Sidestep Mixing - chemicalprocessing.com
Transcript of Sidestep Mixing - chemicalprocessing.com
Sidestep Mixing Missteps
Mixing eHANDBOOK
TABLE OF CONTENTSSucceed at Mixing Scale-Up 6
Understand how best to apply and adapt simple rules
Inline Blending Offers Multiple Benefits 11
These systems offer efficiency, convenience and safety
Carefully Evaluate Blending Requirements 16
When choosing a mixer, consider these four key components
that can lead to improved mixing
Additional Resources 20
Mixing eHANDBOOK: Sidestep Mixing Missteps 3
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One question frequently asked
about mixing scale-up is whether
to use equal tip speed or equal
power per volume. While one of these cri-
teria may guide successful scale-up, you
may need to factor in some additional
limitations or qualifications to get proper
results. Scale-up using these concepts
most often involves equipment with geo-
metric similarity, i.e., length dimensions
in the large-scale mixing equipment are
in the same proportion as those in the
small-scale equipment. Because geo-
metric similarity sets all the dimensions
and impeller features in the large-scale
equipment, the only remaining variable for
scale-up is the rotational speed.
When mixer speed is the only variable in
scale-up, you can reduce the calculation
of the large-scale speed to an expression
starting with the successful small-scale
speed times the inverse scale ratio (small-
scale length/large-scale length) raised to
an exponent:
NLarge = NSmall (TSmall /TLarge )n =
NSmall (DSmall /DLarge )n
where N is the rotational speed, typically
expressed in revolutions per minute, T is
the tank diameter, and D is the impeller
diameter. (You can use either the tank or
impeller ratio because they are the same
with geometric similarity.) The exponent, n,
provides a convenient means for adjusting
the magnitude of the speed change from
the small scale to the large scale. To calcu-
late a large-scale speed for equal tip speed,
the exponent is one, i.e., n = 1. Whatever
Succeed at Mixing Scale-upUnderstand how best to apply and adapt simple rules
By David Dickey, MixTech
Mixing eHANDBOOK: Sidestep Mixing Missteps 6
www.ChemicalProcessing.com
the successful small-scale speed is, you
must reduce the large-scale speed by the
ratio of the small-scale to large-scale length
dimensions. For instance, if the effective
small-scale speed is 250 rpm and the large-
scale length dimensions are five times the
small-scale dimensions, you must set the
large-scale speed at one-fifth the small-
scale speed or 50 rpm.
Using equal power per volume for geomet-
ric scale-up usually runs into an additional
limitation for turbulent mixing conditions.
With geometric similarity in turbulent mixing,
power is proportional to speed cubed and
the impeller diameter to the fifth power.
With geometric similarity, volume is pro-
portional to the tank diameter cubed or,
alternatively, the impeller diameter cubed.
For geometric similarity, the tank diameter
and impeller diameter scale ratio are the
same. If power is defined by speed cubed
and impeller diameter to the fifth power and
volume is proportional to impeller diame-
ter cubed, then power per volume must be
proportional to speed cubed and impeller
diameter squared. So, re-arranging the pow-
er-per-volume relationships to calculate the
large-scale speed from the small-scale speed
raises the inverse scale ratio to an exponent
of two-thirds, i.e., n = 2/3.
An exponent of two-thirds reduces the
large-scale speed by less of a factor than
for equal tip speed. Again, using the suc-
cessful small-scale speed of 250 rpm and a
five-to-one length increase as an example,
the large-scale speed for equal power per
volume is 85.5 rpm. For turbulent condi-
tions, where power is proportional to speed
cubed, the large-scale power for equal
power per volume will be 4.9 times the
power for equal tip speed. This difference
in power becomes even greater with larger
scale changes and may be impractical
for some.
OTHER FACTORSBeyond the obvious differences in the
speed and power changes between equal
tip speed and equal power per volume, the
fluid dynamic reasons for choosing one or
the other set of criteria differ. With geomet-
ric similarity and turbulent conditions, the
flow pattern in a stirred tank is a constant.
In other words, the local velocity magnitude
at any point in the tank is proportional to
the impeller tip speed. Equal tip speed for
turbulent mixing and geometric similarity
will result in similar local speeds and rela-
tive velocities throughout a stirred tank.
The velocity of the impeller tip relative to
the surrounding fluid may define important
You should determine scale-up behavior in small-scale tests for best scale-up results.
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Mixing eHANDBOOK: Sidestep Mixing Missteps 7
velocity gradients, which can affect certain
types of dispersion. Drop size in two-phase
liquid/liquid systems and agglomerate
breakup size in solid/liquid systems may
be closely related to impeller tip speed in
scale-up. Power per volume, which also is
power per mass, can be related to turbu-
lence factors, such as micro-scale length
and time or energy dissipation. These
power-per-volume effects may influence
certain types of chemical reactions and
product distributions.
Although some process generalizations
may point in favor of tip speed or power
per volume, you should determine scale-up
behavior in small-scale tests for best
scale-up results. Varying the impeller size as
well as the speed in these tests often may
help better differentiate between scale-up
by tip speed or power per volume.
NON-GEOMETRIC SCALE-UPGeometric similarity, while reducing the
number of variables, isn’t essential for
successful scale-up. One of the most
common geometry changes is the impel-
ler-to-tank-diameter ratio. By simple logic,
a small impeller operating at a high speed
should provide similar results to a large
impeller running as a low speed. What
“similar results” means depends on the
process. Because impeller pumping capac-
ity and power input don’t have the same
functionality with respect to impeller diam-
eter and rotational speed, the tip speeds
or power requirements likely will differ
depending on the impeller-to-tank-diam-
eter ratio. Small impellers tend to operate
at higher tip speeds and power inputs than
large impellers.
Sometimes geometric similarity isn’t prac-
tical or even advisable. Unfortunately,
non-geometric scale-up is a more difficult
process. It may involve several different
combinations of constant or changing
mixing parameters. A step-by-step scale-up
process may begin with a geometric sim-
ilarity scale-up to the large-scale tank
diameter. Once some conditions have been
established in the large scale, you can
adjust liquid level to alter the volume. Then,
you can make further changes to impeller
diameter or type with assumptions about
equal tip speed, equal power per volume, or
other factors (such as torque per volume,
mixing intensity, surface motion, blend
time, and heat or mass transfer rates) being
kept constant or changed. The combina-
tion of factors best suited for successful
non-geometric scale-up will depend on
the particular aim of the mixing.
Perhaps the most difficult scale-up occurs
when viscosity is a significant factor in
mixer performance. High viscosity almost
always makes mixing tougher. However, the
effect of viscosity on mixing isn’t measured
just by the magnitude of the viscosity.
Instead, the impeller Reynolds number, Re,
typically is used. It includes the effect of
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Mixing eHANDBOOK: Sidestep Mixing Missteps 8
impeller size, rotational speed, fluid den-
sity and apparent viscosity. The Re is the
best way to judge whether fluid motion is
turbulent, transitional or laminar. Because
the impeller diameter appears as a squared
factor in the Re numerator with viscosity
in the denominator, scale-up from a small
mixer to a large mixer increases the Re and
decreases the effect of viscosity magnitude.
This rise in Re with size means that viscos-
ity will have less impact in the large-scale
mixer — and that mixing may get easier as
the scale of the process goes up.
GO BEYOND SIMPLE RULESThe real problem with mixing scale-up is
that the simple rules like tip speed and
power per volume are only part of the
answer. Other factors may help or hurt the
results of using the simple rules. You can
successfully use scale-up to design a mixer
for a process — if you understand the pro-
cess needs and keep the essential features
the same with scale-up. Take advantage
of the many studies of mixing scale-up
reported in books and technical literature.
Scale-up requires some process knowledge
and background information.
DAVID S. DICKEY is a senior consultant at MixTech, Inc.,
Coppell, Texas. E-mail him at [email protected].
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Sometimes geometric similarity isn’t practical or
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Mixing eHANDBOOK: Sidestep Mixing Missteps 9
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Inline Blending Offers Multiple BenefitsThese systems offer efficiency, convenience and safety
Robert Brakeman, Sonic Mixing
For ages, factory workers have been
handling drums, totes and pails to
dump numerous ingredients into large
batch tanks manually on load cells with large
horsepower agitators on top. Drum pumps
might be used to transfer liquid material to
the tank based on weight addition. Smaller
pails of material will be trudged up to the top
of the tank and dumped in by hand. A centrif-
ugal or positive displacement (PD) transfer
pump might be wheeled over and connected
to a tote or raw material storage bulk tank as
larger-quantity materials are transferred again
by weight addition.
Large manufacturing sites with larger bud-
gets might be more sophisticated with their
approach by automating these transfers
and will draw from bulk storage versus
totes, drums, etc., when possible. These
ingredient additions still are dumped one
at a time by weight addition. The load cells
or floor scales have to consider the tank’s
weight, so their resolution typically is poor
when it comes to smaller-ingredient dump
amounts, thereby providing poor ratio con-
trol among ingredients.
More advanced factories may use expensive
mass flow meters to “fly in” liquid ingredients
simultaneously but with no guarantee that
the proper amount was dumped as the flow
meters won’t consider material left in piping,
drain amounts, etc. Typically, manufactur-
ers’ recipes include large quantities of either
water or some bulk ingredient. Transferring
water to a batch tank is a wasteful practice,
but we’ll get to that later.
INLINE BLENDING BASICSBatch mixing is confined to a single tank
where all the materials typically are added
Mixing eHANDBOOK: Sidestep Mixing Missteps 11
www.ChemicalProcessing.com
one at a time. This approach has many
inherent drawbacks:
• A large costly tank is required.
• Tanks consume valuable floor space.
• Ingredients usually are added one at
a time.
• Large bulk materials or water are
transferred to this tank, consuming valu-
able space.
• Agitation at large horsepower is
required in the tank.
• Ratio control is not accurate due to
low-resolution flow scales or load cells.
• More tanks are added and more floor
space is consumed as demand for more
capacity grows.
Inline blending systems are used to eliminate
these restrictions and flaws. A typical system
uses multiple PD pumps with various types
of flow meter technologies to meter liquid
ingredients simultaneously into a common
pipeline with static mixers or an alternate
inline shearing device. These PD pumps get
connected to bulk storage tanks, totes, drums
or the factory water supply. Programmable
INLINE BLENDING SYSTEMFigure 1. This diagram shows the mechanics of an inline blending system. Image courtesy of Sonic Corp.
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Mixing eHANDBOOK: Sidestep Mixing Missteps 12
logic control (PLC) automation onboard the
skid will start and stop these pumps together
and provide PID ratio control for each. Figure 1
illustrates the mechanical concept nicely.
Inline blending systems typically fea-
ture their own onboard controls, which
can be as simple as a PLC by Allen-Brad-
ley or Siemens, for example; an operator
human-machine interface (HMI) panel; and a
variable frequency drive (VFD) inverter cab-
inet. The VFD inverters communicate with
the motors connected to each PD pump to
drive the pump to specific speeds.
The flow meters read the resulting flow from
the PD pumps, and the PLC PID control
block compares the actual flow to a target
flow and adjusts the motor speed (pump
flow rate) automatically via the VFD to track
the flow setpoint accurately. Depending on
the type of flow meters used — Coriolis
mass flow meters by Endress+Hauser and
Micro Motion being the most accurate —
ratio control can be within 0.25 to 0.35%
across two or more feeds.
To keep the inline blending system operating
at a steady state, a buffer tank sometimes
is used that feeds directly to a filling line.
This also eliminates need for large storage
holding tanks, thereby consuming yet less
factory space.
In the most simplistic sense, manufacturers
should avoid transferring water to a batch
tank. Making a concentrate where possible and
using a two-feed inline blend system to meter
the water and the concentrate at ratio is a far
better approach. You do still have to contend
with some level of batch making vis-à-vis the
concentrated premix, but the process is sim-
plified. It ultimately reduces the amount
of water, or other bulk fluid, placed in
a tank, allowing more product yield for
that given tank size.
The idea is to expand from there
and meter all or as many ingredients
as possible. In the case of chemical
cleaning solution, for example, there
are a finite or low number of liquids
to meter from bulk storage and
totes, so zero concentrates or pre-
mixes are required, and everything
is metered from source
such as totes, drums and
bulk storage (Figure 2).
MULTI-FEED INLINE BLENDING SYSTEMFigure 2. This multi-feed inline blending system can be used safely to produce cleaning chemical solutions. Image courtesy of Sonic Corp.
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Mixing eHANDBOOK: Sidestep Mixing Missteps 13
In other processes you might not be so lucky
as to meter everything because you’ll have
powders to deal with, and a premix becomes
unavoidable. Again, the focus is on increased
product yield for given tank and floor space
while reducing tank sizes overall.
THE BENEFITS OF INLINE BLENDINGInline blending can have advantages
over conventional batch mixing meth-
ods. Moving water or other bulk materials
around frequently is wasteful, so moving
from bulk to batch tank and then from
batch tank to hold tank or fillers is waste-
ful. Inline blending systems move finished
product while mixing on the go, in essence
eliminating the middle-man batch mixing
tank. This saves process time by reducing
transfers and eliminating batch tank agita-
tion times. The larger the batch tanks, the
larger the agitator motors. Inline blending
systems can meter as many as four fluids
at 100 gpm total flow at less than 10 hp in
some cases.
Other considerations exist as well. In dealing
with flammable fluids, as discussed, drawing
from bulk tanks located safely outside the
building keeps the building interior safe and
reduces costly fire code issues.
In the case of ethanol or methanol, in the
manufacture of hand sanitizer or windshield
washer fluid, the bulk of the material that
releases larger quantities of flammable
vapors is kept outside.
With batch mixing those materials get trans-
ferred inside in large quantities that render an
XP hazard rating inside the building. An inline
blending system is a closed system that con-
tains only minor volumes of vapor-releasing
liquids inside pumps and piping, insufficient
to require an XP rating (Figure 3).
In summary, inline blending offers:
• elimination of batch mixing tanks
• elimination of multiple transfers
• increased product yield for any premix
tanks used
• increased accuracy of ingredient ratio –
0.25 to 0.35% (flow meter dependent)
• reduced process cycle times
• reduced energy consumption
ROBERT BRAKEMAN is president of Sonic Mixing Corp.
E-mail him at [email protected].
HAZARDOUS CHEMICALS HANDLINGThis multiple-feed inline blend system can be used when working with hazardous chemicals. Image courtesy of Sonic Corp.
www.ChemicalProcessing.com
Mixing eHANDBOOK: Sidestep Mixing Missteps 14
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Carefully Evaluate Blending RequirementsWhen choosing a mixer, consider these four key components that can lead to improved mixing
By Roy R. Scott, Arde Barinco
It is not unusual for mixing suppliers to
receive the following request, or simi-
lar: “I need a mixer for a 500-gal. tank.”
The requestor then may expect a product
suggestion to satisfy all requirements. The
supplier’s typical response is, “What is
your mixture’s viscosity?” Many times, this
is the entire conversation, and a mixer’s
specification and pricing proceed from
there. This often can lead to dissatisfying
results. Here are four things to consider
for successful mixing.
1. MAKE SURE IMPELLER IS IMMERSEDAll batch mixers use some type of impel-
ling device that typically is connected to
a shaft driven by an electric motor. That
impeller, sometimes known as a rotor or
a propeller and other times as a turbine,
must be in sufficient contact with the
mixture if it is going to have any success
impelling that mixture (Figure 1).
IMPELLER LENGTHFigure 1. Impeller shaft must be long enough to reach liquid mixture.
Mixing eHANDBOOK: Sidestep Mixing Missteps 16
www.ChemicalProcessing.com
This may seem obvious, but the details of
the process vessel’s shape determine the
details of the mechanical design of the
shaft connected to the mixing impeller. In
short, the impeller’s drive shaft has to be
long enough to reach down into the liquid
at all times if mixing is to proceed. If the
mixing vessel usually is close to full, then
the mixing impeller will make good contact
with the mixture in almost any circumstance
(Figure 2).
If the batch begins with the vessel half-
filled and the other half of the mixture
must be added while mixing, then the mix-
ing impeller must make good contact with
the liquid even when the tank is half-full.
This result is even more difficult to achieve
if the vessel needs to be stirred at a less-
than-half-filled level (Figure 3).
The mixing vessel’s diameter and depth
will determine how much volume exists
at a given fill level. These dimensions are
required to calculate the fill levels to make
sure that the impeller can impel the mix-
ture. Most impellers require some minimum
immersion, such as 6 or 12 in. of mixture
over top of the impeller, to do the job.
After the mixing impeller is configured
and located so that it can start doing its
job of pumping and moving the mixture
throughout the mixing vessel, the pump-
ing and circulation must be strong enough
to mix all areas in the mixing vessel. No
stagnant locations can exist because, if
any of the mixture’s components enter an
area with no flow, they will, by definition,
stay there and not get mixed with the other
components (Figure 4).
PROPER CONTACTFigure 2. This impeller is well covered and in contact with mixture.
FILL LEVELFigure 3. Here, the fill level is too low to cover the impeller and the mix vessel is too wide and shallow.
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Mixing eHANDBOOK: Sidestep Mixing Missteps 17
2. MAKE SURE IMPELLER IMPARTS FLOW TO ALL AREAS OF MIX VESSELThe mixer supplier must offer an impeller
capable of moving the mixture throughout
the vessel, and that impeller will require
a certain amount of mechanical power.
The mixer manufacturer must configure a
power source (motor) along with its shaft
and impeller that can pump the mixture’s
viscosity and density. However, just causing
good flow from top to bottom and round
and round may not produce any mixing at
all. The impeller must produce a pattern of
flow that causes swirls and eddies that can
intermingle the various components.
Sometimes the impeller-produced flow
needs to be baffled by installing station-
ary vertical obstacles in the mixing vessel.
Other mixers operate at very high flow rates
that cause natural flow patterns to produce
good mixing without the installation of
baffles (Figure 5). Once there is sufficient
flow to produce different velocities within
a mixing vessel, these shearing zones then
can produce the desired result (Figure 6).
That is, all of the various components must
exist in the correct percentage for whatever
sample size is taken from the mixing vessel.
This is the definition of successful mixing.
3. MAKE SURE MIXING QUALITY GOALS ARE METEven if the mixer has impelled all of the
various components into the correct per-
centages, additional quality requirements
may exist, such as a desired particle size
distribution of a solid dispersed into a liq-
uid or an emulsion droplet size distribution.
POOR FLOWFigure 4. Impeller is well covered but good flow doesn’t reach lower areas of vessel, allowing set-tling to occur.
FLOW PATTERNSFigure 5. These mixers operate at very high flow rates that cause natural high shear flow patterns to produce good mixing.
Upward “umbrella” flow
Downward “vortex” flow
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Mixing eHANDBOOK: Sidestep Mixing Missteps 18
Perhaps solids need be dissolved into the
liquid at a given concentration.
Mixing quality can be measured in differ-
ent ways. Different desired process results
often will require different types of mixing
equipment. For fine-particle-size dispersion,
mixing equipment generically described as
“high shear” may be required. However, “high
shear” can refer to thousands of mixer types.
In short, the mixing impeller not only must
mix the components to the right ratio but
also may be required to achieve some other
physical or chemical result.
4. MATCH BATCH COMPLETION TIME TO REQUIRED OUTPUTOne more requirement for a mixer to be suc-
cessful is that it must do everything described
above and also do it in the right amount of
time. For a 500-gal. batch, it has been as-
sumed the mixer will produce the volumes
required for the mixer’s owner. How much of
the mixture needs to be made, and how much
per day and how much per year?
Suppose the annual requirements are 100,000
gal. Mixing time for a 500-gal. mixer includes
filling the vessel, adding the other required
components, mixing, dispensing and cleaning
the vessel to make it ready for the next batch.
If these steps take an 8-hr. shift, then it would
take 200 days on a one-shift basis to make
the required 100,000 gal. Because a typical
work year is 200 days, the mixer is successful.
However, if 200,000 gal. are required annual-
ly, the facility would have to go on a two-shift
basis or install two 500-gal. tanks.
Another alternative would be to specify a
faster mixer that might complete the mixing
process twice in one shift. The decision to
use the 500-gal. mixing vessel size might be
reconsidered. Perhaps a larger batch with
a larger, faster mixer would cost less than
starting a second shift.
Extensive research for blending applica-
tions is available in a number of textbooks.
However, for many processes, no substitute
exists for doing experimental trials on a
small scale and then scaling up.
ROY R. SCOTT is sales engineering manager at Carlstadt,
N.J.-based Arde Barinco. Email him at [email protected].
SUFFICIENT FLOWFigure 6. Impeller is well covered and close enough to the vessel bottom to reach lower areas of vessel to prevent settling.
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Mixing eHANDBOOK: Sidestep Mixing Missteps 19
Mixing eHANDBOOK: Sidestep Mixing Missteps 20
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