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Particle Distribution in tank

CSB 30103

INTRODUCTION

The simplest and common fluid mixing application is simply to add liquid “A” to “B” where the
liquids are soluble in one another and blend them uniformly. Mixing impeller are designed to
pump fluid through the impeller and produce turbulence which both of these effects are essential
to mixing. They produce fluid velocity and fluid shear respectively. Fluid velocity produces
movement throughout the mixing vessel, intermixing material in one part of the tank with
another, prevents solids from setting out and produces flows. Fluid shear in the form of turbulent
eddies is essential to micro-mixing within the large velocity streams breaking up gas bubbles or
immiscible liquids into small droplets. All mixing impellers produce both fluid velocity and fluid
shear but different types of impellers produce different degrees of flow turbulence.

In industrial mixing applications, the power consumption per unit volume of fluid is used
extensively for scale up, scale down and design. In widespread use, the dependence of power
consumption on impeller and tank geometry is defined only in the most general terms. This is
due to the difficulty of obtaining accurate torque measurements on the small scale and due to the
predictive limitations of drag theory, particularly for recirculation three dimensional flows.

The power number is one of the most widely used design specifications in the mixing operation
has proven to be a reliable predictor of a number of process results. Power number is sensitive to
the details of impeller geometry and particular to the blade thickness but it is independent of the
impeller diameter to the tank diameter ratio. Power can be effected by blade angle, blade
thickness, blade chamber and blade number on impeller performance. A significant limitation of
theoretical is the assumption that there is no interaction between the impeller and the tank walls.
Power numbers assume fully baffled vessels with waterlike fluid and proximity correction
factors (off bottom and multiple impellers) of 1.0.

Some process such as flocculation are shear sensitive and require high flow and low shear
mixing. Other processes such as gas dispersion are at the other end of the scale and require high
shear mixing. The selection of the mixer for a particular application depends on numerous
process factors which are type of application (high flow or high shear requirements), viscosity, %
solids, amount of gas addition, tank geometry and retention time. Fluid’s density effected the

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power draw of a mixing impeller. The power draw increases with increasing viscosity. The
viscosity of a fluid can have significant impact on the overall mixer sizing for a particular
application. The main sizing criteria consist of torque invested into the mix, impeller style,
impeller Diameter to Tank Diameter (D/T) Ratio, mixer horsepower, pumping capacity,
superficial velocity and torque volume.

IMPELLERS

Impellers are rotating devices that force liquids, gases and vapors in a desired direction. They are
widely used in pumping, blowing, and mixing applications. This area gives the ability to
search for impellers for pumping and mixing of media and allows selection of type of impeller
and size. Impeller applications, specifications and features, types, and materials are all important
parameters to consider when searching for impellers. The five types of impeller that used in the
experiment which are axial propeller, turbine propeller, flat blade paddle 1.5 inch diameter flat
blade paddle 2.0 inch diameter and flat blade paddle 3.0 inch diameter.

Axial flow impellers are used at high speeds to promote rapid dispersion and are used at low
speeds for keeping solids in suspension. Axial flow propeller impellers are impellers that have 2
to 4 blades and convey the pumped media in the direction along the revolving axis of the
impeller. Turbines propeller are impellers that have multiple fins and convey the pumped media
in the direction along the revolving axis of the impeller. Flat blade impellers are used for mixing
and have one or more paddles. Beside that flat blade paddle have a different diameter of paddle.

The common applications served by impellers include mixing, pumping, air movement,
chemical, compressor or refrigeration, heat exchangers or radiations, high viscosity media,
propulsion, and water or wastewater. Important impeller specifications to consider include the
number of blades or vanes, outside diameter, and bore size. Features include adjustable pitch,
anti-static, coated or plated, corrosion resistant, custom fabricated, folding blades, and

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multistage. Choices for materials of construction include aluminum, brass or bronze, cast iron,
composite, plastic, rubber, stainless steel, and titanium.

MATERIAL

1) Mixing equipment model IM 103


2) Mixer controller
3) Servodyne mixer head
4) Yellow Beads
5) Impeller
-axial propeller
-turbine propeller
-flat blade paddle (1.5” DIA)
-flat blade paddle (2.0” DIA)
-Flat blade paddle (3.0” DIA)

METHOD

1) Mixing tank was filled up with ¾ of water.


2) The axial impeller was attached to the end of the shaft.
3) Small quantity of yellow beads was added into the tank.
4) The initial speed was set to 100 rpm and then the impeller speed was increased in 200
rpm increment until the beads were seen to swirl around the water. The flow pattern was
observed and the flow pattern from front view and top view were drawn.
5) Step 1 to step 4 was repeated with turbine impeller, flat blade paddle 1.5” diameter , flat
blade paddle 2.0” diameter and , flat blade paddle 3.0” diameter.
6) Step 1 to 5 was repeated with baffles in the mixing tank.
7) The flow pattern was drawn on each experiment and the best blade type was determined
and comparison between baffle and unbaffle adjustment. Power needed was calculated
starting from 100 rpm until end of increments.

RESULTS

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Particle Distribution in tank
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Flat blade paddle 1.5” diameter

RPM FRONT VIEW TOP VIEW

100

300

500

700

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Particle Distribution in tank
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900

Flat blade paddle 2.0” diameter

RPM FRONT VIEW TOP VIEW

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100

300

500

700

900

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Particle Distribution in tank
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Flat blade paddle 3.0” diameter

RPM FRONT VIEW TOP VIEW

100

300

500

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700

900

CALCULATION

1.5" Flat Blade Propeller without Baffles

Diameter Size 2∏/60se w (angular speed, T


(cm) RPM c rad/s) (torque,N.m) P (watt)
3.81 100 0.1047 10.47 0.02 0.2094
3.81 300 0.1047 31.41 0.01 0.3141

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3.81 500 0.1047 52.35 0.01 0.5235


3.81 700 0.1047 73.29 0.01 0.7329
3.81 900 0.1047 94.23 0.01 0.9423

Table 1: 1.5" Flat Blade Propeller without Baffles

Graph 1: 1.5" Flat Blade Propeller without Baffles

2.0" Flat Blade Propeller without Baffles

Diameter Size 2∏/60se


(cm) RPM c w (angular speed) T (torque) P (watt)
5.08 100 0.1047 10.47 0.01 0.1047
5.08 300 0.1047 31.41 0.01 0.3141
5.08 500 0.1047 52.35 0.01 0.5235
5.08 700 0.1047 73.29 0.01 0.7329
5.08 900 0.1047 94.23 0.01 0.9423

Table 2: 2.0" Flat Blade Propeller without Baffles

Graph 2: 2.0" Flat Blade Propeller without Baffles

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3.0" Flat Blade Propeller without Baffles

Diameter Size 2∏/60se


(cm) RPM c w (angular speed) T (torque) P (watt)
7.62 100 0.1047 10.47 0.01 0.1047
7.62 300 0.1047 31.41 0.01 0.3141
7.62 500 0.1047 52.35 0.01 0.5235
7.62 700 0.1047 73.29 0.03 2.1987
7.62 900 0.1047 94.23 0.04 3.7692

Table 3: 3.0" Flat Blade Propeller without Baffles

Graph 3: 3.0" Flat Blade Propeller without Baffles

1.5" Flat Blade Propeller with Baffles

Diameter Size 2∏/60se w (angular speed, T


(cm) RPM c rad/s) (torque,N.m) P (watt)
3.81 100 0.1047 10.47 0.01 0.1047
3.81 300 0.1047 31.41 0.01 0.3141
3.81 500 0.1047 52.35 0.01 0.5235
3.81 700 0.1047 73.29 0.01 0.7329
3.81 900 0.1047 94.23 0.01 0.9423

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Table 4: 1.5" Flat Blade Propeller with Baffles

Graph 4: 1.5" Flat Blade Propeller with Baffles

2.0" Flat Blade Propeller with Baffles

Diameter Size 2∏/60se


(cm) RPM c w (angular speed) T (torque) P (watt)
5.08 100 0.1047 10.47 0.01 0.1047
5.08 300 0.1047 31.41 0.01 0.3141
5.08 500 0.1047 52.35 0.01 0.5235
5.08 700 0.1047 73.29 0.01 0.7329
5.08 900 0.1047 94.23 0.02 1.8846

Table 5: 2.0" Flat Blade Propeller with Baffles

Graph 5: 2.0" Flat Blade Propeller with Baffles

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3.0" Flat Blade Propeller with Baffles

Diameter Size 2∏/60se


(cm) RPM c w (angular speed) T (torque) P (watt)
7.62 100 0.1047 10.47 0.02 0.2094
7.62 300 0.1047 31.41 0.04 1.2564
7.62 500 0.1047 52.35 0.13 6.8055
7.62 700 0.1047 73.29 0.27 19.7883
7.62 900 0.1047 94.23 0.48 45.2304

Table 6: 3.0" Flat Blade Propeller with Baffles

Graph 6: 3.0" Flat Blade Propeller with Baffles

DISCUSSION

The mixing intensity can be varied widely by choosing a suitable impeller type and by varying
agitating speeds. The mechanical agitation is effective for the suspension of cells, oxygenation,
mixing of the medium, and heat transfer. Difference shapes of impeller produced difference
shape of flows, with radial flow impellers; the liquid is pushed towards of the container, along
the radius of the container. Axial impellers, the liquid is pushed in a downwards directions; that
is along the axis of the container. Baffles also usually installed to prevent a vortex formation
which can reduce the mixing efficiency and is to promote turbulence flow, therefore better

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mixing. Baffles also needed to stop the swirl in a mixing tank because almost all impellers rotate
in the clockwise or counter-clockwise direction. Without baffles, the tangential velocities coming
from any impellers cause the entire fluid mass to spin. It may look good from the surface seeing
that vortex all the way down to the impeller, but this is the worst kind of mixing. There is very
little shear and the particles go around and this is more like a centrifuge than a mixer. From the
observation made, there is difference flow pattern produced between using baffles and without.
The yellow beads seem to be widely spread when using the baffles and using the flat blade
propeller 2 inch with speed 700 rpm. During agitation of a low-viscosity liquid, the rotating
impeller imparts tangential motion to the liquid. Without baffling, this swirling motion
approximates solid-body rotation in which little mixing actually occurs. The primary purpose of
baffling is to convert swirling motion into a preferred flow pattern to accomplish process
objectives. The most common flow patterns are axial flow, typically used for blending and solids
suspension, and radial flow, used for dispersion. However, baffling also has some other effects,
such as suppressing vortex formation, increasing the power input and improving mechanical
stability. A common agitation objective is suspending settling solids in a low-viscosity liquid. In
the unbaffled vessel, the swirling flow field is ineffective at dispersing the solids that are grouped
in a rotating pile below the pitched-blade impeller. Also, a large surface vortex is visible at the
top of the shaft. In the vessel on the right, the baffles are visible on the left and right sides of the
vessel and as a thin gray strip that bisects the impeller and shaft. The presence of baffles
produces axial flow, in which the discharge flow produced by the impeller impinges on the base
of the vessel, flows radially to the vessel wall, then up the wall, returning to the impeller from
above.

Mixing process without using baffles produces inconstant flow, as the result the beads not
mixing well but only stack at the bottom of the container. Even the high speed applied, but the
beads cannot mix well and vortex formed. Difference when the baffles used, the vortex not forms
and the beads mixed well. This means the baffles can prevent the formation of vortex thus
enhance the mixing process. Based on this experiment, the best impeller chosen is flat blade
propeller with size 2 inch with speed 700 rpm. By using this impeller, the mixing occurred
uniformly from bottom to the top of the container. Flat blade propeller size 1.5 inch with speeds
100,300 and 500 rpm, not efficiently mix, maybe because the speed too low, but at 900 rpm the
mixing occurred but the power consumption higher than speed at 700 rpm. When mixing, the

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speed cannot be too fast because to prevent formation of bubbles, because bubbles can decrease
the mixing rate.

CONCLUSION

Based on the graph obtained, the flat blade paddle 2.0 inch produced constant flow rather than
flat blade paddle 3.0 inch. The constant flow important to get the effective separations between
particles and the medium, if the flow moves much rapidly, the particles not separates well and
can cause the medium become turbid and the separation not occurred effectively. The flow
control is important in separations by using the impeller. If too slow movement of flow, the
separation cannot also occur, because its to gentle to separates the particles.

REFERENCES

1) Chapple D, Kresta M.S, Wall A and Afacan A (2002). ”The effect of impeller and tank
geometry on power number for a pitched blade turbine”. Volume 80, Part A. Trans
IChemE.
(http://www.clevelandmixers.com/Files/Torque%20paper%20as%20published
%20~1.pdf)

2) Anon (1998). “Mixing Fundamentals”. Page 1.01 Rev 2. Hayward Gordon LTD.
(http://www.haywardgordon.com/documents/Mixing_Fundamentals.pdf)

3) http://www.wmprocess.com/impellers-for-mixing-processes/

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APPENDIX

Flat Blade Paddle 2.0 inch” DIA with Baffle (700 rpm)

Side View
Top View

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Equation

Find N2 = N1D1

D2

D1 = impeller diameter

D2 = shaft (0.7 cm)

360 ˚ x µ

180

= 6.283 rads

W = 6.283 rads x N2

60 s

Power P,

P=TxW

Where

T = Torque required to drive the impeller

W = Angular speed (rads-1)

Po = P

ƿN3D5

N3 = N1

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D5 = D1

P2 = P1 x D 2

D1

Where , P2 = Power absorbed by large mixer

P1 = Power absorbed by the model

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