MIXING &

AGITATION
Mixing
• Mixing is a process in which at least two separate materials (which may be present in the same or different phases)
are taken and forced them to be randomly distributed through one another by some mechanical means.
• It is a physical process of reducing non-uniformities in fluids by eliminating gradients of concentration, temperature
and other properties.
• The term mixing implies taking atleast two separate phases and causing them to distribute randomly through one
another.
• Therefore, mixing may involve gases, liquids or solids in any possible combination of two or more components - two
different liquids, a liquid and a gas, a liquid and a powdered solid or two different or same solids.
• Homogeneous and Heterogeneous Mixtures
• A mixture in which its components/constituents are present in a single phase is called a homogeneous mixture. For
example, a liquid mixture of methanol and water, a mixture containing CO2, N2 and O2 gas.
• A mixture in which its components/constituents are present in distinct phases is called a heterogeneous mixture.
• For example, a liquid mixture of benzene and water forms a heterogeneous mixture made up of two immiscible
liquid phases.
Agitation
• It should be noted that agitation and mixing are not synonymous
• Agitation refers to the induced motion of material in a circulatory
pattern inside a tank or vessel
• mixing is the random distribution into and through one another, of
two or more initially separate phases. For e g mixing of liquids with
liquids, gases with liquids, liquids with solids and solids with solids.
Mixing liquids with liquids
A propeller or a turbine in a tank is the most commonly used equipment for
operations involving liquid-liquid and to some extent liquid-solid mixing.
In liquid-liquid mixing, a system may contain liquids with or without solids that
are not viscous (e.g., light oils) liquids with or without solids that are viscous but
pourable (e.g. paints, heavy oils) and liquids with solids that form stiff pastes
(oilbound distempers).
An agitated vessel is a vertical, cylindrical vessel fitted with an agitator. The
agitator is driven by an electrical motor directly or through a speed reducing gear
box. It is provided with inlet and outlet connections, coil, jacket, etc.
In the agitated vessel, the impeller creates a flow pattern, causing the liquid to
circulate through the vessel and return ultimately to the impeller.
An agitator is a combination of the impeller and shaft, i.e., impeller attached to
the shaft. There are various types of impellers and so the agitator types. When
we say turbine impeller, it is also termed as turbine agitator. The terms Impeller
and Agitator are used interchangeably.
Types of Impellers
• 1. Axial flow impellers : Axial flow impellers make an angle of less than 90°
with the shaft. They generate flow currents parallel to the axis of shaft.
• 2. Radial flow impellers: Radial flow impellers have blades parallel to the axis
of the shaft. They generate flow currents in tangential (tangential to the
circular path) or radial directions (perpendicular to the shaft).
• Impellers are further classified into three sub-types as :
1. Propellers, 2. Paddles and 3. Turbines.
Axial Flow Impellers: Propellers, Pitched blade turbine
Radial flow impellers: paddles, curved bed, disc blade turbine
• Axial impellers are used at high speeds to promote rapid dispersion and used
at low speeds to keep solids in suspension. Radial flow impellers are used for
large scale mixing of solid/liquid suspension.
Propellers
• A propeller is an axial-flow, high speed impeller commonly used for low
viscosity liquids. It may be mounted centrally, off-centre or at an angle to the
vessel. It is simple and portable. The diameter of propeller usually lies between
15 to 30% of the diameter of the vessel.
• A typical propeller is shown in Fig. 6.2. The most common propeller is a
standard three bladed marine propeller. A propeller is shaped with a tapering
blade to minimise the effect of centrifugal force and produce maximum axial
flow.
 • Small propellers rotate at full motor speeds, whereas large ones
rotate at a speed of 400 to 800 r.p.m.
• Propellers may also be mounted near the bottom of the cylindrical
wall of a vessel as shown in Fig. 6.4 for blending low viscosity fluids or
suspending slow settling sediments in very large tanks.

Propeller drives the liquid straight down to the bottom of the vessel, at the bottom
the stream spreads radially in all directions towards the wall, then the liquid flows
upward along the wall, and finally returns to the suction of impeller from the shaft.
Such a flow pattern is shown in Fig. 6.4. These agitators are used in situations where
strong vertical currents are desired, e.g., for suspending heavy particles.
Turbines
• Pitched blade turbine is an axial flow impeller while curved blade and
flat blade turbines are radial flow impellers.

They are capable of creating a vigorous mixing action due to centrifugal and rotational
motions generated by them. A stator ring surrounding this impeller gives an efficient
mixing action.
Pitched blade turbine is an axial flow impeller
while curved blade and flat blade turbines are
radial flow impellers.
Flow pattern with turbine
impeller in a baffled vessel
The practical aims of mixing
• To promote a chemical reaction. Since intimate contact between
reacting phases/substances is necessary for a reaction to proceed
properly.
• To produce simple physical mixtures - of two or more uniformly
divided solids, two or more miscible liquids, etc
• To carry out physical change - formation of crystals from a
supersaturated solution.
The practical aims of Agitation
• (i) Blending miscible liquids
• (ii) Dispersing a gas in the liquid
• (iii) Suspending or dispersing relatively lighter solid particles in the
liquid to produce uniformity required for promoting mass transfer and
assisting chemical reactions.
• (iv) Dispersing or contacting immiscible liquids
• (v) Promoting heat transfer between the liquid in the container and a
coil or jacket surrounding the container