Case Studies using the FMP Excel

Design Guide

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© BHR Group Limited 2011

A – Solid Suspension from Known s

- V = 600 litres
- D/T = 0.65
- dp = 200 µm
- 15%wt solids
- rS = 1500 kg/m3
- s = 6.5
- NJS = ?

FMP Mixing Course © BHR Group Limited 2011 Slide 2

A – Solid Suspension from Known s

FMP Mixing Course © BHR Group Limited 2011 Slide 3

A – Solid Suspension from Known s
The first thing to do is to set the tank geometry
1 – Change the units in the tank volume field 2 – Enter desired volume and change
base shape

3 – Select desired baffle type

FMP Mixing Course © BHR Group Limited 2011 Slide 4

A – Solid Suspension from Known s
Now, put some solids in the system

Enter solids properties (density, particle size, concentration)

By checking this box, you can

see all solids properties,
including Zwietering’s X.

FMP Mixing Course © BHR Group Limited 2011 Slide 5

A – Solid Suspension from Known s
To specify the impeller, scroll down to “Impeller 1”

Since there are solids in the system and the

default impeller speed is lower than NJS, you
will get this warning. Click on OK.

Even though the warning pop-up goes away, the warning remains in the “errors and
Warnings” tab and on the top of the input sheet

FMP Mixing Course © BHR Group Limited 2011 Slide 6

A – Solid Suspension from Known s

The geometry is now fully set

In this example we are using the default geometry and

operating parameters for an RCI, but you can change
them by entering values in these sections:

FMP Mixing Course © BHR Group Limited 2011 Slide 7

A – Solid Suspension from Known s
Scroll down to “STR Solid Liquid Calculations”
This is Zwietering’s NJS, for the default s value

To change the s value to your known value, simply enter it here

Final Answer: NJS = 73.5 rpm

FMP Mixing Course © BHR Group Limited 2011 Slide 8
A – Solid Suspension from Known s

You can use the “Monitor Variables” to keep an eye

on (up to six) variables of interest

FMP Mixing Course © BHR Group Limited 2011 Slide 9

A – Solid Suspension from Known s

You can also use the “Diagram” sheet to enter geometry, solids
and operational variables (but you can’t change s here)
FMP Mixing Course © BHR Group Limited 2011 Slide 10
B – Scale up from known NJS

- V = 2 litres - 15%wt solids

- D/T = 0.65 - rS = 1500 kg/m3
- dp = 200 µm - NJS = 350 rpm

V = 600 litres
NJS = ?

FMP Mixing Course © BHR Group Limited 2011 Slide 11

B – Scale up from known NJS

Enter geometry, impeller and solids properties and

“calculate” NJS as in the previous example
Remember: V = 2 litres this time

Change the s value until you get the known NJS

You can use Excel’s “Goal Seek” tool or iterate manually

FMP Mixing Course © BHR Group Limited 2011 Slide 12
B – Scale up from known NJS

Scroll up to “Tank Properties”

Change volume to 600 litres

NOTE: If you have changed any of the impeller dimensions from the default values,
these will need to be adjusted to the new tank scale

FMP Mixing Course © BHR Group Limited 2011 Slide 13

B – Scale up from known NJS

Scroll back down to “STR Solid Liquid Calculations”

Final Answer: NJS at 600 litres = 69.5 rpm

If you specified Zwietering_Njs as a Monitor

Variable, you will also see the new value
here

FMP Mixing Course © BHR Group Limited 2011 Slide 14

C – P/m Calculation at different H/T

- V = 600 litres - 15%wt solids

- D/T = 0.65 - rS = 1500 kg/m3
- dp = 200 µm - N = 75 rpm

FMP Mixing Course © BHR Group Limited 2011 Slide 15

C – P/m Calculation at different H/T

Enter geometry, impeller and solids properties and in

the previous examples
Enter the impeller speed under “STR Operating parameters”

FMP Mixing Course © BHR Group Limited 2011 Slide 16

C – P/m Calculation at different H/T
Since H/T is going to vary, we cannot have a fixed
volume
1 - Scroll up to “Tank Properties” and note the tank diameter (T)

2 – Delete the volume and enter the tank diameter in the green field

FMP Mixing Course © BHR Group Limited 2011 Slide 17

C – P/m Calculation at different H/T
Read the Power/mass value either form the “STR
Operating Parameters” section or the Monitor Variables

This value corresponds to the default H/T value of 1. To see how does P/m vary with
H/T, press the “Add Output to Saved Results” button in the top, left-hand side:

FMP Mixing Course © BHR Group Limited 2011 Slide 18

C – P/m Calculation at different H/T
If you go to the “Saved Results” sheet, you will see a
column with al the current values of all variables in the
input sheet

FMP Mixing Course © BHR Group Limited 2011 Slide 19

C – P/m Calculation at different H/T
Go back to the Input Sheet, change H/T to different
values and click on “Add Output to Saved Results” after
each one.
This will generate columns for each H/T value, which can be used to plot a graph:

FMP Mixing Course © BHR Group Limited 2011 Slide 20

D – Scale up at constant P/M

- V = 2 litres - 15%wt solids

- D/T = 0.65 - rS = 1500 kg/m3
- dp = 200 µm - NJS = 350 rpm

V = 600 litres
NJS = ?

FMP Mixing Course © BHR Group Limited 2011 Slide 21

D – Scale up at constant P/M
Enter geometry, impeller and solids properties as in the
previous examples
Remember: V = 2 litres this time

Enter the impeller speed (NJS) under “STR Operating parameters”

Note the calculated value for P/m

FMP Mixing Course © BHR Group Limited 2011 Slide 22

D – Scale up at constant P/M

Delete the impeller speed and enter the calculated P/M

in the green field

Scroll up to “Tank Properties” and change the volume

to 600 litres

FMP Mixing Course © BHR Group Limited 2011 Slide 23

D – Scale up at constant P/M
Read the Impeller Speed (N = NJS) value either form
the “STR Operating Parameters” section or the Monitor
Variables

NOTE: Scaling up at constant Power per unit mass results in a higher impeller speed
than the scale up based on s (Zwietering). Therefore, scaling up on P/M is more
conservative.
FMP Mixing Course © BHR Group Limited 2011 Slide 24
E – Flow Regime during Scale Up

- V = 2 litres - 15%wt solids

- D/T = 0.65 - rS = 1500 kg/m3
- dp = 200 µm - NJS = 350 rpm

Re = ?
(At constant P/M)

V = 600 litres

FMP Mixing Course © BHR Group Limited 2011 Slide 25

E – Flow Regime during Scale Up
Enter geometry, impeller and solids properties as in the
previous examples
Start with V = 2 litres
Enter a value for P/M in the “STR Operating Conditions” section

Select Re_1 (Impeller 1’s Reynolds number)

as one of the Monitor Variables

FMP Mixing Course © BHR Group Limited 2011 Slide 26

E – Flow Regime during Scale Up
Vary the tank volume several times, clicking on “Add
Output to Saved Results” each time

The Reynolds number increases with increasing scale when scaling up at constant
P/M (also true when scaling up at constant s).
If the flow regime at the small scale is transitional (or even laminar), it may end up
being turbulent at the large scale!
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