Describe two mixers that are suitable for mixing cohesive and non-cohesive

solids respectively. (Final’23)

For Non-Cohesive Solids: Ribbon Blender Mixer
• Description: A ribbon blender has a U-shaped horizontal trough with a double
helical ribbon agitator that rotates inside.
• Mixing Mechanism: The inner and outer ribbons move materials in opposite
directions, promoting uniform mixing.
• Application: Best for free-flowing powders and thin pastes that do not clump or
stick.
• Advantages:
o Gentle mixing
o Moderate power requirement
o Effective for batch or continuous operation
For Cohesive Solids: Kneader Mixer
• Description: Kneading involves squashing, folding, and tearing the mass using
blades.
• Mixing Mechanism: The moving blade shears the material against a stationary
surface, which helps mix sticky or plastic materials.
• Application: Suitable for pastes, rubber, and plastics—materials that resist flow.
• Types:
o Two-arm kneader (least power)
o Disperser
o Masticator (most power)
• Advantages:
o High shear and compression mixing
o Handles high-viscosity materials
What types of mixers are used to mix cohesive solids? Why is it difficult to
mix such solids? (Final’22)
Cohesive solids are sticky, deformable, and often resist flow—making them challenging
to mix. The following mixers are typically used:

1. Muller Mixers
2. Change-Can Mixers
3. Kneader Mixers
Why is Mixing Cohesive Solids Difficult?
1. High Cohesive Forces:
o Sticky solids tend to clump together and resist separation.
o Particles adhere to each other and equipment walls.
2. Poor Flowability:
o They don’t flow freely, unlike powders, making uniform distribution
harder.
3. Viscous and Deformable:
o Often behave like semi-solids or pastes, requiring intense
mechanical energy to mix.
4. High Power Requirement:
o More energy is needed to overcome internal resistance (friction and
cohesion).
5. Non-Uniform Mixing:
o Standard mixing doesn’t work well—needs shear, compression, and
kneading to distribute evenly.
What is mixing? Describe two mixers that can be used to mix non-cohesive
solids and cohesive solids, respectively. (Final’21)
Mixing is the process of thoroughly combining two or more materials to form
a homogeneous mixture. In solids, it aims to evenly distribute particles so that
the composition is uniform throughout the mixture. It is widely used in
industries such as food, pharmaceuticals, chemicals, plastics, and construction.
Mixer for Non-Cohesive Solids:
1. Ribbon Blender : last ques dekh
2. Internal Screw Mixer :
• Description: An internal screw mixer is a vertical or conical vessel that
contains a rotating screw. It is designed to lift, circulate, and mix free-
flowing, non-sticky solids such as powders or granules..
• Mixing Mechanism: Circulates and lifts solids using a rotating screw to
create shear and intermixing.
• Types:
o Type I: Conical vessel, screw both orbits around tank center and
rotates.
o Type II: Conical vessel, screw fixed at center and rotates.
o Type III: Cylindrical vessel, screw at center and rotates.
• Application:
o Used for non-cohesive powders, granules, and bulk solids.
o Common in industries like chemicals, food, fertilizers, and
pharmaceuticals.
• Advantages:
o Good for low-shear mixing of fragile materials
o Handles large batches
 o Offers both vertical and radial mixing

Mixer for Cohesive Solids:

1. Kneader Mixer : last ques dekh
2. Muller Mixers :
• Description: A Muller mixer uses a rubbing and smearing action to mix
cohesive solids such as pastes, clays, or rubbery materials. It resembles
the action of a mortar and pestle, making it effective for sticky and
plastic-like substances.
• Mixing mechanism: Mixes by rubbing, shearing, and compressing solids
using heavy roller wheels.
• Types:
o Stationary Pan Mixer: Pan is fixed, wheels rotate.
 o Rotating Pan Mixer: Pan rotates, wheels may be stationary or rotate
oppositely.
o Countercurrent Muller: Both wheels and pan rotate in opposite
directions for stronger mixing.
• Application:
o Clay mixing in ceramics and foundries.
o Pigment blending in paint industries
o Mixing pastes and plastic-like solids in chemical processing
• Advantages:
o Excellent for very sticky, cohesive materials
o Combines mixing and grinding (size reduction)
o Produces homogeneous and well-distributed mixtures
Tumbling Mixer:
• Description: Tumbling mixers rotate a partially filled container about a horizontal
axis to achieve mixing through gravity-driven movement of solids.
• Mixing Mechanism: As the vessel rotates, solids tumble and cascade, causing
random particle movement and mild intermixing—suitable for free-flowing powders.
• Application: Ideal for dry, non-cohesive powders and granules that require gentle
blending.
• Types:
o Double-cone blender
o Twin-shell (V-type) blender
• Advantages:
o Simple design with low power consumption
o Suitable for fragile or segregating materials
o Can be equipped with liquid spray systems for coating during mixing
Change-Can Mixer:
• Description: Change-can mixers are designed to blend viscous liquids or light pastes,
often used in food processing or paint manufacturing.
• Mixing Mechanism: Mixing occurs by either rotating the can (centrifugal action) or
rotating the agitator blades to stir the contents.
• Application: Suitable for viscous materials such as light pastes, food ingredients, and
paint bases.
• Types:
o Pony mixer: Can rotates to mix.
o Beater mixer: Agitator rotates inside a stationary can.
• Advantages:
o Easy can removal and cleaning
o Suitable for batch processes
o Efficient for medium-viscosity materials
Paddle Mixer:
• Description: Paddle mixers use slow-speed, large paddles to move
material in a radial and axial direction for gentle but thorough
mixing.
• Mixing Mechanism: Paddles rotate to lift, fold, and agitate
materials without damaging particle structure.
• Application: Best for fragile or heat-sensitive solids, or for mixing
with minimal shear, such as spices, cereals, or animal feed.
• Advantages:
o Gentle, uniform blending
o Low energy consumption
o Ideal for batch or continuous mixing
How does a power correlation look like for an agitation tank (i) unbaffled and (ii)
with baffles? (Final’23)
In an agitation tank, the power correlation depends heavily on whether the tank is
baffled or unbaffled, due to the differences in flow patterns and vortex formation.
(i) Unbaffled Tank
In an unbaffled tank, the liquid tends to form a vortex due to the rotational
motion, leading to poor axial mixing and increased surface swirling. In this case:
• Flow is primarily tangential/rotational.
 • Froude number (Fr) becomes significant due to the presence of a vortex.
• Power number (Np) is a function of Reynolds number and Froude number.
Power correlation: NP =ψ(NRe,NFr)
where:
𝑛𝐷𝑎 2 𝜌 𝑛2 𝐷𝑎
• 𝑁𝑅𝑒 = 𝜇
𝑁𝐹𝑟 = 𝑔

(ii) Baffled Tank

In a baffled tank, baffles are used to break the vortex and promote axial and radial
flow for better mixing.
• Vortex is suppressed, so Froude number is less important or neglected.
• Flow becomes turbulent at high NReN_{Re}NRe, and inertial forces dominate.
• Power number becomes nearly constant in turbulent regimes.
Power correlation (especially in turbulent regime):
 NP =ψ(NRe)
or in high Reynolds number:
NP ≈ constant
How would you distinguish a radial flow impeller from an axial flow impeller? (Final’21)
Feature Radial Flow Impellers Axial Flow Impellers

Blade Blades parallel to the vertical axis of the Blades angled less than 90∘90∘ to the
Orientation shaft plane of rotation

Flow Generates currents radially outward Generates currents parallel to the shaft
Direction (perpendicular to the shaft) (top-to-bottom or vice versa)

Primary Uses Gas dispersion, mixing in larger tanks Solids suspension, rapid dispersion, small
tanks (<1000 gal. or <6 ft. diameter)

Fluid Motion Liquid driven radially to walls, splits into Fluid driven axially downward, deflects
upward/downward streams off floor and flows upward along walls

Baffling Requires baffles to reduce circular flow Less dependent on baffles for flow
control

Speed & Typically used at moderate to high High speeds for dispersion; low speeds
Power speeds for suspension (<3 HP in small tanks)

Examples Turbines Propellers

Mention what type of flow (radial or axial) is created by (i) straight blade turbine, (ii)
pitched blade turbine, and (iii) three blade marine propeller. (incourse’21)
Here’s the type of flow created by each impeller:

Impeller Type Flow Type

(i) Straight Blade Turbine Radial Flow

(ii) Pitched Blade Turbine Mixed Flow (Axial + Radial) — but mostly Axial if 45° pitch

(iii) Three Blade Marine Propeller Axial Flow

Explanation:
• Straight Blade Turbine (e.g., Rushton turbine): Designed to push fluid outwards perpendicular
to the shaft — this creates radial flow, suitable for gas dispersion and high-shear mixing.
• Pitched Blade Turbine: The angle of the blades (commonly 45°) introduces a vertical
component, generating axial flow (upward or downward), with some radial contribution —
good for blending and solid suspension.
• Marine Propeller (Three Blade): Shaped like a boat propeller, generates strong axial flow —
ideal for bulk flow and circulation.
Why the bottom of the agitator is kept rounded?
The rounded bottom in an agitated vessel is designed to serve several critical purposes, all
aimed at optimizing mixing efficiency and fluid dynamics:
Key Reasons for a Rounded Bottom:
1. Eliminates Dead Zones: Sharp corners (e.g., in flat-bottom tanks) create stagnant regions
where fluid flow is minimal or absent ("dead zones"). A rounded bottom ensures
smooth, uninterrupted flow, preventing solids accumulation or uneven mixing.
2. Improves Fluid Circulation: The curved geometry guides fluid currents downward and
upward more effectively, enhancing top-to-bottom circulation. This is especially
important for suspending solids or achieving uniform temperature/distribution.
3. Reduces Energy Waste: Dead zones force the impeller to work harder to achieve mixing.
A rounded bottom minimizes resistance, stabilizing power draw and improving energy
efficiency.
In summary, the rounded bottom is a fundamental design feature to ensure efficient mixing,
minimize stagnation, and reduce operational costs.
For a typical agitator, what will be the ratio of liquid depth to agitator
diameter? Why the headspace of an agitator should be kept unfilled?
For a typical agitator, the standard design ratio is:
Liquid Depth (H) : Tank Diameter (Dt) = 1 : 1 (H=Dt)
A 1:1 ratio ensures the impeller’s flow reaches all regions of the tank, critical for suspension,
dispersion, or heat transfer. (Mixing Homogeneity)
Why Keep Headspace Unfilled?
The headspace (unfilled portion above the liquid) is essential for:
1. Vortex Prevention:
o A filled tank can cause excessive vortexing (funneling) near the impeller shaft,
reducing mixing efficiency and potentially drawing gas into the liquid (e.g., air
entrainment).
2. Gas-Liquid Processes:
o For gas dispersion (e.g., aeration in bioreactors), headspace allows gas
accumulation and recirculation.
3. Foam Control:
o Prevents foam overflow in processes generating bubbles (e.g., fermentation,
chemical reactions).
4. Thermal Expansion/Safety:
o Accommodates liquid expansion due to temperature changes, avoiding over-
pressurization.
5. Operational Flexibility:
o Enables addition of ingredients (e.g., reagents, solids) without spillage.
Why the tangential flow is not desirable in most of the agitator? How can you reduce the
tangential flow in an agitator? (incourse’21)
Tangential Flow is Not Desirable in Most Agitators:
Tangential flow occurs when the liquid mainly moves around the vessel in a circular (swirling) path,
parallel to the tank wall. This type of flow has several disadvantages in mixing:

Reason Explanation

Poor Mixing Efficiency Tangential flow lacks vertical or radial movement, so it doesn't mix layers
well.

Vortex Formation It often creates a central vortex, which draws air into the liquid
(undesirable).

Dead Zones Little flow in the center or bottom leads to stagnant zones with poor
mixing.

Inefficient Power Energy is wasted rotating the fluid without significant mixing or shear.
Usage
How to Reduce Tangential Flow in an Agitator:
We can reduce tangential flow and promote axial or radial flow (which are more effective for mixing)
using the following methods:
1. Baffles: Install 4–8 vertical baffles on the tank wall to disrupt tangential flow.
2. Off-Center Agitator: Position the impeller asymmetrically to break symmetry in flow patterns.
3. Multiple Impellers: Use stacked impellers on the same shaft to enhance axial flow.
4. Draft Tubes: Direct flow vertically to control circulation and suspend particles.
5. Side-Entering Impellers: Angle the impeller (1°–12°) to avoid swirl.
 Difference between Natural Draft and Mechanical Draft

Feature Natural Draft Cooling Tower Mechanical Draft Cooling Tower

Airflow Mechanism Relies on natural convection (hot air rises). Uses fans (forced or induced) to move air.

Energy Low (no fans). Higher (requires electricity for fans).

Consumption

Size & Structure Very large (hyperbolic shape for buoyancy Compact (fans allow smaller designs).
effect).

Cost High initial cost (massive construction). Lower initial cost, but operational energy costs.

Efficiency Less efficient in low-temperature differentials. More efficient (precise airflow control).

Applications Large power plants, heavy industries. HVAC, smaller industrial plants, data centers.

Maintenance Low (few moving parts). Higher (fan motors, belts require upkeep).

Noise Quiet (no mechanical parts). Noisy (fan operation).

Plume Visibility Often visible (due to natural airflow). Can be reduced (plume-abated designs available).
 Solution
Actual mass flow rate, Q = 4900 kg/hr = 4900/3600 kg/s
ρmaterial = 960 kg/m³ width, w = 1.22 m
roll’s diameter, D = 7.6 cm = 0.076 m
velocity, u = 1.5 m/s μ = 0.52 α = tan⁻¹(μ) = 27.47°
η = 30% = 0.3 => η = Qactual/Qtheoretical => Qtheoretical = Qactual/η = (4900/3600)/0.3
∴ Qtheoretical = (u × w × 2d) m³/s × ρmaterial kg/m³
=> 4900/0.3×3600 = 1.5 × 1.22 × 2d × 960 => d = 1.29×10⁻³ m
Roll’s radius, r = 0.076/2 m
Product radius, d = 1.29×10⁻³ m
feed radius, R = ?
:. Cos(27.47°) = r + d / r + R
=> R = 0.2827 × 10⁻³
:. reduction ratio = R/d = 4.87