Fluid Mixing in Biotech and Pharmaceutical  Agenda

Applications What is Fluid Mixing?

• Mixing Theory
• Process Design of Agitators
Kevin Eisert, Senior Application
• Blending and Motion, Solids Suspension, Gas Dispersion • A combination of two or more species
• Impellers -- Types and Styles
Engineer through mechanical means to
• Computational Fluid Mixing
Susan Sargeant, Market Manager • Agitator Basics produce a desired result
BPE
Eric Janz, Director-R&D
• Gearbox/Agitator Types • A rotating agitator produces high
• Mounting Styles and Seals velocity liquid streams which come
• Mechanical Design of Shafts
• Information Needed for Specifying an Agitator
into contact with stagnant or slower
• Troubleshooting moving liquid, therefore momentum
• Invited Comment transfer occurs.

1 2 3

Dimensionless Groups - Nomenclature Reynolds Number

Dimensionless Groups
• A measure of the ratio of inertial forces
D = Impeller Diameter
• Mathematical models obeying the (those produced by the agitator) to viscous
T = Tank Diameter forces
laws of conservation of mass and
momentum yields a few significant N = Impeller Rotational Speed • NRe = 10.7 N D2 Sg/:
groups applicable to fluid motion Z = Liquid Level Height (: = cp, D = inches, N = rpm)
• Will not derive the groups from the : = Fluid Viscosity • Affects:
• Power Draw of Impellers
Navier-Stokes equation, rather they Sg = Fluid Specific Gravity
• Pumping Capacity of Impellers
will be presented and significance C = Impeller Off Bottom Clearance • Static Mixer Design
explained S = Impeller Spacing • Surface Deformation
• Number of Impellers
• Baffle Design
4 5 6

Power Number -vs- Reynolds Number

Froude Number Power Number -- Np

• A measure of the ratio of Inertial to • Dependent upon type/design of impeller and

Gravitational Forces fluid properties
• Np = f ( NRe , NFr )
• NFr = N2 D/g = 7.2 x 10-7 N2 D
• Oftentimes NFr is not an effect and for high
(N = rpm, D = inches) NRe (Low Viscosity) the power number is
• Used in Gas Dispersion and Solids Draw constant
Down Applications • Experiments at different speeds, impeller
• In many applications, gravitational effects are diameters, and fluid properties shows:
unimportant and the Froude Number is not P % N3 P % D5 P % Sg
significant • The ratio of Power to N,D, & Sg is the Power
Number:
Np % P/(N3 D5 Sg)
7 8 9

1
What Affects Power Draw? Power Draw Calculation Pumping Number -- Nq
• Fluid Properties such as Viscosity and
Specific Gravity and (if present) Gas
• Dependent upon type/design of impeller
• Impeller Type, Diameter, Pitch, and Width and fluid properties
• Impeller Rotational Speed Hp = 6. 556 x 10-14 N3 D5 Sg Np
• Flow of impeller is proportional to N & D3
• Geometric Effects such as Baffles, Coils, Q % N D3
Liquid Level, Pump Inlets, and Agitator Where:
Mounting • The ratio of these two quantities is the
N = Impeller Speed, rpm Pumping Number, Nq
• Proximity Effects such as Impeller D = Impeller Diameter, inches
Diameter to Tank Diameter Ratio and Off- Nq = Q/ND3
Sg = Fluid Specific Gravity
Bottom Clearance Q = N D3 Nq
Np = Impeller Power Number
• Plus others to a lesser extent (blade • Nq = f (NRe)
thickness)
10 11 12

Pumping Number -vs- Reynolds Number

What Affects Pumping Rate? Pumping Rate Calculation

• Fluid Properties: Viscosity, Presence of
Gas, Specific Gravity
• Impeller Properties: Type of Impeller, Q (gpm) = 4.33 x 10-3 N D3 Nq
Pitch, Width, Diameter, Clearance, etc.
• Rotational Speed
• Geometric Affects: Tank Diameter, Liquid Where:
Levels, Draft Tubes, Baffles, etc. N = Impeller Rotation Speed, rpm
D = Impeller Diameter, inches
Nq = Impeller Pumping Number

13 14 15

Blend Time Blend Time

Blend Time -- Turbulent Flow
• Tb = F(NRe)
• tu = -ln (1-U)/k
Where: tu = Blend Time for “u” uniformity
U = % uniformity
k = Mixing Rate Constant, time –1
(See Advanced Liq. Agitation)

• k = a N (D/T)b (T/Z)0.5
Where: a = Impeller Constant
b = Impeller Constant
N = Impeller Speed, rpm
16 17 18

2
 Blend Time Blend Time
What determines Agitator Size?
• For 99% Uniformity • Blend times for higher viscosity fluids (NRe
t99 = 4.605/k below turbulent) are corrected from a NRe • In simple terms, the size of the
-vs- blend time chart agitator gearbox is rated on “Torque”
Degree of Uniformity Relative Blend Time
• Ways to improve Blend Time • Torque is proportional to Hp and
90 0.50
• Do not start from “Stratified” state Speed
95 0.65
99 1.00 • Introduce additions near impeller J % Hp/N
99.9 1.50 • Pre-blend with Static Mixers (High Viscosity,Sg, • J (in-lbs.) = 63,025 Hp/N
and Volume Ratios)
99.99 2.00
99.999 2.50

19 20 21

Torque Impellers Impeller Styles

• 3 hp at 68 rpm Î 2,780 in-lbs.
• 10 hp at 100 rpm Î 6,302 in-lbs. • Turbine Style Impellers
• Axial Flow (High Efficiency)
• The 10 hp at 100 rpm, would be a size
“3” and the 3 hp at 68 rpm unit would be • Radial Flow (Straight Blade/Disc)
a size “1” agitator • Close Clearance Impellers
• Relative cost difference is about 40% • Helix/Anchor

• For the same type impellers: • High Shear

• Rotor/Stator
Higher Torque = Higher Flow = Higher
Cost
22 23 24

High Efficiency Impeller HE-3 Impeller Flow

Commercial Impellers
• Liquid Blending, Solids Suspension, Heat Transfer,
• Following Impellers Show types of Upper Impeller in Gas Dispersion
Impellers • Low Shear, High Pumping, Axial Flow
• Reynolds Numbers $100
• Examples of the impellers are from • Turbulent Np = 0.28 (0.26 - 0.30)
Chemineer • For a given agitator, the appropriate HE impeller is 20
percent larger than a pitched blade
• Other Manufacturers Manufacture • Jet Foil Impellers will adhere to similar characteristics
similar impeller styles
HE-3 Impeller

25 26 27

3
 High Efficiency/Hydrofoil Impeller High Efficiency High Solidity Impeller

•Liquid Blending, Heat Transfer, Solids Suspension

•Low Shear, Axial Flow, High Pumping
•Similar in performance to HE-3
•Np = 0.55 (0.5 to 0.6)
•Curved design of blade/hub results in higher strength:
lower weight
•Design requires cast impeller hubs
Np = 0.85 (0.8 to 0.95)
• Wide Blade hydrofoil impeller, axial flow
• Applications which require a high solidity axial
flow impeller: three-phase systems, gas
dispersion, abrasive solids, transitional flow
(100>Nre<2,000)

SC-3 Impeller

Maxflo W

28 29 30

Pitched Plade Impeller P-4 Impeller Flow Straight Blade Impeller

• Liquid Blending, Heat Transfer, Solids
Suspension • Straight Blade Impeller with four blades
• Especially good for drawing a vortex or for • Liquid blending, keep outlets clear from solids,
material drawdown solids drawdown, tickler@ impeller, immiscible
• Mixed Axial/Radial Flow fluid blending
• Typical: 4-Blades, W/D = 0.20, 45 degree • Reynolds Number >1
• Turbulent Np = 1.3 (1.15 - 1.45) • Turbulent Np = 2.88
• Reynolds Number >10
• Simple flat blade design is often economical

P-4 Impeller S-4 Impeller

31 32 33

Rushton Turbine
• 6-Bladed Disc Style Impeller
• Gas dispersion at low and intermediate
gas rates, liquid-liquid dispersion
• Turbulent Np = 5.0
• Dated Technology
High Efficiency Gas Dispersion Impellers Gassed Power Draw Comparison
• 6-Bladed Curved Disc Impeller
• Gas Dispersion at all gas rates
• Fermentations, Liquid/Liquid Dispersions
CD-6 BT-6

D-6 Impeller

34 35 36

4
 Mass Transfer Coefficient Helical Ribbon
Anchor Impeller
0.3

BT-6 • Close Clearance Agitator • Close Clearance Agitator

0.25
Mass Transfer Coefficient (1/s)

• Typical D/T Range: 0.95 - 0.98 • Typical D/T range: 0.95 - 0.98
CD-6
0.2
• Viscous Liquids (> 100,000 cp) • Viscous Liquids (> 100,000 cp)
0.15 • Blending and Heat Transfer • Blending and Heat Transfer
D-6
• Less efficient but more cost effective than
0.1
Helical Ribbon
0.05 • Less surface area for cleaning than Helical
Ribbon
0
0 0.02 0.04 0.06 0.08 0.1
Superficial Gas Velocity (m/s)

Retrofit comparison kla at Pu/V = 2.2 kW/m3

37 38 39

Choosing Impellers Impeller Performance - Example

•Flow Controlled Processes: High Pumping/Low Shear
System Geometry and Impellers •Blending Miscible Fluids, Heat Transfer, Solids Susp. HE-3
•High Efficiency/Pitched Blade/High Solidity JF3
•Dispersion Processes SC-3
•Gas Dispersion, Immiscible Fluids Maxflo W
® Impeller System •Radial Flow Impellers P-4
•Combination: Lower Radial (Disk)/Upper Axial S-4
BT-6
® Baffle Recommendations CD-6
D-6
Rotor/Stator Low
Pumping/High Shear
40 41 42

Impeller Performance Geometry

Impeller Design Options
•Buffer Tanks, Blend Tanks, Heat Transfer, Solids Susp. • Number of impellers depends on
• All welded impellers
• High Efficiency Impellers • Type of impeller
• Threaded/sealed impellers • Viscosity/Reynolds Number of fluid
• Reactors:
• High Efficiency Impellers • Bolted (acorn nuts) blades • Liquid Level to Tank Diameter Ratio (Z/T)
• Gas Dispersion Impellers • Set Screws, Keys, other options available • Impeller Diameter/Tank Diameter (D/T Ratio):
• Pitched Blade Impellers • Affects Power Number of Impeller
• Helix (High Viscosity) • Large D/T ratios not advised for Solids Susp.
• Solids Drawdown • Location
• Pitched Blade Impellers • For low level mixing, “tickler” impeller used

43 44 45

5
Baffles
Recommended Baffling Impeller Equations
•Primary Pumping Capacity
• Baffles are used to prevent swirling in lower viscosity • Q (gpm) = 4.33 x 10-3 N D3 Nq
Reynolds
applications and promote Atop to bottom@ mixing.
Number Baffles • Impeller Horsepower Draw
• Baffled Tanks produce the best mixing results NRe > 1,000 T/12 width, T/72 offset •P = 6.556 x 10-14 N3 D5 Sg Np

500 < NRe < 1,000 T/24 width • Impeller Reynold’s Number
• Baffling not required in angled or vertical off center mixing
• NRe = 10.7 N D2 Sg / :
NRe < 500 None
• In certain situations, special baffle configurations may be Where: N = Rotational Speed, rpm
used. Examples include vortex induction, baffles with internal • Number and spacing dependent upon impeller types D = Impeller Diameter, inches
Nq = Impeller Pumping Number
fluid flow for heat transfer capability Np = Impeller Power Number
Where: T = Tank Diameter Sg = Fluid Specific Gravity
: = Fluid Viscosity, cp
46 47 48

Impeller Summary
Mixing Classifications Blending and Motion
•Many different impeller styles available
•Agitator design starts with impeller selection • Liquid in contact with another liquid
• Blending and Motion
•Need to match impeller performance with process
requirements as impeller efficiency can affect agitation. • Solids Suspension • Examples:
• Liquid – Liquid Reactions
•High efficiency impellers can improve agitation for a • Gas Dispersion
given torque by generating a more uniform, axial flow • Blending of Miscible Liquids
pattern • Heat Transfer Improvement
•Special impellers such as the BT-6 improve gas • Blending out Dissimilarities
handling.
• Low Solids Slurries (< 2% Solids)
•Wide blade hydrofoils (Maxflo W) are very good in 3-
phase flow and as pumping impellers above a gas
dispersion impeller.
49 50 51

Blending and Motion

Problem Magnitude Determining Process Requirements
• Size
• Size • Equivalent Volume • How much flow is needed for the
• Difficulty • Veq = Volume Sg process?
• Process Result/Dynamic Result • Specific Blend Times
• Difficulty
• Batch Times
• Fluid Viscosity
• Heat Transfer Requirements
• Process Result/Dynamic Response
• Components being mixed
• Process Results are related to Flow Rate

52 53 54

6
 Determining Process Requirements Blending and Motion Design Determining Process Requirements

• It is difficult to state the process result • Fundamental Dynamic Response for • Bulk Fluid Velocity Calculation:
with precision. Such as how do you Blending and Motion is:
relate flow rate and blend time to: • Bulk Fluid Velocity
• Characteristic of all velocities in the agitated v (ft/min) = Q (ft3/min) / A (ft2)
• Design of a pH adjustment tank? fluid
• A Chemical Reaction? where:
• Design logic starts with the selection of v = Bulk Fluid Velocity
• Blend two very dissimilar components? a “Dynamic Response” Q = Flow Rate
• Design Agitators to produce that A = Cross Sectional Area of
response Tank

55 56 57

Blending and Motion MILD AGITATION Agitation levels 1 and 2 are

Determining Process Requirements characteristic of applications requiring minimum fluid velocities to
achieve the process result.

• Experience has shown the majority of Bulk Fluid ChemScale Scale of Bulk fluid
Velocity Level agitation velocity, ft/min Description
Blending and Motion problems are Agitators capable of level 1-2 will:
solved with Bulk Fluid Velocities of 6 to 6 – 60 ft/min 1 to 10 1 6
Blend miscible fluids to uniformity if the
60 ft/min • The lower the intensity level, the lower specific gravity differences are less than
• It is then possible to assign “Agitation the characteristic velocity, the lower the 0.1.
Intensity Levels” to these Velocities flow rate, and the smaller the Agitator Blend miscible fluids to uniformity if the
• Chemineer calls these levels • ChemScale Levels can be used to 2 12
viscosity of the most viscous is less than
100 times that of the other.
“ChemScale”
describe Process Results in more detail, Establish complete fluid-batch control.
which is called a Dynamic Response
Produce a flat, but moving surface.
58 59 60

MEDIUM AGITATION Agitation levels 3-6 characteristic of fluid VIGOROUS/VIOLENT Agitation levels 7-10 characteristic of
velocity in most chemical process industries AGITATION applications requiring high fluid velocity
Scale of Bulk fluid for the process result, such as critical Example
agitation velocity, ft\min Description reactors
Scale of Bulk fluid Application ChemScale
Blend miscible fluids to uniformity if specific agitation velocity, ft/min Description Media Prep Tank 1-2
3 18 gravity differences are less than 0.3 (Scale 3) Blend miscible fluids to uniformity if Resin Prep Tank 1-2
and 0.6 (Scale 6) 7 42 Sg differences are less than 0.7 (Scale
7) or 1.0 (Scale 10). Buffer Prep Tank 1-2
4 24 Blend miscible fluids to uniformity if the
viscosity of the most viscous is less than Blend miscible fluids to uniformity if pH Adjustment 1-3
5,000 (Scale 3) or 10,000 (Scale 6) times that 8 48 the viscosity of the most viscous is Reactor 6-10
5 30 of the other. less than 70,000 (Scale 7) or 100,000
(Scale 10) times that of the other. Blend Tanks 4-7
Suspend trace solids (<2%) with settling rates 9 54 Suspend trace solids (<2%) with Solids Dissolving 3-5
of 2 to 4 ft/min.
settling rates of 4 to 6 ft/min.
6 36
Produce surface rippling at lower viscosities. Provide surging surfaces at low
10 60
viscosities.
61 62 63

7

Blending and Motion
• Solving Blending and Motion problems also
requires the selection of the optimum impeller
type
• Impellers will produce a combination of flow
and shear (or head)
• For Blending and Motion, increasing flow and
decreasing shear is typically most desirable
• High Efficiency Impellers are used most often
Agitator Selection Blending and Motion
• Process involves
• Pick Impeller Type
• Determine Size and Difficulty
• For a particular Hp/Speed Combination
• Determine Dynamic Response (ChemScale Level)
(Torque Level) the final steps are:
• Choose Impeller Diameter to draw the
• Charts will provide Hp/Speed Combinations defined hp
which when loaded properly will provide the
• Check geometric parameters D/T, C/T, Z/T
Flow to produce desired Bulk Fluid Velocity
and hence Agitation Level desired • Check other process parameters (Blend
Time, Heat Transfer Rate, etc.)
• Mechanical Design (Gearbox, Shaft, Seal,
etc.)

64 65 66

Blending and Motion

Evaluating Agitation Mixing Classifications
• Last step is Economic Evaluation • Motor hp does not correlate directly to mixing
performance • Blending and Motion
• Capital Cost Estimation
• Torque correlates better with mixing intensity • Solids Suspension
• Operation Cost Estimation (Chemscale)
• Optimization • Why? For low horsepower and low speed • Gas Dispersion
combinations, a large impeller is utilized. Flow is
• Luckily, the calculations are proportional to N D3.
computerized and a process and • Torque relates to capital cost. Motor hp relates
mechanical design can be done quickly to operating cost. Consider both when
considering agitator purchase!

67 68 69

Solids Suspension Solids Suspension Solids Suspension

• Liquid in contact with Solids
• Examples:
• Catalytic Media Suspension
• Solids Incorporation
• Resin / Buffer / Media Prep tanks
(depending on specific process)
• Solids suspension applications, like Blending • Design Procedure
and Motion problems, are “Flow Controlled” • Size
• This leads us to use “Flow” impellers rather • Difficulty
than “Shear” (or head) impellers
• Process/Dynamic Response
• High Efficiency Impellers are used most often
• High Efficiency Impellers also reduce particle
shearing

70 71 72

8
Solids Suspension Difficulty Parameter Process Result/Dynamic Response

• Size • Design Settling Rate: • There are (4) levels of Suspension

f (TSR, )Sg, SgL Fw) • No Solids Motion
• Veq = V Sgsl
• Solids Motion on Bottom
Where: TSR = Terminal Settling Rate
• Complete Suspension
)Sg = ) Specific Gravity between
solids and liquid • Complete and Uniform Suspension
Fw = Weight Percent of Solids
SgL = Specific gravity of Liquid

73 74 75

Design Procedure
Design Procedure
Design Procedure • Parameters which Change Answers
0.28
• Calculate settling velocity from solids and
liquid properties or measure experimentally
Njs = k[[
(ρs − ρl ) .
ρl
ut ]]* f (X)* f (D/T)*(T /T )−n
o
• Particle Size & Shape
• Larger particles have higher settling velocities
and require more torque to suspend
• Calculate Njs (Just-Suspended Speed) Where: • Icicle-Like or unusual shapes increase difficulty
based on TSR, Impeller, Geometry --D/T, k = Impeller Constant
Ds = Solids Density • Liquid Viscosity
etc. Dl = Liquid Density • Higher Viscosity hinders settling and makes
• If N > Njs => Complete Suspension ut = Terminal Settling Velocity suspension easier
f(X) = Solids Loading (%) factor
• Calculate Cloud Height or % T0 = Reference Tank Diameter • Problem of Particle Size
“Unsuspended” T = Actual Tank Diameter
• Particle size distribution is important
D = Impeller Diameter
n = Scale up exponent information to design optimum unit
76 77 78

Related Topics
Solids Suspension Summary Mixing Classifications
• Makedown: System Specific. May Need
High Chemscale and Upper Pitched Blade • (3) Levels of mixing • Blending and Motion
Impeller for Fine, Difficult to Wet Solids.
• Solids Motion • Solids Suspension
• Resuspension: Ranges from Easy to
• Complete Suspension • Gas Dispersion
Impossible
• Uniform Suspension
• Solid Particle Shearing:
• Calculate Njs, Cloud Height
• High Efficiency Impellers are best
• High Efficiency Impellers are used

79 80 81

9
 Gas Dispersion Gas Dispersion Design Procedure
• Gas Dispersion applications, unlike Blending
• Liquid in contact with Gas & Motion and Solids Suspension, are “Shear • Size
Controlled”
• Examples: • Difficulty
• This leads us to use “Shear” (or head)
• Aeration Tanks impellers • Process Result/Dynamic Response
• Fermentation • Disc Impellers are most often used (high gas
• BioReactors flow).
• Flow impellers can be used in low gas flow
applications
• Flow impellers are used as upper impellers in
Gas Dispersion Applications

82 83 84

Gas Dispersion Flow Patterns Gas Dispersion Flow Patterns

Gas Dispersion

• Size
• Veq = SgL V
• Difficulty
• Actual Gas Flow Rate
• Process Result/Dynamic Response
• Mass Transfer, kla
• Break gas into smaller bubbles to increase
surface area

85 86 87

Flow Regime Map

Gas Dispersion Flow Patterns Gas Dispersion

• In Turbulent Regime the Flow Pattern • For a “Completely Dispersed” flow

depends on: pattern:
• Aeration Number NA,CD = CCD (D/T)0.5 (NFR)0.5
NA = Qg/ND3 where: CCD is impeller dependent
NA = 1728 ACFM/(N D3)
(0.2 for D-6 and 0.4 for CD-6)
• Froude Number
Increasing speed above this point will
NFr = N2D/g
not change the flow pattern, but will
NFr = 7.2 x 10-7 N2 D
improve gas hold-up and mass transfer

88 89 90 Aeration Number

10
 Gas Dispersion -- Pg/Po Curve Gas Dispersion -- Pg/Po Curve
Gas Dispersion

• Power Requirements
• Power draw will drop when impeller is
“gassed”
• Typically referred to as: Pg/Po
• Designing agitator for the “gassed” state
will yield better results, but need to account
for low or no gas situations
• ACVF Drives

91 92 93

Gas Dispersion -- Hold-Up

• Gas Hold-Up Design Procedure Design Procedure

• As gas is dispersed, the liquid level will rise to varying
degrees. Must account for this in vessel design
• Typically an increase in hold-up signifies smaller gas • First step is to design the agitator so the • Determine specific Mass Transfer Rate
bubbles, thereby increasing surface area, and increasing impeller is not “Flooded” based on process
mass transfer
" = C "(Pg/Vl)A (vg)B • Above flooding, increasing the gas rate • Calculate economical combination of
Where: " = Gas Hold-Up
will increase kla (mass transfer power consumption and gas rate to
vg = Superficial Gas Velocity coefficient):
satisfy the process demands
C ", A, B = Constants kla % (Pg/V)a
• Optimization in pilot plant and then
• Increased power input will increase
mass transfer in the system scale-up is often times used

94 95 96

Gas Dispersion -- Impellers Computational Fluid Dynamics

• A lower Dispersion Impeller is commonly
used to disperse gas and this impeller is
“Concave”
• Using Concave impellers improves the kla
becaue it pumps more than flat blade disks,
which helps minimize “Coalescence”
• The gas is often introduced through a sparge
ring located directly under the impeller
• Recent designs include upper “Flow”
impellers particularly in biological systems to:
• Maintain more uniform dissolved-oxygen
concentrations which is important in fermenters
• Provide excellent overall tank blending
Gas Dispersion Summary
• Choosing the correct impeller system to avoid
“flooding” important
• Higher P/V levels improve performance
• Impeller “Unloading” in gassed –vs-
ungassed state needs to be accounted for
• Gas Sparge System Design is important to
performance of gas dispersion system
• Computational Fluid Design (CFD) can aid in
agitator design

97 98 99

11
 CFD: Setting Expectations Computational Fluid Dynamics
How CFD will help you
What To Expect What Not To Expect • The fluid flow domain is subdivided into a large
• Trends • CFD predicts the flow field that rules the process. number of computational cells. This is called the mesh
• Replacement for
or grid.
• Visualization good engineering
• CFD predicts performance in meeting the intended • Solve the mathematical conservation equations for:
judgement
• Complements physical task: blending time, mixing time scales, heat transfer • mass
modeling. • Complete • momentum
replacement for coefficients, etc. • energy
• Comprehensive data not
testing • Many different impeller styles can and have been • turbulence
easily obtainable from
experimental tests. • Accurate results • chemical species
analyzed.
• Answers for “what if…?” require • Results:
• Detailed models • detailed flow and shear fields
questions.
• Knowledge of your • temperature fields
• Highlights the cause not problem
• chemical concentrations and productivity
just the effect. • Knowledge of
• local mass fractions of additional phases
limitations

100 101 102

The CFD Process

• Determine agitator design you want to simulate CFD

• Boundary conditions are experimentally

established for impeller (LDV, DPIV)
• 2-D runs use a k-, model to solve
equations in turbulent flow
• k = Kinetic Energy of Turbulence
• , = Rate of Dissipation of Turbulence
• Results will produce a time averaged flow
profile

103 104 105

106 107 108

12

109
Flow Patterns at Different
Impeller Off Bottom Clearances
HE-3 Impeller, Turbulent Flow,
Constant Torque, D/T=1/3
Max. Velocity = 268 ft/min Max. Velocity = 299 ft/min
C/T= 0.18
115
Blending Simulation
Why look at flow patterns?
• Flow patterns influence
• Blend time
• Level of solids suspension
• Overall inside heat transfer coefficients
• Distribution of dissolved O2 in fermentations
• Suspension of solids in the tank heel
• Selectivity in competitive/competitive consecutive reactions
• Flow patterns can be affected by:
• Impeller style
• Impeller to tank diameter ratio
• Relative off-bottom distance
• Viscosity (Reynolds number)
Animation
• Impeller spacing
110 111
S-4 Impeller, Turbulent Flow, P-4 Impeller, Turbulent Flow,
Constant Torque, D/T=1/3 Constant Torque, D/T=1/3
Max. Velocity = 97 ft/min Max. Velocity = 128 ft/min Max. Velocity = 91 ft/min Max. Velocity = 110 ft/min Max. Velocity = 110 ft/min Max. Velocity = 110 ft/min
C/T= 0.18 C/T= 0.35 C/T= 0.53 C/T= 0.18 C/T= 0.35 C/T= 0.53
113 114
Observations at Different Summary
Impeller Off Bottom Clearances
Flow patterns can be affected by:
• Radial Flow Impeller: S-4
Max. Velocity = 299 ft/min
• Characteristic 2 cell system at all clearances • Impeller style
• Proportionally more flow to lower cell at • Impeller to tank diameter
intermediate clearances ratio
• Mixed Flow Impeller: P-4
• Relative off-bottom
• Set up large lower cell at high clearances
distance
• Flow in lower cells fraction of upper
• Axial Flow Impeller: HE-3 • Viscosity (Reynolds
• Conical area below impeller grows with clearance number)
• Flow pattern hits bottom even at high clearances • Impeller spacing
C/T= 0.35 C/T= 0.53
116 117
13
 CFD Conclusion Agitator Drives
Basic Components Types
• CFD can be used to analyze: B Built by Agitator Manufacturer
• Laminar blending B Buy-Out with Modifications
P Agitator Drive B Speed Reducer B Buy-Out
• Turbulent blending
P Prime Mover B Motor Configuration
• Stirred tank flow patterns
• Optimize impeller designs
P Drive Mount/Shaft Seal B Right-Angle
P Mixer Shaft B Parallel/Inline
• Laminar and turbulent flow static mixers
P Impeller(s) B Portable/Clamp
• Heat transfer Gearing
• Mass transfer B Spiral Bevel
• And many other mixing applications such B Helical
as fluidized beds, bubble columns, etc B Other (worm, planetary, etc.)
118 119 120

High Torque Gear Drives Medium Torque Gear Drives Low Torque Drive Typical Features
GT Drive
HT Drive
< 1 to 30 hp < Right Angle or Parallel
< Up to 1,000 hp
< Various Gearing Options
< Spiral Bevel & < 11 to 155 rpm
< 1/4 to 5 hp
Helical Gearing < Helical Gearing
< Adaptable to wide < 350 rpm standard
< Tailored to large
application ranges < Customized speeds available
applications
< FDA White or < Equivalent to Chemineer
< FDA White or
Steel-It Paint DT, RBT, BT
Steel-It Paint

121 122 123

Basic Components Prime Mover Basic Components

Electric Motor -
P Gear Drive B Speed Reducer • Gear Drive B Speed Reducer
Foot Mounted / C-Face Mounted • Prime Mover B Motor
P Prime Mover B Motor
P Drive Mount/Shaft Seal TEFC / FCXP • Drive Mount/Shaft Seal
P Mixer Shaft Standard / Chemical / Washdown Duty • Mixer Shaft
P Impeller(s) • Impeller(s)
ACVF Drives B Variable Speed
Air Motors

Other Drives - Hydraulic, Engines, etc.

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Mounting Configurations THINGS TO CONSIDER ABOUT Agitator Seals
AGITATOR MOUNTING Mechanical Seals

• Pedestal Mounted • Weight

• Lip Seal (Low Pressure B 2 to 3 psi) • Types
• Mechanical Seals • Torque • Single/Double
• Single Seals B Up to 150 psi
• Double Seals B Maximum pressure range
• Bending Moment • Lubricated/Dry Running
• Seal Requirements • Manufacturers
• Flange Options • Flowserve
• Ferrule (tri-clamp) • Entry Point of Shaft • John Crane
• ANSI • Chesterton
• DIN

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Agitator Seals Agitator Seals

Basic Components
Double Mechanical Seals
Single Mechanical Seals

• Single Mechanical Seals • Leak Path is into vessel • Gear Drive B Speed Reducer
• Leak path is to the atmosphere • Lowest Leakage Rate
• Lower leakage rates than stuffing boxes • Prime Mover B Motor
• Chemineer uses a Aback to back@
• Suitable to 150 psi
arrangement (Pressurized Cartridge) • Drive Mount/Shaft Seal
• Typically Dry Running
• Carbon -vs- Tungsten Carbide/Viton/316ss • Often requires liquid lubrication • Mixer Shaft
• Optional Materials • Carbon -vs- Tungsten Carbide/Viton/316ss • Impeller(s)
• Silicon Carbide/Kalrez/EPDM/Teflon/Higher Alloys
• Options: Silicon Carbide/ Kalrez/ EPDM/
Teflon/ Alloys

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Shaft Design DESIGN FOR SHAFT DIAMETER ALLOWABLE SHAFT STRESS

• FOLLOW PROCESS/IMPELLER DESIGN SHEAR STRESS= 6,000 PSI SF
• Shaft Stresses (Shear/Tensile) (TWISTING)
• SELECT SHAFT LENGTH
• Shaft Critical Speed TENSILE STRESS= 10,000 PSI SF
• Materials of Construction • DETERMINE THE MINIMUM REQUIRED SHAFT (ELONGATION)
DIAMETER FOR STRESSES
SF = STRESS FACTOR (MATERIAL
• CALCULATE SHAFT CRITICAL SPEED AND TEMPERATURE DEPENDENT)
316ss = 1.0
• COMPARE CRITICAL SPEED RATIO TO 304ss = 0.95
ALLOWABLE VALUE
C276 = 1.33
• ITERATIVE PROCESS

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 SHAFT CRITICAL SPEED CRITICAL SPEED CALCULATION
CRITICAL SPEED RULES
CRITERIA
• Critical Speed 0.394 106 d2 FM
NON-STABILIZED IMPELLER
L pWe p (L + Sb)
•rotation speed corresponding to a natural frequency Nc = -----------------------------
_____ _________
of a shaft/impeller system Pitched/Straight Blade 65%
High Efficiency 80%
• First Critical Speed
•Most Important We = Equivalent Weight
STABILIZED IMPELLER L = Shaft Length
• Agitator Designs Operating Below the first critical Pitched/Straight Blade 80% Sb = Bearing Spacing
speed (lowest) are optimal Well Designed HE NOT REQUIRED
•Low torque designs can be designed to run > critical d. = Shaft Diameter

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Materials of Construction Shaft Couplings

Critical Speed Options
• Carbon Steel • Non-Sanitary
• Increase Shaft Diameter • Stainless Steels • Welded/Bolted
• 304/304L
• Shorten Shaft: A few inches has a • Sanitary
• 316/316L
pronounced effect, but need to maintain • Welded/Acorn Nuts
• Duplex (Al6XN / Ferralium / Avesta 254)
process performance • Threaded
• High Nickel
• Choose Lower Power/Lower Speed Agitator • Alloy 20
• Remove Weight • Alloy 200
•Step the Shaft • Alloy C276/B2
•Reduce blade thickness • Others
• Monel 400 ---- Inconel 600/625/800
• Titanium
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Basic Components Additional Design Considerations

Information for Agitator Design
• Surface Finish Requirements
• Rounded Edges / Smooth Welds
• Gear Drive B Speed Reducer • USP Class VI or FDA elastomers • Type of Data
• Prime Mover B Motor • Debris Well / Flush Ports • Vessel Data
• Drive Mount/Shaft Seal • Beveled Washout • Process Data
• Mixer Shaft • Mechanical Data
• Impeller(s) • Previous Experience
• Documentation Requirements
• See Agitator Data Sheet for typical
required data

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 Process Data
Vessel Data Process Data
• Blending and Motion
• Dimensions • Liquid Properties: Viscosity, Specific Gravity
• Diameter, Straight Side, Mounting Height, Top P Viscosity is most important for Blending
• Additions to be made and quantities
and Bottom Depths, Agitator Mounting Flange • Heat Transfer properties (if required) and Motion and has greatest influence on
Size, Access Way Sizes
• Solids Suspension agitator sizing
• Ratings • Liquid Properties: Viscosity, Specific Gravity P Solids(Size,%,Sg)/Liquid(Viscosity, Sg)
• Pressure and Temperature • Solids Properties: Particle Size, Sg, Weight % Data is most important for Solids
• Internals • Gas Dispersion Suspension
• Baffles (Chemineer will recommend) • Temperature/Pressure of incoming gas P The more accurate the data, the more
• Cooling/Heating Coils • Gas flow rates optimized the agitator
• Other Obstructions • Liquid viscosity
• Mass Transfer Requirements
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Information for Agitator Sizing Conclusion Alternate Agitator

Mechanical Data Designs
• Specifying/Describing the problem is critical
P Materials of Construction for wetted
parts
• Accurate data = Accurate Designs
Bellow Assembly
• Viscosity is most important parameter on
P Sealing Requirements agitator size for Blending & Motion Shaft
P Mounting Requirements • Sealing, Materials, and other requirements
P Other Special Requirements affect the mechanical design of the agitator Impeller
<Motor Requirements • Follow Baffle or Mounting recommendations
<Polishing • Many drive types and products to choose
<Shaft Couplings • Balance Cost, Features, Benefits, & Service

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Impeller Style
The impeller is designed to
convert the rocking motion
of the drive to flow with a
circumferential component
Top view of impeller
O-ring
Hub
End cap
Sanitary removable
impeller design
could be an option.
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Sweeping Blade – New Approach
Eliminates:
• Particle generation
• Rotating mechanical seals & maintenance
• In-Tank bearings used with bottom entry
mixers
• Tank damage associated w/ decoupling of
magnetic mixing impellers and/or bearing
failures
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Sweeping Blade Addresses:
• Zero contamination from wearing parts
• Easy to clean with few crevices.
• Complete Draining.
• Zero leakage through seals.
• Effective mixing (usually low shear) without
baffles.
• 10:1 turndown w/out avoidance range.
• Low center of gravity to avoid top heavy
tank/mixer configurations.
• Ability to produce very small batches.
• Small footprint.
• Lower Cost of ownership
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Summary Questions?
• The Sweeping blade configuration can
effectively address the mixing and
mechanical requirements of your
systems
• Total cost of ownership is lower than
traditional rotating mixers
• Design flexibility to match your needs
• Can retrofit top or bottom entry mixers

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