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High Shear Mixers
High Shear Mixers
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CONTENTS
SECTION
INTRODUCTION/PURPOSE
SCOPE
FIELD OF APPLICATION
DEFINITIONS
4.1
4.2
4.3
4.4
4.5
3
4
4
5
5
5.1
5.2
Recommended Duties
Equipment Data
6
6
10
Recommended Duties
Equipment Data
10
11
6.1
6.2
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12
7.1
7.2
Duties
Equipment Data
12
13
TABLES
15
FIGURES
SHROUDED TURBINE
SAWTOOTH MIXER
13
14
16
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INTRODUCTION/PURPOSE
"High shear" mixers are used widely in the paint, food, pharmaceuticals,
adhesives and coating industries, but their application in the chemical plant
operations has been limited. The break-up of solid agglomerates, especially the
dispersion into paints, is a major application. Many wet filter cakes may be
redispersed by high shear mixers prior to drying. Emulsification and foaming
feature in pharmaceutical, food and cosmetic applications.
"High shear" mixers are particularly effective for dissolving high polymer
additives. It should, however, be remembered that polymer chains in excess of
about 20,000 monomer units are vulnerable to degradation in commercial high
shear mixers. This degradation of polymers is used for viscosity control in the
manufacture of shampoo and in other processes to obtain optimum rheological
characteristics.
The process engineer may be faced with the task of selecting a satisfactory
device from one of the many proprietary designs available. The technical
guidance available from the suppliers often falls short of the ideal; manufacturers
may not always be able to supply such basic information as the power
consumption of a mixer for a liquid of density greater than that of water.
SCOPE
This Process Engineering Guide helps the user to select the appropriate mixer
type for the duty and then recommends criteria to be met for satisfactory
operation.
FIELD OF APPLICATION
DEFINITIONS
SHROUDED TURBINE
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4.2
Turbine Mixers
Turbine mixers, consisting of a vessel and the agitator which are sold as one
unit, are exemplified by the Baker Perkins 'Hydisperser', see Figure 2. These
units are particularly suited to slurrying filter cakes and are suitable for solid
dispersion duties where the solids content exceeds 15% w/w. The standard
system gives poor bulk circulation; Detailed design recommendations and
performance data are given in Clause 6.
FIGURE 2
4.3
Unshrouded Agitators
Unshrouded agitators are often of the sawtooth disc type (see Figure 3 for an
example of the Torrance device). They are recommended for solids dispersion
duties requiring more than 15% w/w of solids. They can give problems with filter
cakes and will be slow to emulsify liquid-liquid systems with a viscosity ratio
greater than 3. Detailed recommendations and performance data are given in
clause 7.
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FIGURE 3
4.4
SAWTOOTH MIXER
In-Line Mixers
Some manufacturers make in-line versions of their shrouded mixers. Oakes Ltd
and Mondo Mix BV supply shrouded mixers with no batch equivalent.
The Oakes mixer with its concentric rows of rotor and stator teeth should ensure
that fluid does not by-pass the active zones. Oakes and Mondo mixers are
particularly effective in the production of foams. Figure 4 illustrates an Oakes
mixer.
FIGURE 4
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Other mixer types may be subject to by-passing of the most intensive agitation
zone and a single pass may therefore not be able to meet the requirements.
Such designs should therefore be treated with caution.
4.5
Ultrasonic Homogenizers
5.1
Recommended Duties
Shrouded turbines give the most intense extensional flow fields and are
recommended for the following duties:
(a)
Emulsification
Shrouded turbines are particularly suited when the dispersed phase is the
more viscous. When the ratio of the viscosity of the dispersed to that of
the continuous phase is greater than 3, a shrouded turbine should be
used.
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(b)
(c)
Polymer Degradation
High molecular weight polymers may be degraded by the action of a
shrouded turbine. Significant heat can be generated in this process.
(d)
5.2
Equipment Data
(a)
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FIGURE 6
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The 'high pumping' head is preferred for most duties and has performed better
than the 'high shear' head for polymer dissolution and degradation. In concept
the 'high pumping' head allows the impeller to digest coarse lumps and circulate
fluid at a higher rate, but should take longer to reach, for example, the same
degree of emulsification because the fluid can bypass the zone of intense
agitation.
The most intense disruptive forces occur in stretching flow where the fluid is
forced between the 'nip' of an advancing rotor blade and a stator port. Because
of this the annular gap between the rotor and stator is not too critical for
emulsification, and polymer dissolution and degradation duties where a gap of
0.25 to 0.5 mm is satisfactory.
(b)
The equation may be used to select a proprietary Greaves or Silverson mixer 'off
the shelf' provided the liquid density is 1000 kg/m3 or less. If the liquid density
exceeds 1000 kg/m3, increase the manufacturer's nominal motor rating pro rata
with the density.
Equation 1 implies a rotor to vessel ratio ranging from 0.12 in low viscosity (0.01
N s/m2) to 0.2 in high viscosity (30 N s/m2) batches and represents competitive
sizing for standard duties.
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(c)
Using a small, variable speed laboratory mixer, establish the tip speed
needed to give the required process effect.
Note that these mixers may not reach a full-scale tip speed.
(2)
(3)
Calculate the full-scale batch mixing time to achieve the required end
result from:
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(d)
Mixer Power
The manufacturer should normally be asked to specify the power required for a
new agitator. Note however that manufacturers have not always been able to
predict the power dissipated in unusual liquids.
The power absorbed depends partly on the mixer's behavior as a turbine and
partly on the torque generated in the rotor stator gap. The latter effect becomes
more important as the liquid density increases. For most liquids, including
solutions of low or degraded polymers (e.g. linear polymer Mw less than 400,000,
Mw/Mn < 4), the power of Greaves and Silverson mixers has been predicted to
within 20% by:
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D'
n
n'
(e)
Pumping Capacity
(f)
No data are available for bulk mixing times and heat transfer, both of which are
flow sensitive. The high shear impellers typically generate about 1/3 of the flow of
a turbine (W/D = 0.2) at a given speed. It is recommended that the turbine
correlations for mixing time and heat transfer, given in GBHE-PEG-MIX-701,
should be used with the speed term corrected to N/3.
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(g)
Shear Rate
The nominal shear rate in the rotor stator gap is given by:
These machines tend to be sold in two performance ranges. The first, typified by
the 'Hydisperser', has a power dissipation of 10-16 kW/m3, and is used by some
operators to liquidize dispersible filter cakes, often before spray drying. The
standard 'Hydisperser' is fitted with a back-swept vaned disc agitator (D/T = 0.45)
in the base. The standard maximum tip speed is 11 m/s with W/D of 0.06-0.07 to
economize on power.
A cruciform baffle cage may be fitted for lower viscosity applications and a
'butterfly' impeller of D/T = 0.65 is also available.
The second performance range includes the Baker Perkins 'Hynetic Mill' and the
Bearsley & Piper 'Speed mixer'. These devices may incorporate mulling wheels
and are better regarded as colloid mills.
6.1
Recommended Duties
(a)
Solids Dispersion
High speed internal mixers can handle 15 - 65% w/w of solids. The upper
limit will depend on the apparent viscosity of the sheared batch and should
be less than 50N s/m2.
k can be as high as 1.9 and will be lower than 1.6 for particles with a wide size
distribution. The limiting viscosity would be reached at 50% v/v solids
(i.e. c = 0.5) with k = 1.6.
(b)
Over 100 dispersible filter cakes have been examined and all are liquidized at
shear rates of 300 l/s or below. All these filter cakes may be dispersed by a high
speed internal mixer in the lower performance range (10-16 kW/m3).
6.2
Equipment Data
(a)
Scale-Up
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Only if the cake fails to disperse satisfactorily at this lower speed should the
manufacturer be requested to supply a non-standard device based on constant
power per unit volume.
(b)
Butterfly type agitators are used to provide a folding action in some paste mixers.
They do not offer any particular advantage in high speed dispersion duties
although the open structure of the butterfly agitator may assist in starting the
movement of a cake with a high yield stress.
(c)
Power Consumption
(d)
The pumping capacity may be estimated for vaned discs of W/D = 0.065 as:
Mixing times will then be of the order of 3 times those expected for standard
turbines working in baffled vessels at the same speed.
Tangential velocities are similar to those generated by a 2-bladed paddle (W/D =
0.33) and this 'pseudo geometry' should be used for heat transfer calculation,
using the method given in GBHE-PEG-MIX-701.
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(e)
Shear Rates
For information on shear rates, consult the GBHE Mixing and Agitation Manual,
Sections D4.4 and D4.5.
7.1
Duties
Emulsification
The sawtooth mixer is not recommended for liquid mixing duties. It should,
however, be effective in blending or emulsification of liquids into concentrated
solid dispersions and is recommended for this duty.
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(c)
Polymer Dissolution
The sawtooth mixer is not recommended for polymer dissolution as it can give a
stratified batch in polymer systems where viscoelastic forces oppose vortex
formation.
(d)
Sawtooth mixers are not recommended for filter cake dispersion. They can suffer
from stratification problems and these would prevent the lifting of the undispersed
solid from the base of the vessel.
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7.2
Equipment Data
(a)
Scale-Up
Using values of D/T and tip speed recommended in 7.1 (a), scale-up from smallscale experiments at constant D/T and tip speed is recommended. The batch
mixing time will increase in proportion to the linear scale.
(b)
Power
Figure 8 shows the relationship between Power number and Reynolds number
for sawtooth and other high speed impellers in baffled vessels and for a Torrance
mixer and a plain disc working in unbaffled vessels.
Hydraulic drives are usually fitted and are recommended for application with
these limited power data as they cannot be overloaded and allow mixing speeds
to be changed in a batch.
A Paints manufacturer produced the power data shown in Table 1. The apparent
power numbers near 0.1 are because the two of the three mixers are operating in
vortex aerated conditions at the highest tip speeds. Using this data they have
been able to replace the hydraulic drives with two speed electric motors which
are easier to maintain. If overloaded (for example by an increase in velocity
which causes loss of vortex) the motor trips to the lower speed. The trip power
may then be calculated from Figure 8. This procedure should only be attempted
with systems of less than 3 N s/m viscosity and then only in consultation with the
manufacturer.
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FIGURE 8
(c)
. . . . . . (10)
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Scale-up should be on the basis of constant tip speed and bulk mixing times will
increase in proportion to the linear scale, i.e. be proportional to volume to the
one-third power:
t'' = t' (V'' / V')1/3
(d)
. . . . . . (11)
Blade Geometry
Experience indicates that there is little to choose between the different sawtooth
blade configurations offered by the various manufacturers.
Sawtooth impellers are more effective than plain or perforated discs in the
creation of fine pigment dispersions. We have found that a circular saw blade is
as effective as a proprietary device in the dispersion of pigment base. The
proprietary devices incorporate blades with a vertical surface oriented
circumferentially (along the direction of rotation) and these blades will be more
effective in the initial break-up of coarse lumps by impaction.
(e)
Shear Rates
Peak shear rates for sawtooth impellers are caused by shear and elongational
flows. To determine the range over which peak shear rates apply, reference
should be made to the GBHE Mixing and Agitation Manual, Sections D4.4 and
D4.5.
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GBHE-PEG-MIX-701
GBHE-PEG-FLO-302
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