the standard until the
development of the airfoil. Theyre useful in blending two or more liquids and are effective in low
bottom clearance with less liquid submergence.

C. DynaflowTM (Hydrofoils)

Viscosity: 0 3,000 cps

This impeller uses the Bernoullis principle in the design of its blade. The camber of the blade
increases the efficiency of the impeller, reducing its power / pumping ratio. A more technical
benefit is the laminar flow created by the camber of this impeller. This camber reduces
turbulence (shear) substantially. That is why it is selected for shear-sensitive applications as
well.

2. Radial Flow Impellers

Unlike axial impellers, radial impellers are commonly selected for low level mixing (known as a
tickler blade) or elongated tanks. They typically give high shear rates because of their angle of
attack. They also have a relatively low pumping number, making them the most sensitive to
viscosity. Radial impellers do not have a high tank turnover flow like axial flow impellers.

Impeller Selection

As you can see, the first step to meeting your mixing objective is to identify your desired flow pattern, which is
dictated by the impeller. Next, you must consider the 4 main factors for configuring your mixer. From there, you
must address the mechanical requirements of your mixing process: pumping or flow. The mechanical
requirements to produce flow or torque per unit volume, the most important relationship in mixing, are explained
next.

Mixing Terms Glossary

Shear Stress

Parallel-acting force where 2 layers inside the fluid slide against each other. This is in contrast to
compression (perpendicular-acting force), tension (stretching force), and torsion (twisting force).

Viscosity

Internal fluid resistance thought of as the thickness or resistance to flow of the liquid (i.e. water has
viscosity of 1 centipoise vs hand cleaner, which is around 3,000 centipoise).

Power Number (NP)

Constant used to calculate power draw, unique to each type of mixing impeller.

Pumping Number (NQ)

Constant used to calculate flow or pumping rate, derived empirically for each unique shape of impeller.

Superficial Velocity

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 Velocity of the fluid being pumped downward by the impeller.

Annular Velocity

Rate at which the liquid is traveling upwards inside a tank past the impeller.

Solid Suspension

State of a solid when its particles are mixed with, but dont dissolve in the fluid and are capable of
separation (i.e. sand in water).

Stratification

Separation of 2 immiscible liquids due to density variation. Such circumstances occur naturally: for
example, due to variations in temperature in the atmosphere or temperature and salinity variations in the
ocean.

If you have questions with your industrial mixer design...

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