LAXMINARAYAN INNOVATION

TCHNOLOGICAL UNIVERSITY NAGPUR

SUBJECT;- Process Intensification
Assignment Topic:- Unit No. 2
(Scale of mixing,Type of mixers, Atomization, Impinging Jets, HiGee Reactors)
Presented By:-
• Harish Mudaliyar
• Harsh Mallani
• Honey Tuwani
• Harshal Sisodiya
• Janhavi Deshpande
• Kanchan Soni
• Karan Uike
• Kartik Zade Guided By
Dr. Sanjay Shirsath Sir
Table Of Content

Sr No. Content
1 Scale of mixing
2 Flow Pattern in Reactor
3 Mixing in Intensified Equipment
4 Static Mixer
5 Design Principle of Static Mixer
6 Application Of Static Mixer
7 Impinging Jets
8 High Intensity Inline Mixer Reactor
9 Chemical Processing In High Gravity Fields
10 HiGee Reactors
11 Automizer
Scale Of Mixing
Process intensification requires optimizing mixing scales, from macro to nano levels. This
enhances efficiency, reduces energy consumption, and improves outcomes within a smaller
footprint. By tailoring mixing scales to specific reactions and materials, industries achieve higher
yields, purities, and selectivities.
The types of mixing are,
1) Macromixing:
Macroscopic scale: Refers to the entire vessel or reactor.
Achieved through bulk motion or convective transfer.
Objective: Uniform distribution of fluid elements within the reactor volume.
Impact: Directly influences residence time distribution.
2) Mesomixing:
Coarse scale: Involves turbulent eddies.
Characteristics:
Turbulent dispersion: Fresh feed disperses turbulently.
Introduction: Feed introduced to a vessel mixed with the surrounding fluid.
Inertial convective breakup: Large eddies break up due to inertia.
3) Micromixing:
Final stage of turbulent mixing.
Length scale: Smallest fluctuations caused by molecular diffusion.
Phenomena:
Deformation by shear: Fluid elements deform due to shear forces.
Diffusion: Fine fluid elements mix at the molecular level.
Flow Patterns in the Reactor

Axial Flow impellers with baffles:-

• Baffles are vertical plates placed on tank walls (approximately 10% of tank
diameter).
• Facilitate top-to-bottom circulation, preventing solid body rotation.
• Promote efficient mixing by preventing central surface vortex formation.
• Ideal for homogeneous mixing applications.

Radial Flow impeller with baffles:-

• Similar to axial flow, but impellers induce radial flow patterns.
• Baffles enhance mixing by disrupting solid body rotation and vortex
formation.
• Effective for blending and dispersing applications.
 Angular impeller in off centred position:-
• Impeller placed off-center to prevent solid body rotation and vortex
formation.
• Provides efficient mixing while minimizing air entrainment risks.
• Suitable for applications requiring precise control over mixing dynamics.

Axial Flow impeller with baffles Radial flow impeller with baffles. Angular impeller with off centred
position
 Mixing in Intensified Equipments
Mixing intensified equipment refers to the integration of intensified or enhanced machinery into a mixing
process. This term could apply to various industries where mixing is a crucial step, such as pharmaceuticals,
chemicals, food processing, and more. Here's a general overview of what this might entail:

• Intensified Mixing Equipment: These are specialized devices designed to enhance the mixing process.
• Integration with Existing Systems: When introducing intensified mixing equipment, it's essential to
integrate it seamlessly with existing production lines or processes.
• Process Optimization: The goal of integrating intensified equipment is often to improve the efficiency,
quality, or consistency of the mixing process.
• Automation and Control: Many intensified mixing systems leverage automation and advanced control
systems to precisely manage the mixing process.
• Overall, mixing intensified equipment integration involves a holistic approach that encompasses
equipment selection, process optimization, safety considerations, and quality assurance to enhance mixing
processes effectively.
 Static Mixers

• Static mixers are widely used in industrial applications due to their

simple design and lack of moving parts, which keeps operating and
capital costs low.
• They are inserted into pipe work to achieve good homogeneity
between two or more streams, essential for processes like catalytic
reactions.
• Static mixers can intensely mix components within a short distance,
typically a few pipe diameters, with minimal additional pressure drop.
• They are versatile and suitable for reactions where at least one phase
is liquid, divided into turbulent flow, laminar flow, and combined
regime mixers.
• Companies like Cal-Gavin market them as heat transfer enhancement
devices, and they've been effective in gas-liquid contacting and liquid-
liquid dispersions.
• Research extends to micro-scale mixers, including glass micro-mixers for small flow
rates and stainless steel mixers for larger-scale production.
• Active enhancement methods like ultrasound and electrokinetic forces can improve
mixing efficiency at small scales, though challenges like thermophoresis and
electrophoresis may arise
 Design Principle For Static Mixers
There are three key parameters that affect the design of a static mixer .

1) Reynolds No. :- There are different static mixers designed to work at different Reynolds No.

2) Pressure Drop :- Pressure Drop is critical parameter because it drives the mixing.
If compared with mechanical agitation, the pressure drop is used to compare with proper I/P.
Therefore, Power for static mixing/Power of Mechanical Agitation = QP/Pimpeller
Where Q is flowrate, P is pressure drop and Pimpeller is the power required for the mechanical agitation.

3) Homogeneity:- There are two measures of this parameter,

• Relative Standard Deviation
• Coefficient Of Vomation
Steps for designing the static mixer:-

1) Calculate the Reynolds No.

2) Select the no of mixing elements based on the Reynolds No

Reynolds No No of mixing elements

<10 24 to 32
10 to 500 16 to 24
500 to 2000 8 to 16
>2000 4 to 8

3) Calculate the Pressure Drop:-

P = a*f*l*Q^2*p / D^5
Where P-Pressure Drop
f – Darcy Friction Factor
l- Length of element
Q- Flowrate
D- Dimeter of Pipe
Application of Static Mixers

Chemical Processing Waste Water Treatment Food and Beverages

Pharmaceutical Petrochemical
Polymer Industry Adhesive and Sealant Environmental Remediation

Biotechnology Paper and Pulp

 Impinging Jets

Impinging jets refer to a fluid flow configuration where two jets of fluid collide with each other. This
collision creates a complex and highly turbulent flow field.
• Impinging jets are commonly used in industrial applications and research due to their ability to
promote efficient heat and mass transfer.
• Some key points about impinging jets include:-
• *Heat Transfer:* Impinging jets are used in heat exchangers and cooling systems because they can
transfer heat rapidly due to the high turbulence generated upon collision.-
• *Mixing:* They are also used for mixing two or more fluids efficiently, as the collision of the jets
promotes thorough mixing.-
• *Cleaning:* Impinging jets are used in cleaning processes, such as in pressure washers, where the high-
velocity jets help remove dirt and debris from surfaces.- *
• Aerodynamics:* In aerodynamics, impinging jets are studied to understand the flow patterns and forces
involved, especially in applications like jet engines and airfoil design.- *
• Research:* They are also used in fundamental fluid dynamics research to study turbulence, boundary
layer behavior, and other flow phenomena.Impinging jets offer a versatile and effective way to control
and manipulate fluid flows in various applications.
High Intensity Inline Mixer Reactor

High shear mixers, also known as high shear reactors (HSRs), rotor-
stator mixers, and high shear homogenizers, are mixers that are
used to emulsify, homogenize, disperse, grind and dissolve immiscible
mixtures. They have high rotor tip speeds, high shear rates, localized
energy dissipation rates, and use more power than ordinary
industrial mixers.
Application: Food Manufacturing
Pharmaceuticals and Cosmetics
Paints and Coatings
 Chemical Processing in High Gravity Fields
High-Gravity Fields:-
• These fields, also known as centrifugal fields, create an environment where
fluid acceleration leads to mass transfer rates two to three orders of
magnitude higher than those achieved in conventional equipment like
packed towers and stirred tanks .

• Heat transfer is also enhanced in high-gravity conditions. The unique

properties of high-gravity fields allow for : Reduced equipment size: Short
contact times and fast transfer rates enable smaller equipment. Lower in-
process inventory:
Applications: Absorption and Stripping: High-gravity fields enhance separation
efficiency. Nanoparticles Preparation: Accelerated mass transfer aids in particle
synthesis. Other applications include sulfonation, polymerization, and
emulsification
 HiGee Reactor

• The HiGee reactor is a rotating packed-bed system designed for efficient

multi-phase operations. Liquid is injected onto the inner cylindrical packing
surface, flowing through the packing due to centrifugal force.Vapors are
forced to flow radially inward and exit via the rotor center. A mechanical
seal prevents vapor bypass flow around the rotor, with labyrinth seals
preferred for their effectiveness at high relative velocities.

• Packing materials must withstand rotor forces and have specific surface
areas between 500-5000 m^2/m^3 and high voidage (85%). Options include
reticulated metal foam, composite layers of gauze or expanded metal, and
wound layers of fibrous material. Packing characteristics are generally
uniform, with possible grading to manipulate local flooding conditions.
• The rotor's radial thickness correlates with separation duty and required stages. Hydraulic capacity
depends on flooding rates at the inner radius and cylindrical surface area, typically operating at 50% of
flooding rates. The pressure drop per theoretical stage is comparable to trayed columns rather than
traditional packed columns.

Overall, the HiGee reactor offers efficient mass transfer in chemical processes, with design considerations
optimizing performance and reliability.
Automizers

An atomizer is a device that creates a fine spray from a liquid by mixing air and
liquid and compressing it through a small opening. The goal of an atomizer is to
produce a homogeneous spray. Atomizers are used in many applications,
including:
•Perfume
•A perfume atomizer is a bottle with a tube connected to a nozzle that releases a
small amount of fragrance mist when pressed.
•Spray painting
•Atomizers are used to spray paint.
Ultrasound automizer: The ultrasonic atomizer mainly relies on ultrasonic
waves to generate capillary waves or cavitation on the liquid surface to
atomize the liquid, and the atomization process is kept at a low
temperature and low atomization
Thank You !