What Is a Tank Agitator Mixer?

A tank agitator mixer is an industrial machine used to mix various process media such as liquids, gases and solids. It is typically made up of a shaft with impellers and an electric motor which offers a range of power options depending on the duty required.

Agitation requirements are taken into account for each agitator design which influences impeller type, fluid properties, shaft size and rotational speed. Some of these include the liquid viscosity, tank size, and desired mixing intensity.

Homogenization

The homogenization process is one of the most important functions performed by tank agitators. It helps to combine liquid/liquid or liquid/solid substances that cannot be fully miscible with each other or are prone to separation into distinct phases of different viscosities. This is the most efficient way to achieve the desired degree of product homogeneity in the shortest possible time, with an optimal control of energy consumption.

To do this, the electric motor transmits energy to agitator shaft. tank agitator mixer This then drives the impeller’s axial movement that creates a flow in the liquid. Agitator impellers come in a variety of shapes and features, such as propellers, paddles and turbines. Different types of flow are produced by these various impellers, which help to achieve a number of mixing goals, such as blending, suspending or dispersing.

The rotary motion of the agitator also causes mechanical shear in the liquid, which breaks down fat globules. This reduces their diameter, which diminishes creaming during storage and improves the stability of the emulsion. Homogenization is an essential process in dairy production, for example, to protect the fat emulsion from gravity separation and prevent the formation of clumps during storage. For this purpose, a high shear mixer with a rotor-stator homogenizer is often used. Homogenization with the aid of US seems to have a better effect than conventional homogenization, but this is only true for higher US power levels (>180 W during 5 min to treat 250 mL of milk). It is recommended not to operate the agitator at speeds that approach its critical speed as this could lead to excessive vibration and potential damage.

Dispersion

The agitator’s function is to introduce flow and shear to a liquid or material, which causes it to homogenize. This occurs by rotating immersed impellers at a controlled speed, usually in the range of rotations per minute (RPM). The specific mixing requirements of a process are considered during its design, including desired flow pattern and intensity. The product’s viscosity, density, rheology, chemical properties, and other variables are also factored into the design to ensure proper fluid mixing.

Agitator design also takes into consideration the fluid’s sensitivity to shear. This impacts the type of impeller and rotational speed, as well as the material selection for the agitator shaft. Other factors include tank volume, agitator mounting configuration, and power requirements.

For example, the Canamix CHG4 high solidity, gassing impeller is designed to accommodate the specific needs of cyanide destruction, hydrogenation, and bioleaching processes, which require high levels of dispersing solids in contact with gas. The impeller is built with a pivoting blade propeller that remains folded while in transit to the installation site and expands upon motor activation.

The agitator is typically mounted on a support structure to provide stability and facilitate maintenance and cleaning. It may be top-, side-, or bottom-mounted, depending on the tank design and process requirements. It can be integrated with control and instrumentation systems for monitoring and regulating the agitation process.

Suspension

The agitator’s ability to generate turbulence and shear allows it to suspend insoluble solids within liquid. This process is known as emulsification, and it’s commonly used in chemical processing and water treatment applications.

To achieve this, the agitator’s impeller design must be tailored to the specific fluid and application. This involves a combination of engineering principles and fluid dynamics analysis to determine the optimal impeller shape and size. The support structure of the agitator should also be designed to ensure stability and proper alignment.

Depending on the tank geometry and process requirements, the agitator can be mounted on the side or bottom of the vessel. Using these configurations helps maximize mixing performance while minimizing agitator shaft exposure to the corrosive or abrasive fluid. The agitator’s motor provides the rotational force that drives the impeller. The motor can be powered by electric, hydraulic, or pneumatic power sources to accommodate the unique needs of each application.

The agitator’s shaft seal protects the agitator against leakage of the fluid being processed. There are several types of seals available, including mechanical seals and lip or packing seals. The type selected depends on the tank’s cleanliness and pressure, temperature, and other factors. Typically, seals are replaced every 2 months to reduce maintenance costs and ensure the safety of workers.

Heat exchange

The agitator’s ability to promote heat exchange between the product and its surroundings is an important aspect of its functionality, especially in industrial applications where precise temperature control is required. Tank agitators can tank agitator mixer supplier also help to maintain suspension in the product, keeping the solid particles from settling at the bottom of the container.

Industrial mixing tanks with agitator mixers work by creating turbulence in the container contents to achieve consistent blending and prevent abrasion or separation of solids from liquids. This agitation is achieved through rotating blades or impellers, which can be adjusted in shape and speed to meet process needs and achieve desired results. Baffles and deflectors can also be added to the mixing system to redirect blade motion or change direction of agitation, allowing operators to optimize mix conditions based on the product’s properties.

Agitator components need to be constructed of materials that are resistant to corrosion and other hazards posed by the liquid being processed. They should also be designed with a support structure that ensures stability, proper alignment and accessibility for maintenance and cleaning.

The power requirements of a tank agitator mixer are determined by the liquid’s properties, tank volume and desired mixing intensity. These factors influence the selection of the mixer’s motor size, gearbox design and type of impeller, ensuring sufficient power transfer is available for effective operation.