AGITATION ANG MIXING PROCESS BACKGROUND

Batch and continuous blending processes are used to manufacture liquid detergent
in industry.
This process can produce between 15,000 and 50,000 pounds (6,800 and 22,700
kilograms) of detergent per hour.
Temperature varies in each process. For mixing process, the temperature range is
40OC - 90oC.
Dry detergent mix contains:
i. Surfactants
- penetrating and wetting fabric
- loosening soils (assisted by the mechanical action of the washing
machine)
- emulsifying soils and keeping them suspended in the wash solution
ii. Builders
- builders enhance the action of surfactants (eg: sodium
tripolyphosphate (STPP) )
iii. Alkalis
- raise the pH of the laundry wash water, which assists in breaking up
oily and acidic soil components. (eg: Sodium carbonate, sodium
bicarbonate, etc.)
iv. Enzyme
- enzymes are proteins that can target, aid, and speed up the breakdown
of particular stain components. (optimal temp: 40 oC)
v. Fragrance
- fragrances do more than give laundry a pleasant smell. They neutralise
the inherent odour of the detergent chemicals, and also of the soils in
the laundry wash.
vi. Brighteners
- brighteners enhance the light reflected from the fabric surface and can
make fabrics appear whiter and brighter, helping to keep them looking
newer for longer.
 MIXING PROCESS OF LIQUID DETERGENT

SURFACTANTS INGREDIENT ENZYME LIQUID FORMED

- Neutralizing MIXING ADDITION - dry powder is
fatty acids - All ingredients - the mixture is simply mixed
with either back in with a
except the cooled and
sodium solution
hydroxide enzymes are milled, and consisting of
(NaOH) or added and the enzymes water and
potassium mixed at a high are added in chemical called
hydroxide. temperature powder form as "solubilizers."

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 DESIGN OF MIXING TANK

1) Height = 2.5 m
Width = 2.0 m
2
π d2 π (2.0)
Volume of the tank = h= (2.5)
4 4
= 7.85 m3

1000 l
7.85 m3 × =7850l
1 m3
1 l=1 kg

7850 kg
=5233 kg /h
1.5 h

Production Rate: 5233 kg /h

Input = Output

Temperature = 40−90 ℃

Non-reactive process ( in steady state)

Tank dimension Designed Mixing Tank Industrial Mixing tank

D 1.0 m 0.75 m
DT 2.0 m 1.5 m

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 ZA 0.75 m 0.75 m

H 2.0 m 1.5 m

R 4 4
WB 0.125 m 0.125 m

N 1.13 Hz 1.13 Hz
P pitched blade impeller pitched blade impeller

W 0.15 m 0.15 m

2) Tank dimension ;

D=1.0 m D=Diameter of agitator

DT =2.0 m D T =Diameter of tank
Z A =0.75 m Z A =Heig h t of agitator ¿ base of tank
H=2.0 m H=Dept h of liquid
R=4 R=No . of baffles
W B=0.125 m W B=Widt h of baffles
N=1.13 Hz N=Speed of agitator
P= pitc h ed blade impeller P=Pitc h of agitator
W =0.15 m W =Widt h of blades of agitator∨ paddle

Geometric similarity of typical mixing tank

DT ZA WB H
=2 ; =1 ; =0.2 ; =2
D D D D

Geometric similarity of our mixing tank

DT ZA WB H
=2 ; =1 ; =0.167 ; =2
D D D D

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AGITATED SYSTEM

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 Dt = 2.0 m

N = 68
rpm

H = 2.0 m
Wb = 0.125 m

Za = 0.125 m
D = 1.0 m

Type of agitator : 4- pitch blade impeller

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CALCULATION OF POWER CONSUMPTION (DESIGNED MIXING TANK)

Steps to calculate power ;

ρN D a2
1) Reynold number ( ℜ ) =
μ
¿(1056)(1.13)¿ ¿
¿ 7.95 ×102

N 2 Da
2) Froude number ( Fr ) =
g
¿¿¿
¿ 0.13

From the graph,

power number ( N P ) =0.1

3) Power consumption

P=N P ρ N 3 D a5

Where;
J
P= power ( ∨W )
s
N P= power number N P=0.1
ρ=density ¿ ρ=1056(kg /m3)
N=rotational speed (rev /sec ) N=1.13 hz
D a =diameter of agitator (m) Da =1.0 m
μ=viscosity of fluid ¿) μ=1.5 Ns /m 2

P= (1.0 )( 1056 ) ¿
¿ 1.52 kW

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CALCULATION OF POWER CONSUMPTION (INDUSTRIAL MIXING TANK)

Steps to calculate power ;

ρN D a2
1) Reynold number ( ℜ ) =
μ
¿(1056)(1.13)¿ ¿
¿ 2.69 ×104

N 2 Da
2) Froude number ( Fr ) =
g
¿¿¿
¿ 0.098

From the graph,

power number ( N P ) =0.6

3) Power consumption

P=N P ρ N 3 D a5

Where;
J
P= power ( ∨W )
s
N P= power number N P=0.6
ρ=density ¿ ρ=1056(kg /m3)
N=rotational speed (rev /sec ) N=1.13 hz
D a =diameter of agitator (m) Da =0.75 m
μ=viscosity of fluid ¿) μ=1.5 Ns /m 2

P= ( 0.6 ) (1056 ) ¿
¿ 2.2 kW

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THE FLOW PATTERNS

PITCHED BLADE TURBINE

Pitched Blade turbine known as an “axial flow impeller” is especially suited for high speed
liquid/ solid applications where tank baffles may be impractical. Direction of fluid flow can
be up or down depending on the pitch. The pitch angle can vary between 0° and 90° from the
vertical. Flow patterns in a fluid (gas or liquid) depend on three factors: the characteristics of
the fluid, the speed of flow, and the shape of the solid surface. Three characteristics of the
fluid are of special importance: viscosity, density, and compressibility. As the viscosity of
liquid detergent is low,1.5 Ns/m2 we need to use pitched blade turbine to make sure the

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mixture circulated evenly and effectively. For mixing to be effective, fluid circulated by the
axial flow impeller will sweep the entire mixing tank in a reasonable time.

Reference/Appendix

Internet

1) www.pinoybisnes.com/home-based-business/how-to-make-liquid-detergent/
(retrieved 2014)
2) www.fusionfluid.com/FusionFluidEquipmentLLC/html/impellers_pbturbine.html
(retrieved 2014)
3) www.unilever.com.my/our-brand/detail/Breeze/335780/ (retrieved 2014)

Books/Journals

1) De Groot, W. Herman. Sulphonation Technology in the Detergent Industry. Kluwer

Academic Publishers, 1991(retrieved 2014)
2) Kuo-Yann Lai, Liquid Detergent. CRC Press Publishers, August 23,2005 (retrieved
2014)

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APPENDIX

4 – pitched blade impeller

Example of Breeze detergent products

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Liquid detergent production process

Unilever logo

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