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The Art of Mixing
The Art of Mixing
The Art of Mixing
Overview
Standard Engineers is one of India's foremost companies in the field of Mixing and Agitation. In terms of
critical duty and complex mixing equipment, it is without an iota of doubt, The Leader in India and amongst
the top in the world.
Business Definition
Standard Engineers is in the Business of providing Mixing Solutions to achieve ANY Desired Process
Result.
Established in 1962, Standard Engineers has played a substantial role in the Chemical, Pharmaceutical
and Fine Chemical expertise that India, as a nation, has built up over the years. The manufacturing unit is
located in Andheri, Mumbai and is equipped with Pilot testing facilities for different complex duties.
Drivers
A burning desire to seek new challenges is the main driver at Standard Engineers. The higher the task
complexity, the stronger the desire at Standard to create solutions. A vast experience spanning all kind of
industries and different technologies over the years has given Standard a unique approach to problem
solving. The other ability Standard brings to the table is it's multi-disciplinary approach. Combining the
latest in Materials sciences, Modern Hydrodynamics derived from Aeronautics, state of the art in
Electronics and control and automation methodologies, Standard is able offer radical solutions.
Pedigree
The entire top management comprises of engineers from some of the Best Institutes from India like the
IICT (Formerly known as UDCT) and IIT. The attitude at Standard is to deliver 'Best in World' solutions.
Clients
The 'Standard' client base reads as a Who's Who of the Chemical world and list of repeat customers is
testimony to their satisfaction. Standard Engineers' thrives on the reputation in the market place and goes
to Extremes to ensure extraordinary Process results.
Past
The Past at Standard was based on the multitude of Process Technologies that Indian companies imported
into India. These included indigenous as well as MNCs
Present
The Present at Standard involves creation of radical new technologies with companies innovating in
process and manufacturing route designs. Standard has launched a slew of World class Products as it
morphs from a custom solution company to a Product driven company
Future
The Future at Standard is one where Standard generates patented technologies that create Paradigm
shifts in Process industries; evolving from a Product creation company to a Technology Developer.
We Mix with the Best <> We Stir things up <> A Stirring Performance ….
Everytime.
The Art of Mixing
Complexity of the Trinity
Mixing is thus the Triumvirate of the Chemical Universe. The Brahma, Vishnu and Mahesh. It is the
Complexity of the Balance between Creation, Preservation and Destruction which elevates Mixing to an Art
form.
Modern Technology
The Best of Computational techniques today are not able to address the complexities of multi phase
interplays with the dynamics of Thermodynamics and Kinetics. Mixing is an Art and like all Art forms it is a
Beautiful quest in whose pursuit all of us from the Chemical domain are fellow Travellers
Mystery
Ask about this Art to the chemist who can get purity in the RBF, but is struggling in the reactor. Ask about it to
the marketing man, whose competition is able to deliver a particle size distribution, while his team is stuck.
Ask about it to the Production man who spends days waiting for the filtration to get over. The List is truly
endless.
Archaic Impellers:
1. The Anchor is dead. Long live the Anchor. This is one impeller that has rendered yeoman service to the Process
industries and has been given more than it's fair share of Processing energy. The fundamental drawback of this
impeller is that there is no axial Mixing, but only tangential swirling. Temperature hot spots, extra fine crystals,
huge variations in batch times, complete lack of consistency in all parameters are all because of this impeller.
The era of the anchor is over. Gates and similar impellers belong to the same category.
3. The Turbine family Axial flow (45deg Pitched) Turbines (also referred to as Pitched blade turbines) and Flat
blade Disc turbines (also referred to as Rushton turbines) are wonderful impellers from the 1960s. Mixing has
moved far ahead since then. It is indeed time to bid Adieu to these workhorses
4. The Marine Propeller is the first impeller that mankind used scientifically for mixing. It is a good impeller, but
uneconomical for larger sizes. The other improper use of this impeller is when it is deployed for shear and radial
mixing needs.
2. One Impeller cannot perform a wide range of duties. This is not true as modern impeller designs allow an
extremely large range of duties with appropriate mechanical design and power inputs.
The Sound Mixer Design Philosophy in today's world is to have a slightly over designed system both, Mechanically
as well as Electrically. This will pay rich dividends in terms of flexibility as well as an ability to deliver under changing
conditions of the future.
Mixer Components
Electro-Mechanical Design
Prime Mover
The prime mover must enable
speed variation
Mixer Types
Top Entry :
• Top entry is the preferred mode of installation because installation and removal Input Connection
Located between prime mover
can be easily done from top.
and gearbox or driven agitator
• Seal is in vapour space and in case of seal failure, tank needn't be emptied for shaft Consumable component
should be easily replaceable
seal change
Side Entry :
• Very economical for large storage tanks and simple blending duties Speed Reduction
The Speed Reducer is also a
• Can be adapted for tanks with H/D ratio of 1 Torque multiplier.
• Sealing has to be maintenance free.
• Seal removal should be possible without emptying tanks
• Swivel feature can reduce blend times. Speed Variation
Extremely powerful tool for
• Inlet and outlet location important optimization of agitator process
• Angle at entry and angle between multiple mixers important performance. Can be used to
maximize performance of mixer
and can also be used to reduce
Bottom Entry : power consumption. Needs
careful handling to ensure no
• Economical option for Tall tanks. resonance between operating
speeds and 1st and 2nd natural
• Also used when mixing is required in bottom portion prior to discharge. frequencies of shaft vibration in
the lateral mode
• Sealing considerations like side entry mixer
Output Connection
Is decided on the ability of the
Inclined Entry : gearbox to absorb part of the
• Can be from top or from side mixer loads Thrust and
bending moment.
• Enables good axial mixing without baffles
• Sealing considerations like side entry mixers if entry is from side
Sealing
Seals off reactor at point of
agitator shaft entry. Type
selection done on severity of
Modern Agitator Design Aspects Temp/Pressure as well as
Hazardous nature / Toxicity /
stability of reactor contents
1) Motor mounting brackets to be avoided if possible
2) Bearings in lantern to be avoided if possible
3) Robustness always ensures long-term economy
4) No compromises in Agitator design
5) Speed variation to be carefully incorporated
Performance Boosters
Complex rotating equipment
charged with the task of
performing many process
duties can be boosted to
ensure higher productivity,
better quality and maintenance
free operation.
• Electric Motor • Pneumatic Motor
AC or DC; 3 phase or single phase up to Suited for Small Mixers; Clean
3HP, TEFC or SPDP; Energy efficiency construction and aesthetics; Requires
Class I or Class II; Flameproof, Increased compressed air; Naturally flameproof; Air
Safety, Non-Sparking or Pressurised; Flow control provides speed variation
Suitable for Inverter duty with or without
independent cooling fan; Temperature rise
limited.
• PIV • Inverter
Economical for Constant Power drives; Has revolutionized Mixer design; Made
Positive variation; Very bulky; Speed possible concept of Universal Mixer - one
variation done by change in PCD of mixer for any application; Needs derating
driver/driven for constant power mode; Can easily be
used at motor frequencies greater than
50Hz; Needs extreme caution in avoiding
resonance; Needs caution in not exceeding
power consumption
• Muff • Flexible
Rigid coupling which can be used for light Used when isolation of the driver motor
fast mixers as well as for super heavy duty shaft or gearbox output shaft needs to be
mixers; Elastomeric and one piece for light insulated from mixer loads; Outdated
duty; Metallic split for heavy duty design for slow speed mixers; Increases
drive height and reduces stability
• Rigid
Metallic construction in welded or
removable types; Removable ones need
taper bore; often used as in-tank couplings
for head-room reduction and in long shaft
extensions
Prime Movers Eff. Class I /II TEFC Induction motors, Slip ring motors, Hydraulic motors,
Pneumatic motors
MOC (ALL Grades) Carbon Steel, Alloy Steel, Stainless Steel, Inconel, Monel, Hastelloy, Nickel, Titanium,
Sealing Vapour seal, Water seal, Dust seal, Stuffing box, Single seal cartridge, Double Seal
Seal Flushing Plan 53,54, Steam sterlisation, Water through flush, Solvent barrier, Pressure Balancing
Device
Current Impellers HFK - Hi-suction hydrofoil, HEP - Hi-discharge hydrofoil, HPP - Hi-pitch
(Axial Flow) hydrofoil, HED - High solidity disperser, UDIF - Up-Down Interference
Flow Impellers, SHX - Spheroidal Helix, HEX - Helixan, HL1 Single flight
Current Impellers HSC - High shear sawcut impeller, GID - Gas Induction disperser,
(Radial Flow) PDT - Parabolic disc turbine, HSR - High shear Stator-Rotor
Former Impellers Axial flow turbine, Flat blade disc turbine, Open turbine, Curved blade turbine,
Anchor, Paddle, Propeller (square and super pitch), Plate, Gate, Inverted vane etc.
Boosters fixing, electro polishing, Abrasion resistance on impellers and bottom brg.
Bottom Entry Saponification reactor Contactor with 75HP x 1500RPM positive circulation mixing system providing
extremely large heat transfer area.
Largest hydrofoil impellers (5.0 M dia) for top entry cantilevered shaft , for a battery of six bio-reactors of 1,000 M3
capacity each.
Longest rubber lined cantilevered shafts (11,500 mm extension) without any intermediate or bottom guide
bearing for 10,800 mm diameter x 12,000 mm high phosphoric acid storage tanks.
Largest fast speed, high pressure, mechanical seal agitators in Monel construction with an installed power of 100.0
HP, operating speed of 1460 RPM , design pressure of 10.5 kg/cm2 and a forced lubrication system with pressure
holding feature.
Dual motion, counter rotating , coaxial shaft grease kettles for high viscosity grease
production with reduced batch times.
Largest in the world, Quadruple Spheroidal helix Polycondensation autoclaves with variable speed drive for 3 x
105 cP viscosity mixing with minimum batch time. The weight of the gearbox alone is 7000Kgs.
Highest pressure temperature mechanical seal agitator with speed variation. Temperature = 290ºC and
Pressure = 100 kg/cm2 g.
High pressure, gas induction hydrogenation reactor agitator for manufacture of Sorbitol
(Pressure = 50 kg/cm2g.)
Hundreds of agitators to synthetic fibre plants in India and abroad including Thai Acrylic Fibre Co.Ltd, Saraburi;
Alexandria Fibres, Egypt; Reliance Industries Ltd ; Garware Plastics & Polyester Ltd., Aurangabad ; Shree
Synthetics Ltd., Ujjain ; JCT Ltd., Hosiarpur ; Punjab Polyfibres Ltd., Hosiarpur; Jindal Polyester and Steel Co.Ltd.,
Gulahoti & Nasik ; Consolidated Fibres and Chemicals Co.Ltd., Haldia ; Garden Cotton & Yarns Ltd., Surat ;
Venlon Polyester Films Ltd., Ester India Ltd; Khatima; Swadeshi Polytex Ltd; Modern Petrofils Ltd; Indo Rama
Synthetics Ltd; Indian Petrochemicals Corpn. Ltd. BCAF etc. J.K.Synthetics Ltd., Kota and Jhalawar; Nirlon
Synthetic Fibres and Chemicals Ltd., Goregaon; Indian Organic Chemicals Ltd., Manali; Gujarat State Fertilisers
Co; Petrofils Co. operative Ltd; SASMIRA Pilot Plant ; National Rayon Corporation , Kalyan; Orkay Polyester
Ltd., Patalganga
Hundreds of agitators, side entry and top entry , for all types of blending and storage
applications in refineries all over India and abroad such as ONGC, IOCL at various locations such as Mathura,
Panipat GREP, Haldia etc.; HPCL : BPCL; Kuwait Oil Co; Madras Refinery' Cochin Refinery ; Mangalore Refinery
and Petrochemicals Ltd.; IBP ; Bongaigaon Refinery & Petrochemicals Ltd., and a host of others.
Hundreds of agitators for various pharmaceutical plants of reputed manufacturers such as Glaxo , Sandoz ,
Bayer , Cyanamid, Hoechst, Lupin Laboratories and several others.
Largest number of agitator exports from India to various parts of the world under stiff global
competition.
Several single and double helix and screw impeller installations in vessels of various shapes
(cylindrical, spherical, conical)
Only fluid mixer manufacturer member of the British Hydro-mechanics Research Association from India.
Sharada Sadan, Third Floor, Opp. Fort Fire Brigade,11, S.A.Brelvi Road, Fort, Mumbai 400 001. India.
Regd. Off. : 78/2 Andheri - Kurla Road, Marol Naka, Andheri (E), Mumbai 400 059. India.
Tel : 2261 1916, 2262 6157 Fax : (022)2262 6152 Works: 2850 0722 Fax : (022)2850 1048
Email : agitator@vsnl.com Website : www.mixingstandard.com