IMPELLER GEOMETRY EFFECT ON VELOCITY AND SOLIDS SUSPENSION

J . Wu, Y. Zhu and L. Pullum

CSIRO Thermal and Fluids Engineering
PO Box 56, Highett 3190,
Victoria, Australia
Email J ie.Wu@dbce.csiro.au
Abstract.
The effect of varying impeller geometrical parameters including impeller type, number of
impeller blades, blade pitch angle and blade thickness on the turbulent velocity fields in mixing
tanks has been studied through LDV measurements. Pitch blade turbines and disc turbines were
used in the experiments. It was found that universal time-mean velocity profiles exist for both
pitch bladed turbines and disc turbines. Flow number correlations based on power number for
both pitch-bladed turbines and disc turbines are presented.
It was found that there is a link between impeller pumping capacity and the S parameter in the
Zwietering's correlation, and this can be expressed as NQ S = K, where NQ is the impeller flow
number and K is a non-dimensional constant independent of the solid/liquid material property
and impeller geometry.
Key-words: mixing, agitation, impeller, impeller geometry, solids suspension, flow number.
INTRODUCTION
A wealth literature is available on detailed velocity fields in mixing tanks agitated by various
impellers. J aworski et al. (1991), using an LDV system, measured the turbulent velocity field in a mixing
vessel agitated by a 45 pitched turbine with 6 blades. Weetman and Oldshue (1988) presented
correlations for power, flow and shear characteristics of a 6-bladed disc turbine, a hydrofoil axial flow
impeller (A310) and a pitch bladed turbine, measured through an automated LDV system. Similarly Nouri
and Whitelaw (1990) and many others have presented the flow field and impeller characteristics through
LDV measurements. Yianneskis et al. (1987) showed detailed flow structures of the tip vortices attached
to a Rushton turbine (6-bladed). Schafer et al. (1997) conducted similar laser doppler velocimetry
measurement on the same type of 6-bladed Rushton turbine. They presented time-mean velocity vector
field and turbulent kinetic energy contour. Stoots and Calabrese et al (1995) measured the detailed 3D
velocity field relative to a rotating Rushton disc turbine. The measurements captured the angular flow
variation through synchronizing LDA sampling with a shaft encoder. In comparison with most other
measured velocity fields, the resolution of LDA point measurements is exceptionally high. Fine flow
structures including the trailing vortices at the blade tip were characterized. They determined energy
dissipation distribution through calculating the velocity strain field.
Dyster et al. (1993) measured the radial discharge velocities of a Rushton turbine for Reynolds
number from 5 to 510
4
, using water, glycerol of different concentrations. They presented the mean
centre-line velocity profile, i.e. the impeller centre radial velocity profile along the radial direction. They
also presented power and flow number correlations with Reynolds number, for Newtonian fluids.
Although the flow fields of many impellers have been investigated in the past, it is still lacking in
the literature to directly link impeller geometry parameter and the flow field generated. It is of practical
interest to determine the pumping velocity, flow turbulence and other flow characteristics in relationship
to the impeller geometric parameters including impeller blade number, blade pitch angle and the blade
thickness. Wu and Pullum (2000) developed an analysis method based on a blade element theory. The
method permits rapid prediction of impeller pumping performance through calculation. This paper is a
further step in systematically quantifying the impact of the impeller geometric parameters on the mixing
velocity field, through a laser doppler velocimetry measurement study. A further objective of this paper is
to relate impeller geometry to off-bottom solids suspension.
EXPERIMENTAL SETUP
The model mixing rig (Figure 1) consist of a T=390mm diameter circular tank placed inside a
rectangular outer acrylic tank. The outer tank is filled with water to minimise the optical distortion. Four
baffles 1/12T in width and equally spaced were installed in the circular tank. Test impellers were mounted
on the central shafts equipped with an Ono Sokki torque transducer and a speed detector. The impeller
speed could be varied from 0 to 1000 rpm by means of a variable frequency drive. Most LDV
measurements were conducted at shaft speeds of 250 or 300rpm, corresponding to a Reynolds number
(Re=

2
ND
) of 1.07x10
5
~1.25x10
5
. The speed and torque were logged using a personal computer
equipped with a suitable data acquisition board, and provided on-line analysis of power consumption etc.
Vr
Vt
A/D
Torque transducer
Gear box Motor
V
Z
Robot
Robot
control
TSI
2D -LDV
system
Laser
Probe
Square glass tank
B
D
C
C
H
r
T
Torque
Speed
Optic
fibre
Figure 1 Mixing tank and laser doppler velocimetry (LDV) measurement system. The LDV probe was mounted on the
robot armwith a positioning resolution of 0.1mm.
Velocity distributions were measured in the model mixing vessel using a TSI 2D optical fibre
LDV system. The LDV probe, which has built-in transmitting and receiving optics, was mounted on an
industrial robotic arm, allowing the laser beams to be automatically positioned within the tank. The time-
mean velocity data thus obtained was found repeatable to within 1%. Time-mean statistics of the velocity
data were obtained using a time-weighted bias correction method incorporated in the TSI package. Tap
water was used as the working fluid in the experiments.
Pitch bladed turbines and disc turbines of various geometrical configurations were used in the
experimental investigation. A majority of measurements were conducted with impeller to tank diameter
ratio of D/T=0.41. The number of blades N
bld
was varied from 2 to 6 for pitch bladed turbines, and varied
from N
bld
=2 to 8 for the disc turbines. Impellers with blade thickness of t/W=4.7%, 9.4, 19% and 38%
were measured to examine the blade thickness effect, where t is the blade thickness and W is the blade
width. Pitch angle of the pitch bladed turbines was varied from 20 to 45 at 5 degree increment. The
impeller geometrical dimensions and notation are illustrated in Figure 2. Other impellers used in the
experiments include Lightnin A310, concave bladed disc turbine (Smith impeller) CD6. All the axial flow
impellers were operated in the downward pumping mode. Liquid level was kept at a constant equal to the
tank diameter during all the experiments.
D/4
D
W = D/5
3/4 D
DT6
DT3

30PBT6 30PBT3
t
Disc turbines
DT
Number of blades, N
bld
= 2, 3, 4, 5, 6, 8
Disc turbine
W = D/5
t
PBT
Number of blades, N
bld
= 2, 3, 4, 5, 6,
Pitch bladed turbine
Pitch angle = 20, 25, 30, 35, 40, 45, 45
Pitch bladed
turbines
Blade thickness t/W = 4.7, 9.4, 19, 38%, where W is blade width
Figure 2 Impeller geometry definition: radial disc turbines and pitch bladed turbines.
For the solids suspension experiments, glass ballotini beads of various size grades were used as
the solid phase and tap water was used as the liquid phase. The liquid/solids flow in the tank bottom was
studied visually through the transparent tank walls, and through the transparent tank floor aided with a
mirror. Settled bed height was manually measured with a ruler. Solid particle size distributions were
quantified through screen analysis.
EXPERIMENTAL RESULTS
Impeller Geometry Effect on Velocity Profile
Figure 3(a), (b) and (c) show time-mean axial velocity V
z
, normalised by the impeller tip velocity
U
tip
. The velocities were measured 10%D below the impeller centreline, with variables including blade
number (a), blade thickness (b) and pitch angle (c). Velocity increases with number of blades and pitch
angle, as is expected. Velocity decreases as the blade thickness is increased. At the extreme case of
t/W=38%, a flow reversal is seen near the hub region as evident from the negative velocity, and that the
axial velocity overall is substantially lower than using thinner blades (Figure 3(b)).
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0 0.5 1 1.5
r/D
V
z
/
U
t
i
p
30PBT2
30PBT3
30PBT4
30PBT5
30PBT6
(a)
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0 0.5 1 1.5
r/D
V
z
/
U
t
i
p
t/W=4.7%
=9.4%
=19%
=38%
(b)
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0 0.5 1 1.5
r/D
V
z
/
U
t
i
p
20 deg.
25 deg.
30 deg.
35 deg.
40 deg.
45 deg.
(c)
Figure 3 Time-mean axial velocity of pitch bladed turbines (down pumping), measured 10%D below the impeller centre. (a) effect
of number of blades. 30 degrees pitch angle, with number of blades from2 to 6, blade thickness t/W=4.7%. (b) effect of blade
thickness. Impellers are 30PBT4, (c) effect of pitch angle, t/W=4.7%. D/T=0.41, C/T=1/3, H/T=1. Fluid: water, Re=1.28x10
5
.
Impeller flow number is defined as:
3
ND
Q
N
Q
=
where Q is the flow rate through the impeller zone (refer to J aworski et al. (1991) and Dyster et al. (1993)
for more detailed definitions). Flow number data integrated from the velocity profiles are listed in Table
1.
-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
0 0.5 1 1.5
r/D
V
z
/
(
N
Q
U
t
i
p
)
30PBT2, t/W=4.7%
30PBT3, t/W=4.7%
30PBT4, t/W=4.7%
30PBT5, t/W=4.7%
30PBT6, t/W=4.7%
20PBT4, t/W=4.7%
45PBT4, t/W=4.7%
30PBT4, t/W=19%
30PBT4, t/W=9.4%
Figure 4 Universal time-mean axial velocity profiles at the outlet of pitch-bladed turbines, at 10%D below impeller entreline. Data
for blade number from2 to 6, pitch angle from20 to 45 and blade thickness fromt/W=4.7 to 19%. D/T=0.41, C/T=1/3, H/T=1.
Fluid: water, Re=1.28x10
5
.
Figure 4 shows time-mean axial velocity profiles normalised by the flow number: V
z
/(N
Q
U
tip
), for blade
number from 2 to 6, pitch angle 20, 30, 45 and blade thickness t/W=4.7%, 9.4%, 19%. Very good
collapsing of the velocity profiles is evident. Thus, Figure 4 can be used as a universal velocity profile for
pitch bladed turbines, at D/T=0.41 and C/T=1/3. This implies that, as an approximation, a velocity profile
measured from one pitch blade turbine can be converted to that of a different pitch blade turbine, if its
flow number is known.
It can be seen from Figure 4 that the maximum normalised axial velocity:
01 . 0 60 . 0
max
=
tip Q
Z
U N
V
which occurs at approximately 0.38D. J aworski et al.(1996) conducted an LDV velocity measurement on
a 45-pitch bladed turbine with 6 blades. A maximum value of 0.62 of V
z
/(N
Q
U
tip
) at 0.40D could be
obtained based on their data, in close agreement with our results, even though the impeller used by
J aworski et al is different.
It is therefore suggested that, the velocity profile "shape" is essentially constant, even if the impeller
geometry parameters including pitch angle, blade number and blade thickness are different.
Radial Flow Disc Turbines
0
0.2
0.4
0.6
0.8
1
1.2
0 0.5 1 1.5
V
r
/(U
tip
N
Q
)
z
/
D
DT2, t/W=4.7%
DT3, t/W=4.7%
DT4, t/W=4.7%
DT5, t/W=4.7%
DT6, t/W=4.7%
DT8, t/W=4.7%
DT6, t/W=9.4%
DT6, t/W=19%
DT6, t/W=38%
Impeller
Figure 5 Universal time-mean radial velocity profile at the outlet of disc turbines, measured at r/R=1.3, R is impeller
radius. Data for blade number from2 to 8, and blade thickness fromt/W=4.7 to 38%. D/T=0.41, C/T=1/3, H/T=1.
Fluid: water, Re=1.07x10
5
.
Similar to the approach used for pitch-bladed turbines, the non-dimensional time-mean radial velocity
profiles were normalised by flow number, as shown in Figure 5, measured at r/R=1.3, R is the impeller
radius. To a good degree of approximation, it can be said again that a universal radial velocity profile
exists, regardless impeller blade thickness, number of blades. The maximum time-mean radial velocity
can be estimated from:
03 . 0 70 . 0
max
=
Q tip
r
N U
V
where V
rmax
is the maximum time-mean radial discharging velocity, for any disc turbines operating in
turbulent flows.
Pumping Flow Number Characteristics
TABLE 1
Impeller specification, flow number, power number and S parameter.
Measured at nominal C/T =1/3 and D/T =0.41, T=0.390m
Impeller Full name
Flow
pattern
Number of
blades
Blade
width
W/D
Flow
number
N
Q
Power
number
P
0
4 45PBT
S
S
A310 Lightnin hydrofoil
impeller
Axial 3 NA 0.56 0.32 1.36
20PBT4 20-degree pitch bladed
turbines
Axial 4 1/5 0.43 0.27 1.77
25PBT4 25-degree pitch bladed
turbines
Axial 4 1/5 0.53 0.37 1.43
30PBT4 30 pitch 4-bladed
turbines
Axial 4 1/5 0.58 0.56 1.31
35PBT4 35 pitch 4-bladed
turbines
Axial 4 1/5 0.65 0.73 1.17
40PBT4 40 pitch 4-bladed
turbines
Axial 4 1/5 0.72 0.97 1.06
45PBT4 45 pitch 4-bladed
turbines
Axial 4 1/5 0.76 1.22 1.00
30PBT2 30 pitch 2-bladed
turbines
Axial 4 1/5 0.49 0.45 1.55
30PBT3 30 pitch 3-bladed
turbines
Axial 4 1/5 0.54 0.53 1.43
30PBT5 30 pitch 5-bladed
turbines
Axial 4 1/5 0.60 0.69 1.27
30PBT6 30 pitch 6-bladed
turbines
Axial 4 1/5 0.61 0.72 1.25
Impeller W/D N
Q
P
0
6 DT
S
S
DT2 2- bladed radial disc
turbine
Radial 2 1/5 0.47 2.18 1.66
DT3 3- bladed radial disc
turbine
Radial 3 1/5 0.58 3.20 1.34
DT4 4- bladed radial disc
turbine
Radial 4 1/5 0.67 4.14 1.16
DT5 5- bladed radial disc
turbine
Radial 5 1/5 0.71 4.90 1.10
DT6 6- bladed radial disc
turbine
Radial 6 1/5 0.78 5.58 1.00
DT8 8- bladed radial disc
turbine
Radial 8 1/5 0.86 6.62 0.91
CD6 6 concave-shaped radial
turbine
Radial 6 1/5 0.63 2.64 1.24
DT6H 6- bladed radial disc
turbine with a hole on
central of each blade, with
dia=1/5W
Radial 6 1/5 0.73 4.20 1.07
TABLE 1 lists flow number and power number for pitch blade turbines and disc turbines, with different
impeller geometry. The flow number of a standard disc turbine (6 blades) is known to be approximately
0.78 from the literature (Yianneskis et al. 1987, Dyster et al.(1993)), which is confirmed by our
measurement (DT6).
It is elementary to show that the pumping rate can be expressed as:
3 / 1 4
3 / 1
0
) )( ( D
P
P
N
Q
Q

=
Where Q is flow rate, P is power, is fluid density and D is impeller diameter. Thus, at a given impeller
diameter D, the pumping rate produced for a given power input is related to the coefficient N
Q
/P
0
1/3
, which
is essentially the impeller circulation efficiency. Figure 6(a) shows that N
Q
is linearly correlated with P
0
,
in close agreement with that Nienow (1998)'s correlation. Therefore, as an approximation, the circulation
efficiency can be assumed to be constant, and that flow number can be predicted from power number.
This correlation only applies to pitch blade turbines with constant thickness. A reduction in the circulation
efficiency is expected as the blade thickness is increased for pitch bladed turbines.
Figure 6 (b) shows a linear correlation for disc turbines. It applies for different blades, different impeller
type including concave impeller CD6, and DT6H, a disc turbine with a hole at the blade.
Based on the above data, we recommend:
3 / 1
0
70 . 0 P N
Q

pitch bladed turbine (thin blade thickness)

3 / 1
0
42 . 0 P N
Q

radial disc turbines

The correlation can be used as a first order approximation.
0
0.2
0.4
0.6
0.8
1
1.2
0 0.5 1 1.5 2 2.5 3
P
0
1/3
N
Q
30PBT2,3,4,5,6
PBT4, pitch 20-45 deg.
Nienow 1998
Present correlation
(a)
0
0.2
0.4
0.6
0.8
1
1.2
0 0.5 1 1.5 2 2.5 3
P
0
1/3
N
Q
DT2,3,4,6,8
DT6, t/W=4.7-38%
CD6
DT6H
(b)
Figure 6 Flow number correlated with power number, turbulent flow. (a) Pitch bladed turbines, (b) Disc
turbines.
Relating Impeller pumping and off-bottom solids suspension
The solids suspension in the tank bottom was visually studied through the transparent tank walls
and tank bottom with the aid of a mirror. In this study a similar approach to that used by Hicks et al.
(1997) was used. The settled bed height versus impeller speed was measured and the just-off-bottom
suspension speed was defined as the speed at which a settled bed was just discerned as the impeller speed
was reduced from a condition of full suspension. The repeatability of the N
js
measurement using this
method was found to be typically within 1% of the impeller speed.
0
50
100
150
200
250
300
350
0 10 20 30 40 50
( ( ( (deg.) .) .) .)
(
U
n
i
t
:

R
P
M
)
N
js
N
Q
*N
js
A310
(a)
0
50
100
150
200
250
300
350
0 10 20 30 40 50
( ( ( (deg.) .) .) .)
(
U
n
i
t
:

R
P
M
)
N
js
N
Q
*N
js
(b)
Figure 7 Variation of just-off-bottomsuspension speed with impeller pitch angle for pitch-bladed impellers (4
blades) pumping downward: fluid water, solid particle size d
50
=70 m, =2520 kg/m
3
, T =0.39 m, H =0.4 m,
D/T =0.41, C/T =1/3 at (a) C
V
=22.5% and (b) C
V
=32%.
N
js
data measured for the pitch-bladed impellers with pitch angle varied from =20 to 45 are
plotted in Figure 7(a) and (b) at solids loadings of C
V
=22.5% and 32%, showing a decrease in N
js
as
pitch angle is increased. This behavior is consistent with expectations. When N
js
is combined with N
Q
, the
resulting group is seen to be independent of the pitch angle. A Lightnin high-efficiency axial flow impeller
A310 was then tested at C
V
=22.5% to see whether this behavior was affected by impeller type. The data
point for the A310 is included in Figure 7(a), and shows a close match to that of the pitch-bladed
impellers, implying that this relationship is true for different impeller types.
0
50
100
150
200
250
300
350
0 2 4 6 8
Number of blades
(
U
n
i
t
:

R
P
M
)
N
js
N
Q
*N
js
(a)
0
50
100
150
200
250
300
350
0 2 4 6 8 10
Number of blades
(
U
n
i
t
:

R
P
M
)
N
js
N
Q
*N
js
(b)
Figure 8 Variation of just-off-bottomsuspension speed with number of impeller blades, pumping downward: fluid
water, solid particle size d
50
=105 m, =2520 kg/m
3
, solids concentration C
V
=20%, T =0.39 m, H =0.4 m, D/T
=0.41, C/T =1/3. (a)30-pitch bladed turbines, 30PBT2, 3, 4, 5, 6; (b) Radial disc turbines, DT2, 3, 4, 5, 6, 8.
A brief report on this novel finding has been presented in our early paper (Wu et. al. 2000a). An
extensive experimental program has been conducted since to validate the theory by systemically varying
impeller geometry parameters including impeller pitch angle, number of blades, impeller flow direction
(axial or radial) and impeller type. As a further example, Figure 8(a) and (b) show the effect of varying
number of impeller blades on N
js
, for both pitch bladed turbines (with 30 pitch angle) and radial disc
turbines, at a solids loading of C
V
= 20%. When N
js
is combined with N
Q
, the resulting group is again seen
to be constant.
In summary, given a solids/liquid material system and impeller diameter, impeller pumping and
solids suspension can be related succinctly as:
N
js
N
Q
= const (1)
The just-off-bottom solids suspension speed N
js
(rev/s) can be predicted by Zwieterings
correlation:
85 . 0
13 . 0 45 . 0 2 . 0 1 . 0
) / (
D
X g d
S N
L
js

=
(2)
The geometric parameters of the system, i.e., type of impeller, impeller to tank bottom clearance,
and impeller to tank diameter ratio, are lumped together in the dimensionless parameter S. Empirical data
on S and its variation with impeller/tank geometry has been given by Nienow (1992), among others.
It is not difficult to conclude from (1) that:
N
Q
S = K (3)
where K is a non-dimensional constant independent of the solid/liquid material property. To use this
equation, generally the designer has to consult the literature for a suitable value of S, and since this is
limited to a very small number of impellers and tank geometries, the designer is usually left to estimate a
value from those available. However, if the designer knows the flow number for the impeller that is to be
used, and the details of an impeller whose S value is already published, then N
js
can be readily computed
by incorporating this relationship with the Zweitering's correlation. Readers are referred to Nienow (1992)
for a list of S values for frequently used impellers.
The advantage of (3) is that it relates the impeller pumping directly to solids suspension, and it offers a
more sound basis for determining the impeller geometry variation on solids suspension. However, it
should be pointed out that Eq (3) does not provide a mean to evaluate the influence of D/T and C/T effect
on S, it merely provides a basis for estimating the change of impeller design on solids suspension at a
given impeller diameter and installation configuration.
Normalised S parameters for pitch bladed turbines and disc turbines are listed in Table 1 (the first right
column), where they are expressed as ratios to the S parameter of the standard 45 pitch 4-bladed turbine
(S
45PBT4
) for axial flow impellers, or the standard 6-bladed Rushton disc turbine (S
DT6
) for radial flow
impellers1. It is interesting to see that S/S
45PBT4
varies from 1 to 1.77 (for 20PBT4); while S/S
DT6
varies
from 0.91 to 1.66 (for DT2) for the impellers tested.
CONCLUSIONS
The impact of varying impeller geometrical parameters including impeller type, number of impeller
blades, blade pitch angle and blade thickness have been studied through velocity measurement with a laser
doppler velocimetry. Universal time-mean flow discharging velocity profiles in the form of Vz/(N
Q
U
tip
) vs.
r/D for pitch bladed turbines and Vr/(N
Q
U
tip
) vs. z/D for radial disc turbines have been presented. Flow
number correlation based on power number for both pitch-bladed turbines and disc turbines are presented.
It can be concluded that N
Q
S = K, where K is a non-dimensional constant independent of the
solid/liquid material property. This establishes a link between impeller pumping capacity and the S
parameter in Zwieterings correlation. S parameters expressed as ratios to that of the standard turbines
have been provided for a range of impeller designs.
NOTATION
C
V
Solids volumetric concentration (v/v)
C Impeller to tank bottom clearance (m)
D Impeller diameter (m)
H Liquid level in the tank (m)
K Constant which is independent of the solid/liquid material system (-)
LDV Laser Doppler Velocimetry
N Shaft speed (rpm, rev/s)
N
js
Minimum speed to just suspend solids off tank bottom (rpm)
N
bld
Number of Blades (-)
N
Q
Flow number =Q/(ND
3
) (-)
P Impeller power (w)
P
0
Impeller power number =P/(N
3
D
5
) (-)
Q Impeller flow rate (m
3
s
-1
)
r Radial distance from the shaft axis (m)
R Impeller radius (m)

1
This is necessary, as the K constant of axial flow impellers is different from that of the radial flow
impellers.
Re Reynolds number =

2
ND

t Blade thickness (m)
S Coefficient in Zweiterings correlation
S
45PBT4
S coefficient for 45PBT4
S
DT6
S coefficient for DT6
T Tank diameter (m)
U
tip
Impeller tip velocity (ms
-1
)
V Impeller characteristic velocity (ms
-1
)
Vr Radial velocity (ms
-1
)
Vrmax Maximum radial velocity (ms
-1
)
Vz Axial velocity (ms
-1
)
Vzmax Maximum axial velocity (ms
-1
)
W Impeller blade width (m)
z Vertical distance from the tank bottom (m)
Blade pitch angle (deg.)
Fluid density (kgm
-3
)
REFERENCES
Dyster, K. N., Koustakos, E., J aworski, Z. and Nienow, A. W., "An LDA Study of the Radial Discharge
Velocities Generated by A Rushton Turbine: Newtonian Fluids, Re>=5", Trans I Chem E, 71,
Part A, J an. 1993, 11-23.
J aworski, J ., A. W. Nienow, and N. K. Dyster, An LDA Study of the Turbulent Flow Field in a Baffled
Vessel Agitated by an Axial, Down-pumping Hydrofoil Impeller, The Canadian J . Chem. Eng.,
74, 3 (1996).
J aworski, Z., A. W. Nienow, E. Koutsakos, K. Dyster, and W. Bujalski, An LDA Study of Turbulent
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