FLUID MIXING

ABSTRACT
The objectives of this experiment are; to observe the various flow patterns that can be
achieved by the use of different impellers i.e. flat paddle, turbine impeller and screw propeller,
with and without the use of baffle; to show how the power consumed by a mixer varies with
speed (increasing speed), type of impeller i.e. flat paddle, turbine impeller and screw propeller,
and with the inclusion of baffles. At the beginning of the experiment, approximately 0.3m of
water is poured into the container. The impeller was then attached and small quantities of plastic
pellets were added so that the flow pattern can be easily seen. The experiment was repeated with
other impeller and inclusion of baffles. As a result, the screw propeller, turbine propeller and flat
paddle form different flow patterns. During the exclusion of baffles, the flat paddle form the
highest vortex followed with turbine propeller and screw propeller. As for inclusion of baffles, no
vortex was observed. The experiment is proceed with the second aim which is power consumed
by the impellers with and without baffles. The fluid used in the second experiment is high
viscosity light oil. As for the result, the power consumed by flat paddle gives the highest reading,
followed by screw propeller and finally turbine propeller.

INTRODUCTION
Theoretically, matter in the liquid or gas state is considered a fluid. For the purposes of
fluid mixers, a fluid is defined as a liquid or mixture of liquids, which may contain modest
amounts of solid particles or gas bubbles. The presence of solids or gas must not alter the basic
capacity of the fluid to flow and be pumped about in the mixing vessel by a mixing impeller. A
liquid must always be present, either thin with a water-like viscosity or thick with relatively high
viscosity. The thickest liquid that can be handled with a fluid mixer will typically have viscosity
of less than 500,000 centipoise.
The simplest and most common fluid mixing application is simply to add liquid A to liquid
B, where the liquids are soluble in one another and blend them to uniformity. Application
requirements can include the time available to mix the liquids and the degree of uniformity to
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which they must be mixed. The second most common mixing application is the suspension of
solid particles in a liquid. This can be for the purpose of dissolving the solids, leaching out
valuable components in the solids, allowing the solids to participate in a chemical reaction with
the liquid or simply to keep the solids in suspension. The typical maximum concentration of
solids which can be effectively mixed with a fluid mixer is 70-75% solids by weight.
Other functions of fluid mixers include dispersion of a gas into a liquid, dispersion of
insoluble liquids into one another and heat transfer applications. Mixing impellers are designed
to pump fluid through the impeller and produce turbulence, both of these effects are essential to
mixing. They produce fluid velocity and fluid shear respectively. Fluid velocity produces
movement throughout the mixing vessel, intermixing material in one part of the tank with
another, prevents solids from settling out and produces flow over heating or cooling coils when
necessary. Fluid shear in the form of turbulent eddies is essential to micro-mixing within the
large velocity streams breaking up gas bubbles or immiscible liquids into small droplets.
All mixing impellers produce both fluid velocity and fluid shear but different types of
impellers produce different degrees of flow and turbulence either of which may be important,
depending on the objection. Mixing impellers fall into one the two categories; radial flow or
axial flow. Radial flow impellers have multiple flate blades mounted parallel to the axis of the
mixing shaft. The blades can be attached to a disc forming a close impeller or on a simple hub
making an open style impeller. Typical uses are gas/liquid dispersion, liquid/liquid dispersion,
flash mixing and loq level mixing applications. On the other hand, axial flow impellers have
blades which make an angle of less than 90 with the mixing shaft axis. These impellers are
further classified as constant angle of attack or variable angle of attack. As for the constant
angles of attack includes pitched blade turbines and the other includes propellers and hydrofoils.
Typical applications include simple blending, solids suspension and flocculation.
In this experiment, the Fluid Mixing Apparatus used is a model designed for experiments
involving solid-liquid mixing and also liquid-liquid mixing. However, for this experiment only
one type of liquid is used at a single time which is water; a liquid with low viscosity, and light
oil; a liquid with higher viscosity than that of water. Based on the Fluid Mixing Apparatus,
certain reading such as torque, angular speed and etc. can be obtained. Thus, power consumption
can be calculated.
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OBJECTIVES
The objectives of this experiment are; to observe the various flow patterns that can
be achieved by the use of different impellers i.e. flat paddle, turbine impeller and screw
propeller, with and without the use of baffle; to show how the power consumed by a mixer varies
with speed (increasing speed), type of impeller i.e. flat paddle, turbine impeller and screw
propeller, and with the inclusion of baffles.

THEORY
All impellers produce two results within the mixing chamber; circulation of fluid and fluid
shear. The power consumed by an impeller is related with Reynolds Number as shown in the
formula below:
Np=

P
3 5
N D

Where N is the speed in Hz and D is diameter of impeller. The pumping capacity of an

impeller is defined as the volumetric flow rate normal to the impeller discharge area. The
pumping capacity of an impeller is proportional to its diameter and speed. In this experiment, the
following formula is used:
P=T
Where T= torque required to drive the impeller or (balance reading x 9.81 (Newtons) x
torque arm radius (m)) and = angular speed in rad/s.

MATERIALS
I.
II.

Water
Light hydraulic oil

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APPARATUS
I.
II.
III.
IV.
V.
VI.

Fluid Mixing Apparatus

Flat-paddle impeller
Turbine impeller
Screw propeller
Baffles
Plastic pellets

EXPERIMENTAL PROCEDURE
(i)

Experiment 1
The tank was filled with water up to a depth of 0.3 m. A flat paddle was

then attached with base of bush level with the end of the shaft. Three to four
plastic pellets were dropped into the tank to observe the flow pattern during
the mixing process. Then the torque arm clamp was make sure to be fixed.
The speed of the impeller was turned on in small increments until the plastic
pellets are seen to swirl around in the water. The procedure was repeated
using other impellers i.e. flat paddle, turbine impeller and screw propeller. The height
of the vortex was observed. Later, baffles were added for each impeller. The
movement of the pellets were observed. All observations were recorded.

(ii)

Experiment 2
The tank was filled with light oil to a depth of 0.3 m. A flat paddle was

then attached with base of bush level with the end of the shaft. The speed
control knob was turned on in gradual increments and the reading on the
speed indicator was recorded. The procedure was repeated using other
impellers i.e. flat paddle, turbine impeller and screw propeller. All readings were

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recorded. The experiment proceeds with inclusion of baffles. All readings

were recorded.
RESULTS AND CALCULATION
(i)

Experiment 1
The height of the vortex varies with each impeller. The flat paddle form the

highest vortex around 0.07m high followed with turbine propeller 0.05m and screw propeller
0.04m. As for inclusion of baffles, no vortex was observed. However, the flow patterns formed
are shown in the appendix.

(ii)

Experiment 2
a) Baffles exclusion
Table 1 : Table for flat paddle without baffles

Torque meter
reading (N.m)
2.62
2.63
2.68
2.80
3.10

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

5.24
10.47
20.94
31.42
41.89

13.73
27.54
56.12
87.98
129.86

50
100
200
300
400

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(rad/s)

Force =
Torque
Radius (0.06 m)
43.67
43.83
44.67
46.67
51.67

Table 2 : Table for screw propeller without baffles

Torque meter
reading (N.m)
2.48
2.53
2.56
2.63
2.64

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

10.47
20.94
31.42
41.89
52.36

25.97
54.98
80.44
110.17
138.23

100
200
300
400
500

(rad/s)

Force =
Torque
Radius (0.06 m)
41.33
42.17
42.67
43.83
44.00

Table 3 : Table for turbine impeller without baffles

Torque meter
reading (N.m)
2.51
2.53
2.56
2.56
2.60

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

5.24
10.47
20.94
31.42
41.89

13.15
26.49
53.61
80.44
108.91

50
100
200
300
400

(rad/s)

Force =
Torque
Radius (0.06 m)
41.83
42.17
42.67
42.67
43.33

b) Baffles inclusion
Table 4 : Table for flat paddle with baffles

Torque meter
reading (N.m)
2.63

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

5.24

13.78

50

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(rad/s)

Force =
Torque
Radius (0.06 m)
43.83

2.66
2.78
3.16
3.56

100
200
300
400

10.47
20.94
31.42
41.89

27.85
58.21
99.29
149.13

44.33
46.33
52.67
59.33

Table 5 : Table for screw propeller with baffles

Torque meter
reading (N.m)
2.52
2.55
2.58
2.60
2.62

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

10.47
20.94
31.42
41.89
52.36

26.38
53.40
81.06
108.91
137.18

100
200
300
400
500

(rad/s)

Force =
Torque
R adius(0.06 m)
42.00
42.50
43.00
43.33
43.67

Table 6 : Table for turbine impeller with baffles

Torque meter
reading (N.m)
2.64
2.66
2.72
2.78
2.85

Frequency
reading
(rev/min)

Power (W) =

Frequency reading (rad/s) =

rev 2 rad 1 min
x
x
min 1 rev
60 s

Torque x Freq.

5.24
10.47
20.94
31.42
41.89

13.83
27.85
56.96
87.35
119.39

50
100
200
300
400

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(rad/s)

Force =
Torque
Radius (0.06 m)
44.00
44.33
45.33
46.33
47.50

Figure 1 : Graph of power against speed for flat paddle

160
140
120
100
Power (Watt)

80
exclude baffles
include baffles

60
40
20
0
5.24

10.47

20.94

31.42

41.89

Speed (rad/s)

Figure 2 : Graph of power against speed for screw propeller

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160
140
120
100
Power (Watt)

80
exclude baffles
include baffles

60
40
20
0
10.47

20.94

31.42

41.89

52.36

Speed (rad/s)

Figure 3 : Graph of power against speed for turbine impeller

140
120
100
80
Power (Watt)

exclude baffles
include baffles

60
40
20
0
5.24

10.47

20.94
Speed (rad/s)

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31.42

41.89

DISCUSSIONS
In this experiment, the objectives of this experiment are; to observe the
various flow patterns that can be achieved by the use of different impellers i.e. flat paddle,
turbine impeller and screw propeller, with and without the use of baffle; to show how the power
consumed by a mixer varies with speed (increasing speed), type of impeller i.e. flat paddle,
turbine impeller and screw propeller, and with the inclusion of baffles. The objectives were
successfully achieved while conducting the experiment. In the beginning of
the experiment, approximately 0.3m of water is poured into the container. The impeller was
then attached and small quantities of plastic pellets were added so that the flow pattern can be
easily seen. The experiment was repeated with other impeller and inclusion of baffles. As a
result, the screw propeller, turbine propeller and flat paddle form different flow patterns. The
patterns for each impeller were shown in appendix section. Please refer to the appendix. During
the exclusion of baffles, the flat paddle form the highest vortex approximately 0.07m high
followed with turbine propeller with 0.05m and screw propeller 0.04m.
As for inclusion of baffles, no vortex was observed. This proves that the baffles main
function is to control the fluid movement in the tank, controlling its pattern thus preventing the
formation of vortex. The experiment is proceed with the second aim which is power consumed
by the impellers with and without baffles. The fluid used in the second experiment is high
viscosity light oil. As for the result, the power consumed by flat paddle gives the highest reading
which is 129.86W and 149.13W for inclusion of baffles and exclusion of baffles respectively,
followed by screw propeller which is 138.23W and 137.18W for inclusion of baffles and
exclusion of baffles respectively and finally turbine propeller with 108.91W and 119.39W for
inclusion of baffles and exclusion of baffles respectively. As a comparison, three graphs
were plotted and it can be concluded that the power consumption is lesser
when baffles were excluded and vice versa when baffles were included.

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CONCLUSION AND RECOMMENDATIONS

The flow patterns for each impeller are different as well as the height of
the vortex when baffles was excluded. However, no vortex was seen when
baffles were included proven the function of the baffles itself which is to
control the fluid movement in the tank, controlling its pattern thus preventing the formation of
vortex.
When the baffles are included, screw propeller gives axial flow whereas flat-paddle and
turbine gives radial flow. Hence, shows that flat paddle and turbine impeller are fit for laminar
fluid mixing. Conversely, screw propeller does not show clear flow patterns, unless operated at
high speeds shows that it is not suitable for laminar mixing. Nonetheless it is more suitable for
turbulent mixing. As for industrial, most industries want to reduce the power consumed for a
green healthy life. Based on the power consumption calculated, turbine shows the lowest value
of power consumption. Therefore, increasing the demand of turbine impeller in industries.
There are some recommendations to avoid imprecise and inaccurate
results obtained. For example, when transferring the solutions, make sure
the solutions was transferred approximately 0.3m and the depth should have
been the same for all experiment to avoid inaccuracy of the torque reading.
Thus, there might be slight inaccuracy in the power consumption calculated.
Moreover, before running the experiment, make sure that the impeller is
attached tightly onto the shaft. This is to avoid the impeller from falling off from the shaft during
mixing, especially when the experiment is conducted at high speeds. Large errors in observations
and calculations can occur if the impeller falls off during mixing, due to the impeller not being
properly attached on the shaft.
Other than that, safety precaution should be taken seriously before entering the pilot plant.
For instance, lab coat with long sleeve as well as the safety cap should be worn before entering
the pilot plant and conduct the experiment. These are to avoids any unwanted accidents inside
the pilot plant.

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REFERENCES
i) Skoog, West, Holler & Crouch, Fundamentals of Analytical Chemistry, 8th Ed, Thomson
Brooks/Cole, 2004.
ii) Rajeev K. Thakur, Ch. Vial1, G. Djelveh & M. Labba, Mixing of Complex Fluids with
Flat-bladed Impellers: Effect of Impeller Geometry and Highly Shear-Thinning Behaviour,
http://utcan.ut.ac.ir/member/journal/labbafi/Mixing%20of%20complex%20fluids%20.pdf,
accessed on 20th March 2014.
iii) Liquid Mixing Equipment, http://www.solution.com.my/pdf/FM103(A4).pdf, accessed on
20th March 2014.
iv) Gabriel Ascanio, Robert Legros & Philippe A. Tanguy, A Fluid Mixing Laboratory for ChE

Undergraduate,

ChE

Division

of

ASEE,

Canada,

2003,

http://ufdcimages.uflib.ufl.edu/AA/00/00/03/83/00157/AA00000383_00157_00296.pdf,
accessed on 24th March 2014.

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