Design Calculations for

Slurry Agitators
RAJENDRA KUNWAR
FollowRAJENDRA KUNWAR
Associate Vice President - Projects at JSW Steel Limited

Hi Friends,

Today I am presenting the gist of my technical paper on "Motor rating

calculations for slurry mixing agitators in Alumina refinery" which
has been published recently in aluminum issue of the
magazine "Minerals & Metals Review" (page 30 and 31 in MMR,
August 2011 issue).

In various technical forums, process experts as well as equipment

manufacturers have opined that the design of agitators for mixing
bauxite, residue and hydrate in Alumina refinery is complicated and
tricky issue. In this paper, we will discuss the subject with brief
description of involved terminology, associated design parameters
and methodology with sample motor rating calculations for the slurry
mixing agitator of a Pre-desilication tank of Alumina refinery.

Method to arrive at motor rating:

Impeller power for slurry mixing agitator is calculated using

following mathematical relations-

Impeller Power, P = Ni * *N3 * Di5/(16*104) h.p.

Where Di = Diameter of impeller in meters,

N = Revolution per minute for impeller,

Ni = Power number for impeller and

= Specific gravity of slurry.

Sample calculations:

Simplified calculations to arrive at the motor rating for the agitator of

Pre-desilication tank of around 3000 m3 gross capacity with realistic
assumptions have been presented below-

Fluid Height in Tank, H = 16 m and Diameter of tank, D = 14 m

Slurry volume in tank = *D2*H/4 = * (14)2*16 /4 = 2463 m3

Solid consistency in Slurry = 50 % (w/w), Specific gravity of slurry,

= 1.602,

Viscosity of slurry, = 550 cp

Agitator Impeller Diameter, D= 33 % of tank diameter = 14 * 33% m

= 4.62 m

Tip speed of Impeller = 290 m/minute, Drive motor RPM = 1500

rpm.

Gear Box Reduction Ratio = 75

∴ Agitator RPM, N = Drive Motor RPM/Gear Box Reduction

Ratio = 1500/75 = 20 rpm
Flow Number Nf = 0.56 and Power Number, Np = 0.51 (assumed
figures)

∴ Pumping Capacity = Nf. Np.D3 m3/minute

= 0.56 * 20 * (4.62)3 = 1104.44 m3/min. = 18.41 m3/sec.

Area of Tank = D2 = (14)2 / 4 = 153.94 m2

Bulk fluid Velocity = pumping capacity/area of tank

= 1104.44 / 153.94= 7.18 m/min.= 23.55 ft./min.

Degree of Agitation = bulk fluid velocity / 6

(For 6 ft/min., degree of agitation =1 and Degree of agitation varies

from 0 to 10)

= 23.55 / 6 = 3.93 ~ 4

Annular Area = * (Dt2- Di2 ) /4

Where Dt = Diameter of tank and Di= Diameter of impeller in

meters.

= 3.14 * (142 4.622) / 4 = 137.18 m2

Rising velocity of particles = pumping capacity / annular area

= 1104.44 / 137.18 = 8.051 m/min. = 0.1342 m/sec.

Tank Turnover rate = Pumping capacity / tank capacity

= 1104.44 / 2463 = 0.45 times / min.

Impeller Power Number Ni = 0.51

Shaft Power, P = Ni* *(D)5 * N3 /(16 *104)

Where Ni = Impeller power no., D = Diameter of impeller in

meters, Shaft RPM, N = revolutions per minute

∴ Shaft Power,

P = 0.51*1.602* (4.402)5*203/ (16 *104) = 85.98 h.p.

Taking Gear Box Efficiency = 80% and Drive Motor Efficiency =

95%,

Design margin = 1.15

∴ Drive Motor Rating = 1.15 * 85.98/(0.80 * 0.95) =130 h.p. =

97.0 kW.

Thus the drive motor of about 100 kW shall be adequate

for successful operation of agitator of 3000 m3 capacity

Pre-desilication tank in Alumina refinery.

Mixing 101: Flow Patterns & Impellers
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.

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

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.
Mixing 101: Optimal Tank Design
UNDERSTANDING HOW TANK DESIGN AFFECTS
MIXING
Apart from the actual mixer, the design of the mixing tank is the single most
important factor in producing a successful result in any process.

In order to allow optimal performance from a mixers impeller, it is essential to

create an environment that supports both correct impeller positioning and
appropriate liquid coverage of the impeller. Incorrect positioning negatively affects
the performance of a mixer, the quality of a product, and may even be detrimental to
the performance life of the mixer drive.

When looking at tank designs, vertical cylindrical, and square or rectangular tanks
are most common.

In the process of selecting the optimal tank design for an application there are
certain rules of thumb to observe.

1. Liquid Level to Tank Diameter Ratio

For most mixing applications the ideal liquid level to tank diameter ratio is 0.8,
however, any ratio that is close to 1-to-1 is sufficient.

A ratio that is too small does not allow proper axial mixing in the tank. Anything less
than a 0.6 ratio should be avoided.

When the ratio is in excess of 1.4, dual impellers should be employed.

Any time that the liquid level to tank diameter ratio exceeds 2.0 the tank selection
should be re-evaluated, as these slim tanks are not the most cost-effective solutions
for mixing.

As the mixer shaft length extends, so does the price of the mixer. For example, if we
take a typical 5,000-gallon tank based on the ideal scenario and the slim tank
scenario, the following will occur:
 Tank Liquid Volume Liq. Level to Typical Mixer
Dimensions Level Dia. Ratio Budget Price

10 Dia x 10 H 8 H 5,000 Gallons 0.8 $6,500

7.5 Dia x 16 H 15 H 5,000 Gallons 2 $12,000

As you can see from the table above the typical mixer price almost doubles.

Vertical Cylindrical Tanks

Vertical cylindrical tanks are the most common type

of tank in use.

A key consideration for cylindrical tanks is to ensure that they are either baffled or
offset-mounted to prevent swirling from occurring. Refer to section 2 below (The
Use of Baffling) for details.

Generally baffles are not required for smaller tanks (<5,000 gallons in volume or <10
height). However, for larger tanks, it is much more cost effective to install baffles
than to invest in a more expensive, more heavy-duty mixer that is offset-mounted.

Rectangular Tanks
 Rectangular tanks have an equivalent diameter that
can be calculated by taking the square root of Length x Width and multiplying it by
1.13.

A similar liquid level to equivalent tank diameter ratio of 0.8 applies.

Rectangular tanks can be effective when used for blending, as these tanks are self-
baffling.

However, rectangular tanks are not recommended for solid suspension because
packets of solids will form in the corners.

These dead spots will occur in a tank with corners. Therefore, a greater level of
mixing is required than is needed in a cylindrical tank of equal size to achieve a
similar result.

Cone or Round Bottom Tanks

Some tanks will have a round (dish) or cone bottom. Below are some standard
guidelines about approaching mixing for these tanks.

1. Cone bottom: Ideally the cone angle should be less than 15, but anything
less than a 30 angle is acceptable. If a cone is too deep, it just becomes that
much more difficult to provide good mixing inside it.

2. Round Bottom: The same rules apply for a round bottom as for a
cone. Generally a round bottom is better for solids suspension as there are
no sharp angles in the tank, so it eliminates dead spots.

3. Baffles: If a cone/round bottom tank is very deep, baffles can be put inside
this part of the tank as well, to promote good axial mixing and prevent swirling
from occurring.
2. The Use of Baffling

Rectangular tanks are self-baffling, so the use of baffles is a requirement when using
cylindrical tanks only.

If an agitator is center-mounted in an un-baffled cylindrical tank, it produces a

swirling motion, which is very inefficient. As an example, imagine two particles
swirling in a circular motion, they will always be chasing each other and will not mix.

There are two solutions to consider:

1. Install Baffles: Installing baffles in the tank is the best option.

2. Offset the Mixer: Mounting the mixer with an offset of approximately 1/6th of
the tank diameter will prevent swirling from occurring. The drawback to this
option is that the unbalanced forces will create greater stress on the mixer
shaft and will require a larger heavy-duty mixer. This becomes cost-prohibitive
for larger applications with shaft length requirements over 10.

Typical Baffle Arrangements

Baffles are typically mounted 1/72 of the tank diameter off the wall of the tank, and
are 1/12 of the tank diameter in width. The optimal installment is comprised of four
baffles within a tank, but the use of three baffles is sufficient for most applications.

Baffles should fully extend the length of the tank, leaving some space at the bottom
to avoid the build-up of solids. Therefore, the configuration for a 12 diameter tank
would be 1 wide baffles mounted 2 off the tank wall.
Mixing 101: Baffled by Baffles?
HOW BAFFLE CONFIGURATION CAN OPTIMIZE
INDUSTRIAL MIXING
In our previous posting on configuring your mixer, we learned that the tank type
and volume, viscosity, specific gravity and the process are key factors the mixing
process. In this article, we dive into how baffle configuration and mixer mounting can
prevent the undesirable flow pattern of swirling.

Lets look at a common tank configuration: an un-baffled cylindrical tank. If a mixer is

center-mounted in this tank, what we see is a very inefficient flow pattern: the
tangential velocities coming from the impeller cause the entire fluid mass to spin
(Fig. 1). Basically, the entire fluid (and its solids) moves like a merry-go-round. In
solid suspension applications, the solid particles will swirl around at the bottom of the
tank: no axial (top to bottom) flow is created to lift them up and suspend them in the
fluid.

FIGURE 1. Center-mounted mixer in an unbaffled cylindrical tank

There are three ways swirling can be prevented, and weve listed them by
preference:

1. Installing baffles in tanks

2. Offset angle mounting of mixers
3. Offset vertical mounting of mixers

Using baffles or offset mounting techniques will generate unbalanced loads that will
act on the mixer shaft. When these unbalanced loads become significant, a heavier-
duty agitator gearbox and bearing are needed. As a result, the mixer is more
expensive.

Baffles are our first choice because the loads generated are much less than those
generated by offset angle or vertical mounting techniques. For smaller tanks (<10
diameter), offset mounting will work just fine, and the extra cost associated with
compensating for unbalanced load is minimal. For larger tanks, however, it becomes
expensive to go with the heavier-duty mixer, and installing baffles is more cost
effective.

Baffle Design

Baffles are long, flat plates that attach to the side of the tank to prevent swirling &
promote top to bottom fluid movement. They are most commonly used for blending
and solid suspensions because these applications often use vertical, cylindrical
tanks that tend to create swirling patterns, regardless of the type of impeller being
used.

The flow pattern illustrated here shows that the use of baffles results in excellent top-
to-bottom circulation and great radial mixing.
 FIGURE 2. Mixing in a baffled cylindrical tank

Baffle Configuration

Baffles should be designed using the following guidelines (Fig 3):

Number of baffles = 3 to 4 (4 is ideal, but 3 will result in sufficient mixing).

Adding any more than 4 baffles will not result in any significant mixing
improvement.
Width = 1/12 of the tank diameter (i.e. for a 12 diameter tank, the baffle width
will be 1)*
Length = starts approximately 6 inches from the bottom and ends just above
the maximum liquid level
Mount Position = 1/6 of the baffle width off the tank wall**. (i.e. a 1 wide
baffle will be mounted 2 off the tank wall)

* For medium viscosity mixing (ie. viscosities over 3,000 cps or Reynolds Numbers
from 10 to 10,000), we often reduce the width of the baffle to 1/2 of standard width

** When agitating slurries, baffles are often located up to 1/2 of their width from the
vessel wall to minimize accumulation of solids on or behind them.
 FIGURE 3. Standard baffle design

Going Baffle-less

There are instances where baffles are not required

Square or Rectangular Blending Tanks: Most blending applications that use

square/rectangular tanks dont need baffles because these tanks are self-
baffling. However, they are less suitable for solid suspension because dead
spots are formed in the corners.
High Viscosity Mixing: For high viscosity mixing (viscosities over 5,000 cps or
Reynolds Numbers < 10), the same power is consumed by the impeller, with
or without baffle, so theyre seldom used.

Mixer Mounting

Offset Angle Mounting

With axial-flow impellers, an angular off-center position where the impeller is

mounted approximately 10-15 from the vertical, can be used (Fig. 4). Its worth
noting that the angular off-center position used with axial impeller units is usually
limited to those delivering 3 HP or less. The unbalanced fluid forces generated by
this mounting can become severe with higher power.

FIGURE 4. Offset angle mounting

Offset Vertical Mounting

If an angle mount is not available, the mixer can be offset while being placed
vertically in the tank. The rule of thumb for this is to offset the mixer on the x-axis,
1/6th of the total tank diameter. So, for a 60 diameter tank the mixer would be offset
10 from center (60/6 = 10).
 FIGURE 5. Offset vertical mounting

As you can see, baffle configuration and mixer mounting have a significant impact on
the mixing process. When engineered correctly, the right application of these
techniques can decrease costs & increase equipment life while optimizing the mixing
process.