Experiments in Chemical Engineering, 2nd ed.

Agitation of Low Viscosity Fluids

by Servillano S.B. Olaño, Jr.

EXPERIMENT A8

AGITATION OF LOW VISCOSITY-FLUIDS

INTRODUCTION

Blending, agitation and mixing of solutions or mixtures are very common in the
chemical process industries. These operations are necessary in preparing raw materials for
processing either by homogenization or during chemical reactions in batch or continuous stirred
tank reactors for the reacting components to react efficiently. Among the important factors that
contribute to the cost of processing is the power requirement needed to attain the desired
consistency of the mixture. Thus, a chemical engineer has to be familiar with the factors that
contribute to the energy requirement during the mixing process. In this experiment, the chemical
engineering student will have a hands-on experience in observing how these factors affect the
energy requirements, be able to measure them and use them in calculating the power
requirement. Important agitation behavior such as vortex formation, movement of eddies, effect
of tank dimensions, effect of baffles and type of agitators are studied.

OBJECTIVES

1. To monitor the power consumption of an agitation system defined by parameters such as

impeller speed, liquid density, liquid viscosity and impeller type for baffled and
unbaffled tank.

2. To correlate the dimensionless groups necessary to predict the power requirement of any
available agitation system desired; to compare this correlation with previous
investigations, if such exist.

3. To study the vortex formation patterns in unbaffled tank systems and to correlate this
vortex magnitude (in terms of cross-sectional area of vortex) with a dimensionless
number, specifically, the impeller Reynolds number.

4. To determine the limiting impeller Reynolds number for each type of impeller; this is the
limiting number at which the vortex first touches the impeller.

THEORY

The most important consideration in the application of agitation operations is the

power requirement of the agitation system desired. The power delivered or absorbed by the
agitated liquid in order to put it in a desired condition of mixing is known as the power

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requirement or power consumption of the agitation system. The system is defined by the
variable parameters such as impeller type, impeller speed, liquid density, liquid viscosity,
tank type (baffled or unbaffled) and the geometry of the agitators relative to the geometry of
the tank.

By experimentally monitoring this power using these parameters, the power

requirement can be predicted by the correlation of the dimensionless groups involved for
each agitation system.

These dimensionless groups, obtained by dimensional analysis, are as follows:

A. Impeller Reynolds Number

The presence and absence of turbulence in an impeller stirred vessel can be

correlated with an impeller Reynolds Number defined as

Da 2 Νρ
Ν Re = (1)
µ

where Da = Impeller diameter, ft

N = Rotational speed, rps
ρ = Fluid density, lb./ft3
µ = Viscosity, lb./ft-sec

Flow in the tank is turbulent when Nre = 10,000. Thus, viscosity alone is not a
valid indication of the type of flow to be expected. Between Reynolds numbers of
10,000 and approximately 10 is a transition range in which flow is turbulent at the
impeller and laminar in remote parts of the vessel. When the Reynolds number is less
than 10, flow is laminar.

B. Froude Number

The Froude Number, NFr, is a measure of the ratio of the inertial stress to the
gravitational force per unit area acting on the fluid defined by the equation

DaΝ 2
Ν Fr = (2)
gc

where gc = 32.17 ft/sec2

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This factor appears in fluid dynamic situations where there is significant wave
motion on a liquid surface, and situations in which the liquid in the tank swirls to such
an extent that a deep vortex is formed.

The effect of the Froude Number appears when there is vortex formation, and
when the Reynolds number is greater than 300. For baffled tanks, or for side-entering
propellers, or for Reynolds numbers less than 300, a vortex does not form, and the
Froude number is not a factor.

C. Power Number

The Power Number, NPo, is analogous to a friction factor or a drag coefficient. It

is proportional to the ratio of the drag force acting on a unit of the impeller and the
inertial stress. The initial stress in turn is related to the flow momentum associated with
the bulk motion of the fluid. The form of the equation is

Ρg c
Ν Ρo = (3)
Ν 3 Da 5 ρ

D. Power Correlation

The effect of the Froude number appears when there is vortex formation, and
only if the Reynolds number is greater than 300. For baffled tanks, or for side-entering
propellers, or for Reynolds number less than 300, a vortex does not form, and the Froude
number is not a factor. The Froude number is taken into account, when it is a factor, by
the exponential equation

Νp
m
= f (Ν Re , S 1 , S 2 ,...................S n ) = φ (4)
Ν Fr

where
S1 = Dt/Da S4 = W/Da
S2 = E/Da S5 = J/Da
S3 = L/Da S6 = H/Da

of which Da is the diameter of the impeller, Dt is the tank diameter, E is the height of the
impeller, L is the length of impeller blades, H is the depth of the liquid in the vessel, J is
the width of the baffles and W is the width of the impeller. The quantity φ is called the
power function.

The exponent m, for a given set of shape factors, is empirically related to the
Reynolds number given by the equation,

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a − log Ν Re
m= (5)
b

where a and b are constants. The magnitudes of these constants are given in the text.
Equation (4) is applied by determining the quantity experimentally as a function
of Reynolds number for constant shape factors and plotting separate curves of φ versus
NRe for each set of shape factors.

E. Theoretical Power Consumption

The power delivered to the liquid is computed by combining Equation 4 and the
definition of NPo to give

φΝ Fr m Ν 3 Da5 ρ
Ρ= (6)
gc

When the Froude number is not a factor, the power is generally given by

φΝ 3 Da 5 ρ
Ρ= (7)
gc

At low Reynolds number, the lines NPo versus NRe for both baffled and unbaffled
tanks coincide, and the slope of the line on logarithmic coordinates is -1. The flow
becomes laminar in this range, density is no longer a factor, and Equation 1 becomes

Ρg c
Ν p Ν Re = = ΚL (8)
Ν 2 Da 3

from which
Κ L Ν 2 Da 3
Ρ = (9)
gc

Equations (8) and (9) can be used when NRe is less than 10.

F. Vortex Formation

A vortex is produced due to the centrifugal force acting on the rotating liquid. In
spite of the presence of the vortex, there is a limit in the rotational speed that may be
used, since once the vortex reaches the impeller, severe air entertainment may occur. In
addition, the swirling mass of liquid often generates an oscillating surge in the tank
which coupled with the deep vortex may create a vibrating force on the mixer shaft. One

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method controlling the vortex is by installing baffles inside the tank. Another way is to
incline the mixing shaft away from the center.

EQUIPMENT

A. Actual Equipment

Ammeter Voltmeter

Mixer
Figure 2: Ammeter (left) and Voltmeter (right)

Impeller

Figure 1: Mixing Tank Apparatus

Figure 3: Impellers
B. Equipment Description

The equipment used in this experiment was a mixer having a set of impellers. An
ammeter was used to measure the current flowing in the system while a voltmeter was
also used to measure the voltage in the system. A tachometer was also used to obtain the
number of angular velocity of the mixer. Other apparatus needed are variable
transformer and spring balance. The dimensions of the equipment are tabulated as
follows:

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Outer Tank Diameter = 20.0 cm

Inner Tank Diameter = 17.9 cm
Tank Height = 31.3 cm
Thickness of wall = 1.0 cm
Height of Baffle strip = 27.85 cm
Width of Baffle strip = 2.6 cm
Thickness of Baffle strip = 6 mm

PROCEDURE

1. Fill the tank up to a height equal to the diameter of tank with a liquid or liquid mixture of
mixture of known density and viscosity. Pure water can be used.

2. Place the four baffles in the tank.

3. Connect the first type of turbine impeller.

4. Using the variac, set the motor speed at the lowest possible speed. Record the voltage,
amperage readings and force readings. Describe or draw the flow pattern created in the
agitated vessel.

5. Increase the speed by a reasonable increment, about 100 rpm up to the maximum speed.
Record the voltage, amperage readings, force readings and significant changes in the
flow patterns.

6. Repeat the procedure using the different types of stirrers.

7. Remove the baffles and repeat steps 3, 4 and 5 (See Note 1)

8. If the water or any liquid of low viscosity was used, test a second liquid or mixture of
higher viscosity. Sodium silicate of about 80% by volume can be used. Repeat 2 to 7.

9. To change the density and viscosity of the mixture, dilute the mixture using water by
removing a certain volume from the tank and then diluting it up to the original level.

Note 1: If vortex formation occurs, (for unbaffled tank), use the vortex measuring device
and record the depth versus distance from tank wall.

Note 2: The optimum electrical setting for motor speeds greater than 100 rpm is a field
voltage of 26.5 volts. Then adjust the armature voltage to obtain the desired speed.

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DATA SHEET

I. Without Baffles, Small Propeller

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM

II. Without Baffles, Large Propeller

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM

III. Without Baffles, Turbine, 2 Wings

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM

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IV. Without Baffles, Turbine, 4 Wings

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM

V. With Baffles, Small Propeller

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM
Remarks

VI. With Baffles, Large Propeller

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM
Remarks

VII. With Baffles, 2 Wings

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)

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Vortex Diameter (in)

RPM
Remarks

VIII. With Baffles, 4 Wings

Parameters A B C D
Volt Reading (V)
Actual Reading (V)
Maximum Current (A)
Minimum Current (A)
Vortex Height (in)
Vortex Diameter (in)
RPM
Remarks

ANALYSES AND CALCULATIONS

1. Calculate the power function,φ for every impeller speed of each impeller type used.
Calculate the impeller Reynolds number corresponding to each φ calculated.

2. For one type of impeller, plot θ versus NRe in a single log-log scale same for other
types of impellers.

3. Plot vortex depth versus distance from tank wall in the unbaffled tank system for
every impeller speed in each impeller used. Ordinary scale is used.

4. By graphical integration determine the vortex depth cross-sectional area for each
depth versus distance plot.

5. In a single graph, plot the vortex area versus NRe curve for each impeller type used.

GUIDE QUESTIONS

1. At NRe < 10,000, did the φ value approach a constant value for every impeller used?
If so, what are they (for baffled and unbaffled tanks)? What are the deviations from
the theoretical values?

2. For each φ versus NRe plot, what was the convergence point for the baffled and
unbaffled tank φ curves? What are the deviations from the theoretical values?

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