Professional Documents
Culture Documents
Agitation and Mixing of Fluids: Dr. Vimal Gandhi Department of Chemical Engineering, D.D.University, Nadiad
Agitation and Mixing of Fluids: Dr. Vimal Gandhi Department of Chemical Engineering, D.D.University, Nadiad
MIXING OF FLUIDS
12/30/20 1
AGITATION & MIXING OF LIQUIDS
“Many processing operations depend for their success on the effective
agitation & mixing of fluids” ……McCabe
Agitation
It is an induced motion of a material in a specified way.
the pattern is normally circulatory.
it is normally taken place inside a container.
Mixing
Random distribution, into & through one another
of two or more initially separate phases
12/30/20 2
Purposes of agitation of liquids
12/30/20 3
AGITATORS
Multi-bladed paddle Simple straight-blade turbine
agitators with short
blades
– Turn at high speed on
Disk turbine
centrally-mounted shaft
– Smaller diameter; 30-
50% of diameter of
vessel
– Effective over wide Pitched-blade turbine
range of viscosities
Concave-blade
12/30/20 CD-6 impeller 4
Agitation vessel
12/30/20 5
Mixing Flow patterns (3 types):
12/30/20 7
(ii) Tangential flow.
The currents acts in the direction tangent to the circular path
around the shaft.
Usually, it produce vortex (disadvantageous) & swirling the
liquid.
vortex
Unbaffled vessel
12/30/20 8
Vortex
12/30/20 9
vortex
Preventing vortex
(i) Baffles on the tank walls
12/30/20 11
Agitation in an unbaffled
vessel leads to swirling flow
with vortex formation &
poor distribution
Standard baffling
promotes flow that
results in good
solids distribution
12/30/20 12
(ii) Impeller in an angular off-center position
Mount the impeller away from the center of the vessel & tilted in
the direction perpendicular to the direction of flow.
12/30/20 13
12/30/20 14
12/30/20 15
Impeller:
Three main types of impellers :
(i) Propellers; (ii) paddles & (iii) turbines
(i) Propellers:
Create an axial-flow (flow of
currents is pushed in downward
direction).
High speed for low viscosity liquid.
Effective in very large tanks.
In a deep tank, 2 or more propellers
may be mounted on the same shaft.
12/30/20 16
(ii) Paddles:
Suitable for stirring simple liquids at low to
moderate speeds (between 20-150 rpm).
Paddles push the liquid radially (radial flow).
Anchor is one type of paddle agitator.
Ratio of paddles diameter to the vessel
diameter is typically 50-80%. Dia >o.6 Dt
Width of blade is 1/6 to 1/10 of its length.
Anchor
12/30/20 17
(iii)Turbine:
Diameter ~ 30-50% of vessel diameter.
Suitable for wide range of viscosity.
For low viscosity, it generates strong currents which
continue throughout vessel.
Principal currents produced: radial & tangential.
12/30/20 18
Agitator selection and viscosity Ranges
12/30/20 19
IMP- Standard turbine design
Dimension of a vessel & turbine impeller is :
Da 1 H J 1
1
Dt 3 Dt Dt 12
E 1 W 1 L 1
Dt 3 Da 5 Da 4
Da = impeller diameter
Dt = tank diameter
12/30/20 20
Draft tubes
Propeller
Turbine
12/30/20 21
Circulation, Velocities, and Power
Consumption
Volume of fluid circulated by impeller must be
sufficient to sweep out entire vessel in reasonable
time
Velocity of stream leaving impeller must be sufficient
to carry current to remotest parts of tank
In mixing, also need turbulence
– Results from properly directed currents and large velocity
gradients in liquid
Circulation and generation of turbulence both
consume energy
Large impeller + medium speed = flow
Small impeller + high speed = turbulence
12/30/20 22
Power consumption in agitated vessels
12/30/20 23
(i) Flow number, NQ
q n Da
3 q
NQ
Where q is the volumetric flow rate, nDa3 -
measured at the tip of the blades, n is the -
rotational speed (rpm), Da is the impeller 3 Dt -
qT 0.92nDa
diameter -
Total flow was shown to be
Da
-
n = speed (rotation/s) -
NQ is constant for each type of Da = impeller diameter
impeller.For flat-blade turbine Dt = tank diameter (
(FBT), in a baffled vessel, NQ may 2
be taken as 1.3; For marine )
propellers (Square pitch), NQ = 0.5;
For four blade 45o turbine, NQ =
0.87;
For HE impeller- NQ=0.47
12/30/20 24
(ii) Power consumption
Power required to drive the impeller.
Power number, Pg c
NP 3 5 or from Fig 1
n Da
12/30/20 25
(iii) Dimensionless Group
12/30/20 27
(iv) Power Correlation
Typical plots of NP versus NRe is shown in Fig. 1 below
Curve A, B, & C for baffles; Curve D for unbaffled
For unbaffeld tanks, at high NRe (higher than 10,000), a
vortex forms & NFr has an effect. So empirically,
a log10 N Re
m
b
The NP(corrected) must be corrected by multiplying NP by NFrm
N P ( Corrected ) N P N m
Fr
12/30/20 28
Fig 1
Unbaffled
(curve D) n 2 Da
N Fr
g
Table 1- Constants for unbaffled tank
a log10 N Re
Turbine a b m
b
Three 1.7 18 Constants a & b
blades (Table 9.1)
Six 1 40
blades
12/30/20 30
Dimensional analysis for fluid agitation systems
Basic quantities
Characteristic length: Impeller diameter D (m)
Characteristic time: Inverse impeller speed: 1/N (s)
Characteristic mass: Liquid density and cube
of impeller diameter: D3 (kg)
Derived quantities
Characteristic velocity: Impeller diameter and speed: DN (m/s)
Characteristic pressure: Density and velocity
square: D 2 N 2 (Pa)
Characteristic flow rate: Velocity and area ND3 m3 /s
12/30/20 31
Dimensionless numbers
N D2 Wbrake
Reynolds N Re = ; Power N Po =
N 3 D5
N 2 D3 N2D
Weber N We = ; Froude N Fr =
g
Qi
Flow N Q =
ND3
12/30/20 32
Dimensionless Correlations
12/30/20 33
POWER CORRELATIONS-DIMENSIONAL
ANALYSIS
Pg c nD 2
nD 2
a , a , S ,
1 2 S ,..., S
n
3 5
n Da g
N P ( N Re , N Fr , S1, S 2 ,..., Sn )
P = (n, Da, gc, , g, )
Where NRe is Reynold’s no.; NFr is the Froude no.
nDa2/ is proportional to an NRe calculated from the diameter and
speed of the impeller
NP is analogous to a friction factor or a drag coefficient associated
with the bulk motion of the fluid
N Fr is a ratio of the inertial stress to the gravitation force per unit
12/30/20 34
Shape Factors
Various linear measurements
– Base measurements of Da (diameter of impeller) and Dt
(diameter of tank)
Calculate remaining shape factors by dividing by
magnitude of Da or Dt
– S1, S2, S3, …, Sn
Two mixers of the same geometrical proportions but
of different sizes will have identical shape factors, but
differ in magnitude of Da
Geometrical similarity
12/30/20 35
Power Correlations for Specific
Impellers
Given in plots of NP vs. NRe for various
types of impellers, propellers, and turbines
12/30/20 36
Power number NP vs. Reynolds number Re for turbines and impellers
12/30/20 37
Power number NP vs. Reynolds number Re for marine propellers and helical ribbons
12/30/20 38
Power correlation for a 6-blade turbine in pseudoplastic liquids
12/30/20 39
Power required for complete suspension of solids
in agitated tanks using pitched-blade turbines
12/30/20 40
Power Consumption
Power required to drive impeller
q nDa3 N Q
(V2' ) 2
Ek
2gc
V’2 slightly less than tip speed, u2
V / u2
2
' V2' nDa
n 3 Da5 2 2
P N Q
Power Requirement gc 2
12/30/20 41
Calculation of Power Consumption
N P n 3 Da5
P
gc
12/30/20 42
Calculation of Power Consumption
At NRe>10,000 in baffled tanks, P is
independent of NRe and viscosity is not a
factor
N P KT
K T n 3 Da5
P
gc
12/30/20 44
Power Consumption
In general
P = NPn3Da5
For Re < 10
NP = KL/Re
P = KLn2Da3
For Re > 10,000
NP = KT
P = KTn3Da5
12/30/20 45
Power Consumption
P N P N 3 D5
P K1 ND
3
P K2 D
2
12/30/20 46
Example
12/30/20 48
Solution (a) baffled
n = 90rpm / 60 s = 1.5 r/s
Da = 0.61m
µ = 12cP = 12x10-3 kg/ms
N RE
Da2 n
0.61 (1.5)(1498)
2
69600
12 10 3
n 2 Da (1.5) 2 (0.61)
N Fr 0.14
g 9.81
From Table 1, the constants a & b are 1.0 & 40.0 respectively
12/30/20 50
From curve D, the power number for NRe = 69600 is 1.07
So the corrected value of NP,
N P (Corrected ) N P N Frm 1.07 0.14 0.096 1.29
Thus power,
N P n 3 Da5
P (1.29)(1.5) 3 (0.61)5 (1498)
gc
550mN / s 550 W
12/30/20 51
Problem
The agitation system mentioned above is to
be used to mix a rubber latex compound
having a viscosity of 120 Pa.s and density
1120 kg/m3. What power will be required?
(KL= 65 – from table 2 given before)
12/30/20 52
Blending and Mixing
More difficult to study and describe as
criterion for “good mixing” is often visual
observation
– Interference phenomena to follow blending of
gases in a duct
– Color change of acid-base indicator
– Rate of decay of concentration or temperature
12/30/20 53
Mixing Using a Standard 6-Blade
Turbine: Mixing time models
For a given tank and impeller or geometrically
similar systems, mixing time, tT, varies
inversely with stirrer speed
5V Dt2 H 1
tT 5
Dt q 4 0.92nDa2 Dt
q 0.92nD
3
a
Da
2
D Dt
ntT a const 4.3
Dt H
12/30/20 55
Mixing time predictions - Norwood-Metzner
General correlation for turbine impellers
Correlation of blending times for miscible liquids in a turbine-agitated baffled
vessel
2 1/ 2 1/ 6
2 2 / 3 1/ 6
tT (nD ) g 1/ 2
D Da Dt g
ft a
1/ 2 3 / 2
a
ntT 2
H D t Dt H n Da
1.67 0 .5
Dt H
nTT 16.9
Da Dt
12/30/20 57
Problem
An agitated vessel 1.83 m in dia contains a six –
blade straight-blade turbine 0.6 m in diameter, set
one impeller diameter above the vessel floor, and
rotating at 80 rpm. It is proposed to use this vessel
for neutralizing a dilute aqueous solution of NaOH
at 70 0F with a stoichiometrically equivalent
quantity of concentrated HNO3. The final depth of
the liquid in the vessel is 1.83 m. Assuming that
all the acid is added to the vessel at one time, how
long will it take for the neutralization to be
complete?
12/30/20 58
Solution
Dt = 1.83 m Da = 0.61 m E =
0.61 m
n = 80 /60 = 1.333 /s, density of
liquid (given) = 1000 kg/m3,
viscosity of liquid (given) 2
Find Re = n Da Dt
ntT const 4. 3
Da^2.density/viscosity = Dt H
503000
Find ntT from figure and then tT.
12/30/20 59
Mixer Selection
Choice of impeller can also affect mixing time
Propellers typically require longer mixing times
compared to turbines
– Propellers have lower power consumption
Gas bubbles, liquid drops, or solid particles also
increase blending time
No direct relation between power consumed and
amount or degree of mixing
When mixing time is critical, best mixer is one that
mixes in required time with least amount of power
– Mixing time is a compromise arrived at by considering
energy cost for mixing and capital cost of equipment
12/30/20 60
Suspension of Solids
Produce a homogeneous mixture
Dissolve solids
Catalyze a chemical reaction
Promote growth of a crystalline product
from a supersaturated solution
12/30/20 61
Critical Stirrer Speed
0.45
nc D 0.85
a Sv D g
0.1
0.2
p B 0.13
Where nc = critical stirrer speed
Da = agitator diameter
S = shape factor
v = kinematic viscosity
Dp = average particle size
G = gravitational acceleration
= density difference
= liquid density
12/30/20 B = 100 x weight of solid/weight of liquid 62
Shape Factor, S
Impeller type Dt/Da Dt/E S
(E is height of impeller
above vessel floor)
12/30/20 64
Different processes require different degree of suspension.
Defining the suspension condition in the order of increasing power
input or stirrer speed;
12/30/20 66
SCALE UP OF AGITATORS
N P n 3 Da5 2
P V Dt H
gc 4
P N p n Da
3 5
Dt H
1 2
V 2 Da Dt
Dt H
4
Dt 1 Da H 2 Dt H 21 Da
68 12/30/20
N p n Da3 5
P
V 2 2
1 Da 21 Da
4
If
3 5
P N n Da
P N p n Da
3 2
p
V 3
1 2 Da 3
3
V 1 2
4
4
P 2
P Kn 3 D 2
Kn Da
3
V V lab
lab lab
P 3
Kn plant D plant
2
V plant
69 12/30/20
P = P
If then
V lab V plant
If
3 2
Kn plant D plant 3 2
= Knlab Dlab
2/3
nlab Daplant
n plant Dalab
=
70 12/30/20
Criterion (iii) Same impeller tip sped
1.54V
ntm
Da3
71 12/30/20
Problem:
1.54V
ni t m 3
Da
1.54V 1.54 2.7
tm tm 0.055 min 3.32s
600 0.5
3
3
n i Da
73 12/30/20
Problem:
A pilot plant vessel 1 ft (305 mm) in dia is agitated by a six
blade turbine impeller 4 in (102 mm) in dia. When the
impeller Re no. is 10000, the blending time of two immiscible
liquids is found to be 15 s. The power required is 2 Hp/1000
gal (0.4 kW/m3. (a) What power input is required to give the
same blending time in a vessel 6 ft (1830 mm) in dia (b) What
would be the blending time in the 6 ft (1830 mm) vessel if the
power input per unit volume were the same as in the pilot
plant vessel?
74 12/30/20
N P KT
KT n D 3 5
P a
At high Re no’s gc
76 12/30/20
Pa Pb 3 2 3 2
, then na Da nb Da
Va Vb
2/3 2/3
n b Da 6
3.3
na Db 1
The blending time in 6 ft vessel 3.3 15s 49.5s
77 12/30/20
A vertical tank 2.4 m dia is provided with a flat blade turbine
impeller (6 blades) mounted centrally in the tank at a height
of 0.8 m from bottom. The turbine is 0.8 m in dia and the
blades are 167 mm wide. The tank is filled to a depth of 2.4 m
With rubber latex compound having density 1120 kg/m3
and viscosity 120 kg/m.s. If the tank is baffled and turbine is
Rotated at 90 rpm, what is the power consumption in hP?
Take Np. Re = 65 for laminar flow and 5.75 for turbulent flow.
78 12/30/20
Da n 0.82 90 1120
2
Re 8.9610
60 120
( So la min ar )
79 12/30/20
Newtonian and non-Newtonian Fluids
Newtonian fluids:
Fluids which obey the Newton's law of viscosity are called as
Newtonian fluids. Newton's law of viscosity is given by
Non-Newtonian fluids:
Fluids which do not obey the Newton's law of viscosity are called
as non-Newtonian fluids. Generally non-Newtonian fluids are
complex mixtures: slurries, pastes, gels, polymer solutions etc.
There is also one more - which is not real, it does not exist -
known as the ideal fluid. This is a fluid which is assumed to have
no viscosity. This is a useful concept when theoretical solutions are
being considered - it does help achieve some practically useful
solutions.
12/30/20 80
Type of fluids
– Newtonian
– Non-Newtonian (Shear
thinning - Shear thickening)
v x
xy
y
12/30/20 81
Toothpaste
Latex
Paint
Corn
Starch
12/30/20 82
12/30/20 83
12/30/20 84
Power law fluids
Newtonian fluid:
dv x dv x
xy :
dy dy
Power Law Fluid:
xy
xy K n
: a K n 1
When n<1, viscosity decreases with shear
When n>1, viscosity increases with shear
12/30/20 85
Power Consumption in
Non-Newtonian Liquids
Non-Newtonian liquids – viscosity varies with
shear rate
Use apparent viscosity, a
nDa2
N Re,n
a
n ' 1
du
a K '
dy av
Reciprocating
Rotary
Centrifugal
Axial
12/30/20 87
TYPES OF COMPRESSORS
http://en.wikipedia.org/wiki/Gas_compressor
12/30/20 88
12/30/20 89
12/30/20 90
12/30/20 91
12/30/20 92
12/30/20 93
12/30/20 94
12/30/20 95
12/30/20 96
§9-1.The Types of gas compressors
There are two general types compressors
Reciprocating compressor
12/30/20 97
§9-1.The Types of gas compressors
Air compressor
12/30/20 98
§9-1.The Types of gas compressors
Motor
Compressor
Refrigerator compressor
12/30/20 100
§9-1.The Types of gas compressors
Compressor
Motor
12/30/20
Icebox compressor 102
§9-1.The Types of gas compressors
12/30/20
Centrifugal rotative compressor 104
§9-1.The Types of gas compressors
P1
1
H2 V
Wc
H1
12/30/20 Q≈? 106
§9-2. The principle of reciprocating compressors
1.The principle
p T
P2 2T 2n 2s 2s
2n
2T
P1 P2
1 1
P1
v s
12/30/20 107
§9-2. The principle of reciprocating compressors
1.The principle
12/30/20 108
§9-2. The principle of reciprocating
compressors
2.The work of compressor
Adiabatic compressor
k 1
k k p2 k
wc ,s h2 h1 ( p2v2 p1v1 ) RgT1 1
k 1 k 1 p1
12/30/20 109
§9-2. The principle of reciprocating
compressors
2.The work of compressor
Isothermal compressor
v2 p2
wc ,T RgT1 ln RgT1 ln
v1 p1
12/30/20 110
§9-4. Multilevel compress with intercoolers
1.System
Cooling water
Intercooler
3’ 2 ’
2 1
2nd-stage 1st-stage
compression compression
12/30/20 111
§9-4. Multilevel compress with intercoolers
2.Diagram
p
P2 3T 3’
g 3
Pm 2
f 2’
P1
1
e
12/30/20 112