Mixers

Mixing is one of the important unit operation widely used from reaction to
finishing stages in chemical industry. A production (chemical) engineer has to
operate the running and modifications with the installed type for the particular
process or recommend one in case of plant erection or process design. The
selection or modification with these equipments is highly subject to the set of
properties of material being handled. Mixers are meant to shift the non-
homogeneity of a batch to a homogenous state. The degree of success in this
operation is never the hundred percent, since we can’t assume that a molecule A
will take the very next position to the molecule B and so on. Our auditing analysis
is therefore subject to spot sampling methods that take concentrations at
randomly selected locations in a sample in to consideration to estimate the
overall mixing efficiency of the entire batch.

Different mixers being employed follow three1 mixing phenomenon: the small-
scale random motion (diffusion), the large-scale random motion (convection) and
the interchange of particles by virtue of slip zones (shear). Mixers are employed
both for solids and liquids phases with varied interests. These include be but not
limited to blending of ingredients, cooling or heating purposes, drying or roasting
of solids, reaction engineering, coatings, agglomeration or even size reduction.
Confining our focus the mixing of solids, powders and particles, our selection is
subject to a set of properties2 which include: particle size distribution, bulk
density, true density, particle shape, surface characteristics, flow characteristics,
friability, state of agglomeration, moisture or liquid content of solids, density,
viscosity and surface tension, and temperature of ingredients. Referring our case
to the nature of solid particles, we have two classifications to cater for: non-
1
Perry’s Chemical Engineering Handbook, Solid-Solid Operations and Equipment, Section 19, pg. 12
2
Perry’s Chemical Engineering Handbook, Solid-Solid Operations and Equipment, Section 19, pg. 10
cohesive solids and cohesive solids. Further is the discussion over the types of
mixers for this classification.

For Non-Cohesive Solids

Mixers for non-sticky solids have a wide variety available for consideration. This may
range from free-flowing powders’ preferences to heavy pastes’ options. Mixing could be
carried3 out by agitation, tumbling, centrifugal action and impact forces. Following is a
brief about the options for discussed type of solids:

Internal Screw Mixer

It consists of a vertical vessel with a screw rotating to achieve the circulation of material
and secondly the elevation of material. This results in intermixing of solid grains as well
as shear action to the ones in contact with the screw or the walls of container. The feed
enters from bottom usually with aim to nullify the gravity factor which could escape the
molecules without desired mixing. Two vessel shapes are normally used for this
category, the cylindrical and the conical. On the basis of screw movement, it could
further be classified4.

3
McCabe Smith, Unit Operations of Chemical Engineering, Mechanical Separations, Vol 7, pg 979
4
Perry’s Chemical Engineering Handbook, Solid-Solid Operations and Equipment, Section 19, pg. 15
Type I: Conical shaped vessel, with a screw orbiting the centre of axis of the vertical
tank and also rotating around its own axis
Type II: Conical shaped vessel, with a screw fixed at the centre and rotating around its
own axis
Type III: Cylindrical vessel with a screw in centre and rotating around its own axis

Internal screw mixers are normally used for free-flowing grains and other light solids. In
type II, the conical tank is such tapered that with increase in height the area swept
increases.

Ribbon Mixer
Suitable for light and finely divided materials to fibrous sticky feed, ribbon mixer is
operated in both batch and continuous orders. It consists of a horizontal vessel with two
blades or ribbon in opposite directions with rotating at different speeds to intermix the
feed batch. The operation size5 could be as large as 34m3 for heavy ribbon mixers. The
size of ribbon widely affects the operational advantages. For example, broad ribbon can
be used for lifting or conveying purposes, while a narrow ribbon can cut the materials.
The type is further classified on construction parameters with differing features 6 of
ribbon cross section and pitch, clearances between outer ribbon and shell, and number
of spirals etc.

5
McCabe Smith, Unit Operations of Chemical Engineering, Mechanical Separations, Vol 7, pg 979
6
Perry’s Chemical Engineering Handbook, Solid-Solid Operations and Equipment, Section 19, pg. 12
Tumbling Mixers
Tumbling mixers include mixers in which the vessel rotates, mixing the feed to optimum
levels, similar to tumbling mill that aim for size reduction. The closed vessel rotating
about its axis can handle heavy solids and dense slurries through diffusion mixing. The
shapes could include5 and are not limited to V-mixer, double cone, rotating cube. The
equipment main include internal sprays for addition of liquids to facilitate the mixing
process. Baffles could also be installed in an attempt to reduce segregation.

The retention time in a tumbling mixer is fixed since initial blending is rapid followed by
gradual uniform mixing. Excess time may affect and even decrease the quality of mixing
levels.

For Cohesive Solids

Cohesive solids employ maximum consideration in terms of mixer selection and
operating parameters due to influence of rheology and forces of cohesion. The power
consumption for this type of mixers is high due to these factors. Mixing of sticky solids
however is supported7 by shearing, folding, stretching and compressing elements.

7
McCabe Smith, Unit Operations of Chemical Engineering, Mechanical Separations, Vol 7, pg 980
Muller Mixers
Suitable for heavy solids and pastes, muller mixer applies smearing, rubbing and
somewhat skidding action to achieve the desired mixing levels. Its working action is
similar to that of mortar and pestle. It has several types, three most common include:
Stationary-pan mixer, Rotating-pan mixer and Countercurrent-pan-muller mixer. The
roller wheels move in a circular chamber to ride over the material, producing shearing
action that causes size reduction as well as intermixing of material.

Change-can Mixer
Used for blending of viscous liquids & light pastes like food and paints, its most used
types are pony and beater mixer. In pony mixer, the can rotates to produce centrifugal
action to mix the materials, while in beater mixer, the agitator rotates to do the job. The
vertical shaft contains blades and paddles which are slightly twisted. When the mixing is
complete, agitator head is raised, lifting the blades out of can and the material can be
drained by tilting it.
Kneader Mixers
It is used to mix deformable or plastic solids by squashing the mass flat, folding it over
and squashing it once more7. It may tear the mass and shear it between the blades and
walls of mixer. The power requirements for this type of mixers are relatively high, esp. in
case of stiff materials. Examples (in order of power requirements) include: two-arm
kneader, disperser, masticator (intensive mixers), banbury mixer (internal mixers), and
continuous kneaders.

The two-arm kneader with minimum power requirements handles suspensions, pastes
and light plastic materials. A disperser with heavier construction body and more power
consumption is suitable for additives and coloring agents into stiff materials. Masticator
with maximum work capacity can work on scraping rubber and plastic materials. The
body is heavier than disperser and consumes more power.

In internal mixers, the chamber is sealed during the working time; making dispersions of
feed in liquid usually water. Example of such a type is Banbury mixer, a heavy-duty two
arm mixer in which the agitators are in form of interrupted spirals. The turning frequency
is 30 to 40 rpm. Kneaders work both in batch and continuous operation with equipment
parameters differing accordingly.
Paddle Mixers
These mixers are open air chambers with agitators scooping the materials and dropping
them again to those chambers, thus achieving the mixing levels via relocation of
material. The lifting action of blade is adjusted to the desired pace. This cross missing
configuration provides a homogenously mixed product. The use is effective even in
cases where bulk densities of component materials vary greatly. The design and bends
of the paddles are precisely made to ensure shear mixing in addition to convective one.