Introduction

Mixing is an extremely important part of the chemical process industry, and is necessary in
almost every chemical process. If mixing is not present among the reacting species of a
process, no or little reaction will take place. Although it is not addressed in depth in most
engineering curricula, the determination of the correct type, geometry, and size of mixers
and/or impellers to be used for a specific process is an integral part of reactor design. We will
limit our discussion of mixers here to some common correlations used and different types of
impellers.
When dealing with mixing processes, it is important to know that there is no standard mixer
which will work best in any given process. Each process is unique and different impellers and
tank geometries must be experimented with to determine the best design for a given situation.

Correlations

Some very useful correlations which can be used to obtain the power draw and the pumping
rate of the impeller are shown in the graph below. This graph plots both the pumping number
and the power number as functions of the Reynold's number. One can calculate the Reynold's
number for a given system, and the use the graph to. When using these graphs, it is important
to verify that the correlations are appropriate for the impeller and tank geometry present in
your system. The correllations shown here are for a pitched blade turbine, and a high-
efficiency turbine (a variation on the pitched blade turbine) with a D/T ratio (impeller
diameter/tank diameter) of 1/3.

Figure 1: Power number and pumping number versus impeller Reynold's number
for two impeller types

Another useful correlation helps one to maximize the process result by adjusting the D/T
ratio. This correlation is again specific for different impeller types and tank geometries
Figure 2: Process result versus D/T ratio for two impellers showing the optimal D/T
ratio

There are many different correlations available for different impellers and tank geometries
which can be found in the literature and texts such as Perry's Chemical Engineers'
Handbook.

Impeller Types

Impellers are classified as either laminar (viscous) or turbulent mixers.

For situations involving very viscous fluids where laminar mixing is
present, the diameter of the impeller approaches the diameter of the
tank. The larger impellers aid in the transport of momentum throughout
the tank and ensure that the fluid is moving close to the tank wall. Some
common geometries of laminar impellers are the ribbon impeller, the
screw impeller, and the anchor impeller.
 Figure 1: Laminar Flow Impellers

These impellers are also very useful in heat transfer applications when it
is important that the fluid closest to the wall moves at high velocities.

Turbulent mixers can be further categorized as axial or radial flow mixers.

Axial flow impellers cause the tank fluid to flow parallel to the impeller's
axis of rotation while radial flow impellers cause the tank fluid to flow
perpendicular to the impeller's axis of rotation. The following figure shows
the different flow patterns achieved by using either a radial or axial flow
impeller.
 Figure 2: Typical Flow patterns achieved using
a radial flow impeller
(b) an axial flow impeller

Some common geometries for radial flow mixers include disk style flat
blade turbines and curved blade turbines, while some common axial flow
impellers are the propeller and pitched blade turbine.
 Figure 3: Turbulent

Figure 3: Turbulent Flow Impellers

Axial flow impellers are very useful in mixing solid-liquid suspensions because they
prevent the solid particles from settling at the bottom of the tank. The type and
geometry of impeller used will vary from process to process and the determination of the
best geometry for a specific process requires a great deal of experimentation. Radial flow
impellers should be used in situations where high shear rates are needed, such as in
dispersion processes.

Flow Patterns

While mixing liquids, it is necessary to avoid solid body rotation and a

large central surface vortex. When solid body rotation occurs, the fluid
rotates as if it were a single solid mass and results in no appreciable
amount of mixing. A central surface vortex results from the centrifugal
force of the fluid being thrown outward by the impeller. If the vortex
reaches the impeller air entrainment may result.
 Figure 1: (a) Solid body rotation
The central surface vortex

These undesirable situations can be avoided by putting baffles on the tank

walls or by placing the impeller in an angular off-center position. Baffles
are vertical plates (typically about 10% of the tank diameter) that stick
out radially from the tank wall and cause an increased amount of top to
bottom circulation. For situations where a solid is suspended in a liquid, a
gap may be left between the baffle and the wall to prevent any solid
particles from being trapped. The following diagrams show the flow
patterns for axial flow impellers with baffles, radial flow impellers with
baffles, and for an angular impeller in an off-center position
Figure 2: Flow pattern for an axial flow turbine with tank baffles

Figure 3: Flow pattern for a radial flow turbine with tank baffles
 Figure 4: Flow pattern for propellers in an angular and off centered position

Dimensionless Numbers

To aid in the effective design of impellers, several dimensionless numbers have been
introduced. The first of the dimensionless numbers we will define is the impeller Reynold's
number, NRe, which is used to characterize the flow in the tank as either laminar, turbulent,
or in the transition region. The impeller Reynold's number can be derived from the Reynold's
number for flow in pipes, Re.

where:

d is the inside diameter of the pipe

u is the fluid velocity
r is the fluid density
m is the fluid viscosity

The impeller Reynold's number can be obtained by substituing in the impeller diameter, D,
for the pipe diameter and the angular velocity of the impeller, ND, for the fluid velocity to
yield:

where:

N is the rotational speed of the impeller

 D is the impeller diameter

Another dimensionless quantity commonly used to characterize impellers is the power

number, NP. It has been shown through experimental data that the power consumption of an
impeller, P, is proportional to the cube of the rotational speed of the impeller, the fifth power
of the impeller diameter, and the density of the fluid. Therefore, the following relationship
holds :

Solving for NP yields the following expression for the power number:

Two other dimensionless numbers that are encountered are the Froude number, NFr, and the
pumping number, Nq. The Froude number is defined as

where: g is gravitational acceleration

The Froude number is useful in studying vortex motion during scale up. The pumping
number is defined as:

and can be used to find the pumping rate of the impeller, Q.

References

Aref, Hassan and El Naschie, Chaos Applied to Fluid Mixing, Pergamon Publishing,

New York, NY, 1995.

Cheremisinoff, Nicholas P., Guidebook to Mixing and Compounding Process, Prentice-

Hall, Englewood Cliffs, NJ, 1994.

Harnby, N., M. F. Edwards, and A. W. Nienow, Mixing in the Process Industries 2nd
Edition, Butterworth-Heinmann, Boston, MA, 1992.

Nauman, E. B. And B. A. Buffman, Mixing in Continuous Flow Systems, Wiley and

Sons, New York, NY, 1983.

Oldshue, James Y., Fluid Mixing Technology, McGraw-Hill Publishing Inc., New York,

NY, 1983.

Ottino, J. M., The Kinematics of Mixing: Stretching, Chaos, and Transport, Cambridge

University Press, New York, NY 1989.

Tatterson, Gary B., Fluid Mixing and Gas Dispersion in Agitated Tanks, McGraw-Hill

Publishing Inc., New York, NY, 1991.

Tatterson, Gary B., Scale-Up and Design of Industrial Mixing Processes, McGraw-Hill

Publishing Inc., New York, NY, 1994.

Ulbrecht, Jaromir J. And Gary K. Patterson, Mixing of Liquids by Mechanical Agitation,

Gordon and Breach, New York, NY, 1985.

, What are the different flow patterns an agitator creates in a

vessel?
Determining the desired flow pattern of the material in your reactor is dependent on
your agitation objectives. There are two types of flow patterns that can be created –
axial flow and radial flow. They are clearly illustrated in the figures below:

Figure 1. Axial Flow

Figure 2. Radial Flow
In axial flow, the most common mode of operation, the agitator pumps down the axis
of the vessel and up the wall (see figure 1). This flow is designed to produce high flow
to power ratio. Agitators that produce this movement are typically run at a relatively
high rotational speed and are suitable for applications that require high product flow
and low turbulent energy. Suspending settling solid particles and low viscosity bulk
blending are examples of processes that work well utilizing axial flow.

Radial flow propels liquid outward from the agitator blade and revolves around the
vessel axis, producing upper and lower circulation loops (see figure 2). While axial
flow can be carried out with or without the use of a baffle, radial flow should always
be operated with baffles to enable circulation between the top and bottom circular
flows that are created from this flow pattern. Radial flow is ideal for de-
agglomerating solids, dispersion and emulsion.

Agitators
Introduction
This article takes an in-depth look at agitators.

Read further and learn more about topics such as:

 What are Agitators?
 Agitators vs. Mixers
 Parts of an Agitator
 Flow Patterns of Agitator Impellers
 Types of Agitators
 Configurations of Agitators
 And Much More…
Chapter 1: What are Agitators?
Agitators are equipment used to homogenize media inside a tank. They work by
rotating immersed impellers at a controlled speed, also called revolutions per minute
(RPM). The work exerted by the impeller induces the flow and shear of the media inside
the tank, causing a single or multi-component media to homogenize. The flow of the
media is kept at a uniform rate and pattern.

Agitators can perform diverse functions in any industrial plant, which include:

 Homogenizing solutions and suspensions to achieve a uniform consistency

 Maintaining solutions in a mixed state and preventing concentration gradient
 Dispersing a gas into a liquid solvent
 Promoting chemical reaction inside a reactor
 Maintaining a consistent temperature of the solution inside a vessel
 Promoting heat transfer to a jacket
Agitators can handle liquid, gaseous, and solid (e.g., granules, powders) media. They can
also work with slurries, suspensions, and highly viscous liquids. However, selecting the
appropriate agitator type, sizing, and design for the specific nature of media is crucial.
Viscosity and sensitivity to shear stress are essential considerations when selecting an
agitator. Agitators are widely used in many industries, including food and beverage,
pharmaceutical, agricultural, biotechnology, paint, and water treatment industries.

Agitators vs. Mixers

The terms “agitators” and “mixers” are often used interchangeably, but they technically
do not mean the same thing. Mixers are equipment that rapidly blends two or more
components together. These components may be of the same or different phases (e.g.,
solid-liquid, liquid-liquid, gas-liquid). When a component enters a mixer, it is often in a
“pure” state and leaves combined with other components. On the other hand, agitators
maintain homogeneity and equilibrium in an existing mixture. They prevent the
formation of concentration and temperature gradients and ensure uniform consistency
in a mixture.

Chapter 2: Parts of an Agitator

Agitators consist of three main components:

Motor Component
The motor drives the agitator assembly. It produces the required torque to induce flow
and shear to the media at a controlled degree. The power requirement of an agitator
depends on many factors such as:

 Viscosity, specific gravity, and solid content of the media

 Speed or rpm of the impeller
 Impeller diameter
 Power number of the impeller
 Number of impellers
Shaft Component
The shaft is connected to the motor’s driveshaft and transmits the torque to the
impeller. Couplings, end caps, and other devices are used to build the shaft assembly.
Sealings are also used to prevent material build-up.

Impeller Component
The impeller is considered the most critical component of agitators that determine the
flow pattern, efficiency of the homogenizing process, and mixing parameters. It is
responsible for exerting energy directly to the materials being mixed. It induces fluid
flow and shear patterns as it rotates. This component does the actual mixing.
Impellers mainly consist of a hub and blades. The hub is directly connected to the shaft
through a shaft key and a grub screw. The agitator blades are attached to the hub by
welding or screwing. A welding connection is more hygienic because it prevents
material-build on the fasteners and fittings. There could be more than one impeller
installed in an agitator shaft. The number of impellers depends on the type of impeller,
the maximum height of the media inside the vessel, vessel diameter, and specific media
gravity. This information is also necessary when determining the spacing between the
impellers.

Impellers may be classified as an open- or disc-type. An open blade impeller has blades
directly connected to the shaft. There are open spaces between each blade which
makes cleaning-in-place easier. A disc-type impeller consists of a disc with attached
blades. It creates a more uniform radial flow and is used in gas dispersions.
 Leading Agitators Manufacturers and Suppliers

KADY International Frain

Industries, Inc. Charles Ross & Son Company Admix,

Inc. PerMix North America ARDE

Barinco, Inc.

Chapter 3: Flow Patterns of Agitator Impellers

Impellers are classified based on the flow pattern they create. An impeller can produce
more than one flow pattern, with one flow pattern more dominant than the other.

Axial Flow Impellers

Axial flow impellers cause the media to flow parallel to the impeller’s axis of rotation.
These impellers have angled blades that make less than 900 to the plane of rotation.
The rotation of the impeller causes a “top-to-bottom cyclic” flow pattern. The fluid at the
upper portion of the tank is forced to flow down until it is deflected at the tank bottom.
It then spreads over the tank bottom and subsequently flows up along the wall before
being drawn by the impeller. This motion mixes the fluid at the top and bottom of the
tank and prevents the solids and solutes from settling at the tank bottom.

Axial flow impellers are suitable for solid suspensions and low to medium viscosity
fluids. Their low shear characteristics make them ideal for shear-sensitive media (i.e.,
non-Newtonian fluids or fluids changing viscosity due to applied stress). They are also
used for heat transfer applications. Axial flow impellers are typically installed in tanks
with high liquid levels where large vertical currents are desired.
Radial Flow Impellers
Radial flow impellers cause the media to flow perpendicularly to the impeller’s axis of
rotation. The rotation of the impeller causes a “side-to-side flow pattern.” As the fluid
ejects from the impeller, it flows towards the tank’s walls. It then moves either upward
or downward until it is drawn again to the impeller's center. This motion is repeated to
incorporate the contents of the tank thoroughly. As opposed to axial flow impellers,
radial flow impellers do not have angled blades that force the fluid downwards. Baffles
are essential when using these impellers to minimize vortex formation and swirling
motion.

Radial flow impellers produce a high degree of shear and less flow since the fluid flows
sideways. Hence, they are suitable in blending viscous liquids and for gas-liquid and
liquid-liquid dispersions. Radial flow impellers are used for low-level mixing inside
elongated tanks.
Tangential Flow Impellers
Tangential flow impellers cause the media to flow in a circular path around the shaft.
The fluid rotates around the vessel together with the impeller blades. A very low vertical
flow is produced as the fluid hits the tank wall. These impellers induce low shear.

Tangential flow impellers are used in blending highly viscous media and stratification.
Close Clearance Impellers
Close clearance impeller is a category of impeller types with a high diameter ratio (ratio
of the impeller diameter to the tank diameter). The diameters of these impellers are
about 80% of the tank diameter, making a small clearance between the tank wall and
the outer edges of the impeller. These propellers can slightly scrape the sticky products
building up on the tank walls, thereby improving product homogeneity and preventing
fouling, reducing heat transfer rate.

Close clearance impellers are used in the low-speed laminar blending of highly viscous
liquids (greater than 50,000 cP). The fluids these impellers handle include paints, inks,
adhesives, grease, polymer solutions, and other viscous products.
Examples of close clearance impellers are anchor, paddle, gate, and helical ribbon
impellers. The diameter of other impeller types, such as turbine impellers and
propellers, generally have one-third of the tank diameter.

Chapter 4: Types of Agitators

Paddle Agitators
Paddle agitators consist of two flat paddle-shaped impeller blades extending to reach
the tank walls. They are used if no extensive axial and radial flow is required. These
impellers can produce a laminar low shear flow and are used for low viscosity liquid
mixing, crystallization, dissolution, and heat transfer. They are typically operated at low
speeds and predominantly give a tangential flow pattern. Secondary blades can be
installed on the paddle blades to enhance the mixing of more viscous materials.

The impeller blades are inclined from the plane of rotation to create an axial flow
pattern. This variation of paddle agitator is typically used for homogenizing
suspensions.
Anchor Agitators
Anchor agitators have impellers that resemble the shape of an anchor. They typically
have a U-shape that matches the contour of the tank. They generate a predominantly
tangential flow pattern, but angled blades can be incorporated on their horizontal
supports to create an axial flow.

Anchor agitators are used for blending and heat transfer of highly viscous liquids. Their
impellers generate a laminar low-shear flow; hence, they are used to mix shear-
sensitive media. Anchor agitators are considered the most economical laminar flow
agitator. They are suitable for tanks with rounded or conical bottoms. The impeller can
be designed to have a low clearance with the tank wall.
Helical Ribbon Agitators
Helical ribbon agitators have a helical impeller blade fixed in the shaft by rods. These
impellers are an alternative to anchor impellers which can generate laminar flow. These
agitators create an axial flow pattern. They generally have a higher fluid contact area to
mix fluids with higher viscosities.
Double Helical Ribbon Agitators
Double helical ribbon agitators are designed to have two helical blade flights running
through the shaft in opposite directions. The additional flight enhances the mixing of
more viscous fluids. These impellers are also used in heat transfer applications and are
considered the best high viscosity laminar flow impeller. The impeller can also be
designed to have a low clearance with the tank wall.
Agitators With Screw Impellers
Screw impellers are close clearance impellers with a helical flight directly attached to the
impeller shaft. They provide an excellent top-to-bottom turnover. They are used in
blending high viscosity and shear-sensitive media.
Propeller Agitators
Propeller agitators mainly produce an axial flow pattern, though tangential flow can also
be produced. The fluid is displaced and accelerated longitudinally after the impeller
blades draw it. The deflection of the fluid depends on the inclination of the impeller
blades. The impeller blades are tapered towards the shaft to minimize centrifugal force
and maximize axial flow.

Propeller agitators are operated at medium to high speeds. Marine propellers are
typically used for propeller agitators.

Propeller agitators are used in homogenization, dispersion, and suspension of low

viscosity products. They are used in solid-liquid suspension systems and chemical
reactors to prevent solids settling at the tank bottom. They may be installed in
unbaffled tanks when the propeller is inclined vertically from the centerline or in an off-
center position.
Turbine Agitators
Turbine agitators are an intermediate between propeller and paddle agitators. They
usually have larger diameters than propeller agitators. These agitators combine
centrifugal and rotational motion. They are used in emulsification and dispersion
processes in which the media is required to flow at high speeds. They offer a good
balance between flow and shear. They are typically operated at high speeds. They can
handle a wide range of material viscosities and still provide a high mixing efficiency.

The types of turbine agitator impellers are the following:

 Straight blade turbine impellers consist of two to eight flat vertical blades. These
turbine impellers generate a radial flow pattern and high shear. They are used in
solid suspension systems, heat transfer applications, and moving solutes from
the bottom of the tank.
 Pitched blade turbine impellers have flat angled blades. The most common type
is a four-blade turbine that makes a 450 angle with the vertical. They provide a
combination of axial and radial flow; the axial flow is more dominant than the
latter. They generate high shear and have good mixing efficiency. They are used
in gas dispersions and solid suspensions.
 Rushton turbine impellers consist of flat vertical impeller blades arranged
symmetrically around the circumference of a horizontal disc. These impellers
generate a radial flow pattern. Rushton turbine impellers are effective for gas
dispersion applications. The gas is sparged and captured below the rotating disc
and then diverted in high turbulent regions near the blades. They can also be
used in gas-liquid contacting and mixing.
 Smith turbine impeller is a variation of a Rushton turbine impeller, in which semi-
circular or curved blades are attached instead of flat blades. This impeller is
designed for gas-gas and gas-liquid dispersions and emulsions. It has a lower
power requirement and larger gassing duty before flooding than Rushton
turbine impellers.
 Curved blade turbine impellers, also known as sweptback turbine impellers,
consist of curved blades mounted vertically to the central hub. These impellers
also produce a radial flow pattern. They have a lower power requirement and
produce less shear compared to flat blade turbine impellers. They are used in
low level mixing, solid suspension systems, and heat transfer.
Agitators with Retreat Curve Impellers
Retreat curve impellers consist of three curved blades with rounded edges and corners
that can be easily coated with glass material. The glass coating can prevent corrosion
and contamination, critical in the food, beverage, and pharmaceutical industries.
Retreat curve impellers primarily create a radial flow pattern; the axial flow depends on
the diameter ratio and the clearance of the impeller from the tank bottom.

Retreat curve impellers are used in achieving uniform dispersion in solid-liquid and
slurry media. The rounded corners can prevent turbulence and generate low shear,
making them suitable for shear-sensitive media. These impellers typically operate at low
speeds.
Agitators with Hydrofoil Impellers
Hydrofoil impellers are composed of two to four narrow tapered and cambered blades.
The three-blade configuration is the most common in industries. Their blade angle
increases from the tip to the hub. These impellers generate an axial flow pattern.
Hydrofoil impellers maximize the fluid flow while producing a low shear rate and
consuming the least energy, making them more efficient than pitched blade impellers.
Hydrofoil impellers are more economical than propellers when used in tanks with large
diameters.

Standard hydrofoil impellers are used in mixing, suspension, and flocculation systems
involving low viscosity fluids. They are also used in shear-sensitive media such as high-
biomass slurry.

Wide blade hydrofoil impellers have a higher solidity ratio compared to standard
hydrofoils. The solidarity ratio refers to the ratio of the total blade area to the area of
the circle circumscribing the impeller. These hydrofoil impellers are suitable for gas-
liquid dispersions due to their large contacting area. The power requirement for these
impellers is higher than standard hydrofoil impellers. However, the power requirement
of a pitched blade impeller is still greater.
Agitators with Dispersion Blade Impellers
Dispersion blade impellers consist of a disc with sharp outer blades or teeth at its edges
which break down agglomerations of solids and viscous liquids into fine particles. The
sawtooth design is common in industries. The outer blades sharpen through use
because of their abrasion with the media. These impellers are operated at high speeds
to achieve high shear and turbulent flow. Dispersion blade impellers are typically made
of hard metals such as carbide and stainless steel.

Dispersion blade impellers are commonly used in solid-liquid or liquid-liquid dispersion.

They are used in dispersing pigments in a viscous paint mixture. They are also used in
emulsification and grinding applications.
Agitators with Coil Impellers
Coil impellers have springs that act as the impeller blades. They primarily create a radial
flow pattern. The spring has high mechanical rigidity to overcome the resistance given
by the solids at the bottom of a suspension during mixing. These impellers are also
used to prevent solids from settling at the bottom of the tank.
Chapter 5: Configurations of Agitators
The types of agitators based on their configuration when it is installed in a mixing tank
are the following:

Top Entry Agitators

Top entry agitators are installed at the overhead of the liquid level, commonly at the
centerline of a baffled vessel. They are ideal for wide tanks with small aspect ratios (i.e.,
the ratio of liquid level to tank diameter) of about 1:1. They may be installed with an
angle offset with the vertical to suspend solids in the solution effectively. They are
suitable for sealed tanks and can be attached by plate mount or flange mount. Their
structure and position allow easy dismantling and cleaning.

The top entry is the most common configuration found in industrial mixing.
Side Entry Agitators
Side entry agitators are installed on the sidewall of a tank. They are used when the
width of the tank is much greater than the liquid level. They are also used in tanks with
low ceiling clearance, which does not permit the installation of a top-entry agitator.
However, less consistent mixing is achieved because the fluid is pushed along the walls
of the tank. The fluid content must be drawn during maintenance. The power
requirement of side entry agitators is also higher than top entry agitators.
Bottom Entry Agitators
Bottom entry agitators are installed at the bottom of the tank. They have a short shaft
that is directly connected to the motor's driveshaft. Bottom entry agitators are used for
mixing the materials which tend to settle at the tank bottom. They are commonly used
in large volume tanks. They are used in homogenizing mixtures such as oils, milk, juices,
and others.
Conclusion
 Agitators are equipment that induces flow and shear to a fluid or material, which
causes the fluid to homogenize.
 Mixers are used to blend two or more components rapidly. Agitators ensure
homogeneity and equilibrium in an existing mixture.
 The main components of an agitator are the motor, shaft, and impeller. The
impeller is considered as the most critical component that primarily determines
the flow pattern, efficiency of the homogenizing process, and others.
 Agitator impellers can be classified based on the flow pattern they produce.
These flow patterns are axial, radial, and tangential flows.
 The types of agitators are paddle agitators, anchor agitators, helical ribbon
agitators, propeller agitators, turbine agitators, agitators with screw impellers,
retreat curve impellers, hydrofoil impellers, dispersion blade impellers, and coil
impellers.
 The configurations of an agitator when it is installed in a mixing tank are top
entry, side entry, and bottom entry.