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We identify, and will look at, six different combinations of components that may have to
be mixed
1. miscible liquids
2. immiscible liquids
3. gas and liquid
4. solid particles in liquid
5. solid particles with each other
6. solid particles and gas.
Nagata S (1975) Mixing Principles and Applications, John Wiley & Sons, New York.
Tatterson G B (1991) Fluid Mixing and Gas Dispersion in Agitated Tanks, McGraw-Hill,
Inc., New York.
Dietsche W (1998 August) ‘Mix or Match: Choose the Best Mixers Every Time’,
Chemical Engineering p.70-75.
Dickey D S (2000 May) ‘Facing the Challenge of Mixing Problem Fluids’, Chemical
Engineering p.68-75.
The requirement is to bring two or more liquids together and form a single phase. The
mixture is intended to be permanent, unlike other mixing situations where the phases are
combined into a mechanical mixture, which can subsequently separate or be separated.
Examining the second case briefly, it can be shown mathematically that if an entering
stream with a regular fluctuation of frequency f in some property is blended in a fully-
mixed vessel of residence time then the amplitude of the fluctuation is attenuated by
the factor 1 / square root [ 1 + (2 )2 ( f . )2 ]. For example
f . Attenuation factor
0 1.0
0.1 0.85
0.2 0.62
0.5 0.30
1.0 0.16
2.0 0.08
5.0 0.03
This application relies on the presence of ‘back mixing’ or axial mixing. In some other
applications the requirement is only for radial uniformity.
Hicks R W, Morton J R and Fenic J G (1976 April 26) ‘How to design agitators for
desired process response’, Chemical Engineering p.102-110.
Wilkens R J, Henry C and Gates L E (2003 May) ‘How to Scale-Up Mixing Processes in
Non-Newtonian Fluids’, Chemical Engineering Progress p.44-52.
Bakker A and Gates L E (1995 December) ‘Properly choose mechanical agitators for
viscous liquids’, Chemical Engineering Progress p.25-34.
Gibson w D (1999 April) ‘Impelling mixers to move viscous fluids’, Chemical
Engineering p.49-57.
Helical-ribbon agitator
Anchor agitator
Perry and Green D W (1997) Perry’s Chemical Engineers’ Handbook, seventh edition,
chapter 18, p.20-21
Myers K J, Bakker A and Ryan D (1997 June) ‘Avoid Agitation By Selecting Static
Mixers’, Chemical Engineering Progress p.28-28.
Bayer T, Himmler K and Hessel V (2003 May) ‘Don’t Be Baffled By Static Mixers’,
Chemical Engineering p.50-57.
In cases 1, 2 and 3, the phases are subsequently separated from one another: care may
have to be taken not to disperse so finely that a permanent emulsion results. In case 4 ,
separation is undesirable.
Turbine agitators are again suitable. For dispersing one liquid in another the agitator
blades are held parallel to the axis of rotation. The objective is to convert power of
rotation into comminution of droplets.
Radial Flow
pattern
The drop size created by an agitator of specific size, shape and speed depends on the
properties of the liquids. Coalescence of small droplets may be taking place
simultaneously, so agitation must be carried on continuously while mass transfer and/or
chemical reaction is taking place. In-line mixers are not suitable for this application
because the residence time in the mixer is too short.
Myers K J, Reeder M F, Ryan D and Daly G (1999 November) ‘Get a Fix on High-Shear
Mixing’, Chemical Engineering Progress p.42.
Light
Heavy
phase
phase
Light
phase
Heavy
phase
Gases are dispersed as bubbles in liquids and liquids are dispersed as sprays in gases, for
such purposes as cooling, mass transfer, and chemical reaction.
An adequate dispersion of gas in liquid may be attained simply by sparging the gas into
the liquid. If a finer dispersion is desired (e.g., to obtain greater interfacial surface area),
then a rotating agitator may be used. The same style of flat-bladed impeller is used as for
dispersing immiscible liquids. A problem arises in that the cloud of bubbles may
overwhelm the action of the agitator and make it ineffective. Hicks and Gates (1976)
and also Van Essen (1998) provide predictive equations for this effect and for how it may
be overcome.
Hicks R W and Gates L E (1976 July 19) ‘How to select turbine agitators for dispersing
gas into liquids’, Chemical Engineering p.141-148.
Lee S-Y and Tsui Y P (1999 July) ‘Succeed at Gas/Liquid Contacting’, Chemical
Engineering Progress p.23-49.
The other type of gas-liquid mixing is the dispersion of a liquid into a gas, generally by
means of atomization. The main example is spray drying. Other applications are cooling
of gases, scrubbing of particulates, humidification, absorption of vapours, and chemical
reaction. All of these phenomena rely on a high ratio of surface-to-volume.
Welander P and Vincent T L (2001 June) ‘Select the Right Spray Nozzle’, Chemical
Engineering Progress p.75-79.
16.4. Solid Particles in Liquid
Assuming a turbulent liquid, the agitator of choice is a turbine with blades pitched to
produce a component of axial flow. The flow pattern is as shown in section. 3.7.1.1.
The speed and power of the agitator is a function of
the terminal velocity of the particles and
the degree of suspension required.
Obviously, the greater the terminal velocity the harder it is to keep the particles
suspended. Particles that are small and/or similar in density to that of the liquid are easier
to keep in suspension.
The degree of suspension refers to the uniformity of solids concentration in the vessel: is
it enough just to sweep particles periodically off the bottom of the vessel or must there be
uniformity almost right to the top. If a slurry is being prepared, then the height to which
uniformity must extend is dictated by the point of slurry draw-off.
Gates L E, Morton J R and Fondy P L (1976 May 24) ‘Selecting agitator systems to
suspend solids in liquids’, Chemical Engineering p.144-150.
Probably most cases of particle mixing have the objective of removing or blending out
non-uniformities. The operation may be batch or continuous. Particle blenders come in
different styles.
The tumbling blender rotates, causing particles to tumbling over one another, hopefully in
a random manner.
Convective blenders are stationary and have an internal rotating system of paddles or a
screw to impart motion to the particles. Fluidized beds use a gas to move particles
relative to one another. A recirculating vessel with multiple staggered down-comers can
rearrange particles.
To Vacuum
Elutriator
Vacuum
Breaker
Downcomers
Air
Filter
Clump C W, ‘Mixing of Solids’, in Uhl V W and Gray J B, editors (1967) Mixing Theory
and Practice, volume II, Academic Press, Inc., New York.
Conveying (e.g., by air) is carried out in one of two modes: dilute-phase or dense-phase.
As indicated by the nomenclature, the ratio of solids to gas is quite different in the two
modes. In dilute-phase, the particles are mixed into the gas stream simply by being
dropped in; a rotary feed valve is needed if the gas system is under pressure. In dense-
phase, the solids are assembled and then gas is introduced to start moving them.
If the objective is mass transfer or chemical reaction then intimate mixing can be done in
a fluidized bed. The bed is designed in accordance with well-established fluidization
technology. High rates of surface transfer are achieved relative to say a packed or slowly
moving bed.