Sepro Mixing and Pumping are experts in designing custom mixing systems that fit a wide array of process requirements. Everything from agitator impeller design to tank geometry and everything in between gives us an infinite combination of factors to play with to create your optimal mixing system. However, we can only build your mixing system when your goals, restrictions, and process requirements are thoroughly understood. 

That’s why we’ve developed this quick mixing process guide. Use it as a reference to understand how we can build the ideal mixing system for you. If you have any questions about agitators, mixing systems, or agitator impeller design, be sure to contact Sepro Mixing and Pumping

1. Classify Your Mixing Process

There are nine fundamental ways to classify your mixing process. They are:

  • The blending of miscible liquids
  • Dispersion
  • Dissolving
  • Crystallization
  • Solids suspension
  • Heat transfer
  • Solvent extraction
  • Gas dispersion
  • Chemical reaction

Your mixing process heavily influences your mixing design. But it’s not the only thing that will affect the design of your mixing system!

Taking this a little further, think about the following:

  • Does the material need to be precipitated and/or settled out?
  • What degree of solid suspension is necessary, if any?
  • Is the final product, or any of the constituents, Newtonian or non-Newtonian?
  • What is the apparent viscosity at different shear rates?

2. Understanding Your Material Properties

Material properties play an essential role in tank and agitator impeller design. There is a significant difference between using an impeller for gas versus liquids, and if solids are involved. Further considerations:

  • Fluid properties: density, viscosity, temperature
  • Gas properties (if applicable): density, pressure, temperature
  • Solids properties (if applicable): size, shape, density, temperature
  • Relative proportion and total mass or volume of all material in the mixing system

3. How will material be introduced to the system?

The type of material, how it will enter the system, and where it will enter the system all play a significant role in designing your mixing system. With this in mind, consider the following:

  • Will additional materials (e.g. reagents, flocculants) be added as solids, powders or liquids?
  • Where are the constituents introduced in the process?
  • Do solids enter with the liquid as a slurry, or added to the liquid in the tank?
  • How is gas introduced into the tank? Is it injected through a pipe, sparge ring, or another device?
  • Does air or oxygen need to be drawn from the vapour phase? 
  • Does the tank need to be sealed from the atmosphere to prevent gas from entering or escaping? If so, what pressure is required?

4. How will the material exit the system?

Just as important as material entering the mixing system is how it will exit. This is especially important for mixing processes such as solvent extraction. Also, consider the following:

  • Will a single material stream or multiple material streams exit the tank? 
  • Does the outflow material exit as an overflow or bottom discharge?
  • Will the process be batch or continuous?

With the proper evaluation of all these factors, we can be sure to create your ideal mixing system to achieve the required result. If you’d like to learn more about mixing systems, agitator impeller design, or get started on building your optimal mixing system, contact Sepro Mixing and Pumping today.