MIXER POSITIONING

PRINCIPLES
Intranet Edition

1
 DEFINITION OF KEY WORDS
aerobic Process conditions with significant amount of free oxygen in the water
anoxic Process conditions without free oxygen; with bound oxygen, normally NO2/NO3, available
anaerobic Process conditions without oxygen
apparent viscosity Viscosity for Bingham plastic liquids at a certain shear rate
batch (tanks) Tanks that are 1) filled, 2) liquid processed, 3) emptied, in contrast to throughflow tanks
Bingham plastic Non-Newtonian behavior with a yield stress and a linear increasing stress with shear rate
blending Mixing of soluble liquids
bulk flow Total flow in a tank (any section, through the center of rotation, times the integrated velocity
gives the bulkflow, when divided by 2 - forward and recirculated flow)
clogging Build-up of (unwanted) solids on a propeller, the hub or any piece of equipment
consistency Usually, concentration by weight or d.s., dry solid content
degree of homogeneity The degree of homogeneity can be measured as solids in suspension at a certain level or as a
concentration (difference) as a function of time
destratifying Breaking layers of liquids with different densities, caused by differences in temperature, etc.
detention time Time for processing
dispersion Fine scale mixing or distribution of non-miscible phases, e.g. solid-liquid, gas-liquid.
E.g.: intensive mixing of water and cement or bentonite slurry
dynamic viscosity Internal friction in a (Newtonian) fluid, defined as the ratio of shear stress to shear rate.
Kinematic viscosity times the density [Pa s]
efficiency Hydraulic efficiencies; ratio between mass flow times pressure produced and the power consump
ejector A construction which uses a high velocity jet to eject a secondary phase, e.g. water, gas or
solids. (A momentum-based technology)
emulsion Intensive mixing of non-soluble liquids, e.g. water and oil
erosion Transportation of material from a surface by a shearing flow(here, normally particles from a
bottom layer). Cf. abrasion (mechanical destruction) and corrosion (chemical destruction).
floating (scum) Here, unwanted layer which can build up on the surface in a waste water treatment process,
usually taken away by use of chemicals, surface drawoff, water spray, or which can be broken
down by a mixer jet
Flymitec Submersible jet mixing concept, unique to ITT Flygt
Froude number Dimensionless number, telling the relative importance of inertial (> 1) and gravity (< 1) forces.
get complete mixing One of the four major mixing requirements to fulfill (a certain degree of) homogeneity
guide bar system Metal frame to which the mixer is attached and which can be used as a hoist
homogenizing Here, mixing the fluid to reduce differences in concentration
inertial force The force it would take to stop a moving body or fluid.
inflow The flow into a tank
ITT Flygt One of the three largest mixing companies
jet A flow beam that, during expansion (in water), entrains a secondary liquid
jet ring Ring around the propeller that improves efficiency for creating a jet
kinematic viscosity Dynamic viscosity divided by density
kinetic energy The energy associated with the motion of a body or fluid, half mass times velocity squared
laminar (flow) Liquid elements moving in straight lines without being mixed; occurs at low Reynolds number
large scale mixing Mixing of the whole, or major part of, the tank volume
losses Here, usually friction or point losses, expressed as a force (N)
MiDS ITT Flygt unique mixer design program
mixer Machine that mixes liquids (or solids, or gases); a submersible m. contains a propeller driven
by a submersible electrical motor
mixer performance The mixer performances can be measured in Newtons and power consumption. Flow is usually
calculated.
mixing performance The result from the mixer such as bottom free from sediment, a homogeneous liquid
mixing time Time for the mixer to mix the liquid to a certain degree of homogenization
momentum One of the basic dynamic quantities: mass flow, momentum and kinetic energy
NPSH Net positive suction head, (absolute) pressure limit for cavitation
off-bottom Defines degree of suspension, no particle stays for more than 1-2 seconds, but without demand

2
 on particle distribution
prevent separation One of the four major mixing requirements to fulfill (a certain degree of) homogeneity,
significant in mixtures with several components with different densities, suspensions with
solids, stratification, etc.
prevent short-circuits One of the four major mixing requirements to fulfill (a certain degree of) homogeneity,
significant in throughflow tanks
plug flow A flow that moves like a plug, without axial mixing, from inlet to outlet
power uptake (Electrical) power consumption
racetracks Closed, long ditch with center dividing wall around which the liquid circulates
rain water Brings sand, waste, leaves. Usually combined with sewer but sometimes in separate, duplicate,
systems.
retention basin Buffer tank to equalize peak flow
residence number Describes how close to a true plug flow the throughflow is
resuspend sediments One of the four major mixing requirements to fulfill (a certain degree of) homogeneity, lift
particles from tank bottom after they have settled
retention time Average time the liquid stays in the tank
Reynolds number Dimensionless number; velocity times length scale/viscosity, kinematic. Tells the relative
importance of inertia to viscosity, and determines flow regime: turbulent or laminar flow
tracer Can be Lithium, used to detect the characteristics of the mixing in a tank
turbulence The liquid elements are intertwining, crossing in a disorderly manner. Inertial forces are
greater than viscous forces
thrust Force produced on the fluid while it is flowing through the propeller and which affects the
flow of the bulk volume
Sanitaire Excellent US company producing bottom diffusers for aeration in STP
scour The effect of erosion
seal, mechanical Here, a face seal: two rings which are pressed together, one static and one rotating
separation See prevent separation
serpentine Racetrack with four or more straight legs
settling velocity Particle settling velocity is affected by density, viscosity, particle size and number of particles
shaft power The power delivered from the motor to the propeller
Shield Researcher who made early, now classic, basic investigations into particle erosion
shear rate Velocity gradient (dv/dy, [m/s/m = 1/s])
shear stress Friction between layers. Here, also friction between liquid and bottom layer
short circuiting The fluid flows directly from inlet to outlet
slurry Here, non-organic mixture of solids and liquid, e.g. lime and water
specific gravity SG; defined as density divided by 1000
stratification Layers of liquids caused by density differences, temperature, type of liquid, etc.
STP Sewage treatment plant
submergence Distance between propeller tip and surface
suspension Mixture of particles and liquid
throughflow Continuous flow through a tank
viscosity The resistance to movement between one layer of fluid and an adjacent layer, see dynamic
viscosity.
vortex The formation of air suction vortices from the surface (depends on dynamic head of
approaching surface flow in relation to sink head due to pumping)
vortex protection shield A plate installed above the propeller that allows a mixer to be used at low submergence
WWTP Waste water treatment plant
yield stress The stress a liquid/gel can withstand without deformation or floating

3
 INTRODUCTION
The brochure is intended to be used as a handbook for designing mixer installations. Text
in italics refers to additional reading.

To achieve effective and efficient mixing, equipment must be installed and procedures must be followed in accordance with
established practices. One of the most important decisions for a particular installation is the correct placement of the
mixer(s) within the container of the liquid(s) to be mixed. Special characteristics of some systems are highly viscous liquids,
suspensions and unusual configurations. These can affect key factors such as power, required spacing, clearance and the
number of mixers. Failure to create proper conditions for mixing can waste energy, lead to unsatisfactory performance and
increase costs.

Flymitec
New mixing possibilities were opened up when ITT Flygt introduced the submersible mixer. It meant considerable
savings in energy consumption over traditional mixing methods.

In many mixing applications, a good mixing result depends on creating a sufficiently strong bulk flow in the tank. This
means putting the tanks entire content in motion, so that all parts of the tank are efficiently mixed.
The submersible mixer allows complete freedom in positioning in all kinds of tanks, creating a bulk flow with minimum
consumption of energy. FLYMITEC is the name used to describe the positioning principles and mixer sizing
calculations we use to achieve this mixing efficiency.

Together with ITT Flygts proven mixer range, FLYMITEC provides the solutions that our customers seek: optimum
mixing result and minimized energy consumption.

AutoMix
AutoMix is a drawing tool based on Auto Cad for positioning ITT Flygt mixers used by ITT Flygt sales companies. The
program considers tank shape and type of mixer and suggests a location for the mixer(s) according to the guidelines here.

4
 Mixing objective
The installation must fulfill the following objectives:
Perform the required mixing (the primary task);
Perform the task efficiently (high mixer performance), be cost-effective;
Operate smoothly so as to ensure long life of the equipment and efficient operation.
The attainment of these objectives depends essentially on the location and orientation of the mixers within the containers of
the liquid to be mixed.

Mixing requirements
The most common mixing requirement is (a degree) of homogenizing. Homogenizing
can be: time dependent as in mixing up a volume (batch mixing) or vary with depth
such as fluids that separate, e.g. solids suspensions, or as in throughflow tanks, mixing
in of flows and stopping short-circuits, where the homogeneity varies with the distance
between inlet and outlet. In all these cases, the strength of the bulk flow governs the
level of homogenization. To fulfill the homogenization requirement the following
mixing requirements must be fulfilled:
Get complete mixing; All components and/or all inflows must be mixed together. In
the brochure, blending, in particular, is referred to in this item, get complete mixing.
Stop short-circuits; The throughflow should not pass directly from inlet to outlet
without being mixed throughout the volume.
Prevent separation; Mixture with components with different densities can separate if
not mixed. In the brochure, solids suspensions, in particular, are referred to in this
item, prevent separation. Another type of separation is liquids with different
temperatures.
Resuspend sediments; A common customer requirement is to keep the tank bottom
clean, in other words, erode old sediments or constantly prevent any particles from
settling at the bottom.

5
 GENERAL GUIDELINES
To utilize mixing power optimally, the over-all flow in the tank, the bulk flow, should be maximized. This ensures an even
distribution of the velocities and consequently the shear stresses. The shear stress is the governing parameter for avoiding
settled matters, and the velocity the governing parameter to keep particles, organic matters etc., suspended.

The shear stress at the bottom and the wall balances the thrust from the
mixer(s). In a circular tank the situation can be calculated by using a
torque model over the hydraulic situation.
A
F a = dA b
mixer
0
Fmixer is the mixer thrust
a is the perpendicular distance: momentum source - tank center
b is the distance from the tank center to each area element
is the local shear stress in each area element
A is the total wetted area

Experience has shown that the optimal velocity

profile is obtained when the jet is directed at 1/2
radius, 1/4 tank diameter, as in the diagram above.
The same principle can be used in rectangular
tanks; direct the mixer towards 1/4 of the width at
the centerline.

As the jet expands, flow entrains into the

jet and the bulk flow increases. To utilize
the jet source optimally and achieve
maximum flow, the jet should be directed
over a long path so that the general bulk
flow follows the shape of the tank and the
flow pattern forms an unbroken loop.
After 10-20 loops all liquid elements will
have passed through the intensive mixing
zone close to the jet source and the whole
volume will be homogenized and the large
scale mixing will be complete.

6
It is generally worthwhile remembering that the jet needs to entrain surrounding liquid to maximize the flow. Entrained
liquid must be fed from around the jet despite the fact that boundaries restrict entrainment.

When multiple units are used it is advantageous to locate them together. Some clearance
between the mixers and walls is necessary to prevent the mixers interfering with each other.

Clockwise rotation of the bulkflow is recommended.

Depending on the rotation of the propeller, the jet
heads towards the surface if the jet is directed in the
tank for clockwise bulk flow rotation. This decreases
friction (head) losses towards the bottom.
As the jet heads towards the surface, it creates top-
to-bottom mixing. An exception is when resuspending
sediments in deep tanks; with an anti-clockwise
rotation the jet heads towards the bottom, which in
this case is where the mixing should be concentrated.

Positioning the mixers together creates a pressure at

the other side of the tank, diagonally, which creates a
top-to-bottom mixing necessary also in shallow
tanks. The return flow will be uniform, which is
important for solving the mixing tasks, e.g. resuspend
(prevent) sediments, in the whole tank.

For best mixer performance, any disturbances

to the flow just upstream or just downstream of the propeller should be kept to a minimum so that the jet transports the
liquid effectively. Unbalanced forces could be caused by obstruction etc. and might cause unbalanced loads on the propeller
and vibrations affecting the life length of the mixer and installation.

To ensure the mixer performance, the flow should approach the propeller uniformly in all inflow directions without
significant interference from structural elements or the walls of the tank. The speed of the approach flow should be much
lower than the velocity through the impeller. The mixer should be sufficiently submerged to suppress vortices.

Large diameter mixers should normally be positioned close to the bottom to ensure sufficient
bottom shear stress. Exceptions occur for deep tanks, stratified liquids, floating scum, etc.

7
 RECTANGULAR TANKS
The following are recommendations for positioning mixers to fulfill the mixing
requirements; complete mixing, prevent separation and resuspend sediments, in other words
homogenize the volume.
Other mixing requirements can be to break up scum or stratification, which are described in
the Special applications chapter.
Guidelines for inlet / outlet considerations can be found in the Considerations in
throughflow tanks chapter.
In all cases where large tanks and/or large number of mixers are involved, please consult
with an ITT Flygt application engineer.
Minimum clearances to tank walls, surface, bottom and other mixers should always be
checked.

To maximize the bulk flow in the whole tank, which is the aim of
correct positioning for homogenizing, suspensions, blending, mixing
in flows, mix-up the volume etc., the mixer should be directed towards
1/4 of the width through the center line of the tank.
With two mixers in shallow tanks, the outer mixer should be directed
towards 1/8 and the inner mixer at 3/8 of the width at the
perpendicular center line. This will spread the two jets over equal
wetted (bottom) areas and the total momentum over a 1/4 of the area,
which ensures an even velocity over the whole bottom, hence optimal
mixing.

To ensure the performance of the mixer, there must be a certain inflow to the propeller and the jet, and enough clearance to
the rear- and side walls. This is especially important in a large tank where large flows are involved at relatively small
depths (no entrainment of flow into the jet from surface or bottom). There must be a clearance behind the mixer(s) to ensure
entrainment to the jet on both the inner and outer side of the jet.

The weakest mixing is in the corners. By positioning the mixer(s) in one corner the risk of sedimentation and zones with low
mixing is minimized.

The minimum number of units is a very important consideration. The jet from the mixer
expands at an angle of approximately 1:2.5. To ensure circulation back to the jet source,
propeller, space for the return flow must be available. The maximum length one mixer can
mix is therefore 2.5 times the width or depth.

Shallow tanks
These recommendations are valid for tanks where the depth is much smaller than the length.

To avoid high local losses just downstream of the propeller, a clearance between the
propeller and the bottom is recommended. The compact mixer should be installed with a
clearance of 1-2 propeller diameters, tank bottom to propeller tip. Two propeller diameters
clearance when the tank depth is approximatley the same as the tank radius and one propeller
diameter when the tank is very shallow. Large diameter mixer should be positioned with a
clearance of 0.3-0.6 m (1-2 feet).

8
 In very shallow tanks there must be space between the rear wall to ensure the inflow to the
propellers. See Minimum clearances. Note that the inner mixer must have a larger space as
there must be an inflow area behind it for both mixers.

For very shallow tanks, such as retention basins, the mixer should be located in the center to ensure entrainment from both
sides into the jet. This will keep particles suspended but the homogeneity of the liquid will be decreased as there is little
exchange or mixing, between the two sides of the tank.

One unit
The mixer is positioned in the corner and
directed towards 1/4 of the width with clockwise
rotation.

The minimum clearance to the rear wall must be

checked to avoid choking the propeller.

Two units
The outer mixer should be directed towards 1/8 and the inner mixer at 3/8 of the width at the
perpendicular center line with clockwise bulk flow rotation. See the drawing in the
introduction to this chapter.
The minimum clearance to the rear wall must be checked to avoid choking the propeller,
especially the inner mixer as flow to both the inner and outer mixer has to pass behind the
inner mixer.

Deep tanks
Recommendations valid for tanks where the depth is greater than the length.

The (upper) mixer should be positioned as close

to the surface as the minimum submergence
allows to get a long path for the jet.

The mixer(s) should work in an anti-clockwise

direction (viewed from above) which increases
the top-to-bottom mixing due to the rotation of
the jet.

9
 To prevent separation and solids suspension, at least one (compact)
mixer should produce a vertical flow for top-to-bottom mixing.
When resuspending sediments is the critical requirement, a mixer
should be positioned at the bottom.

When several mixers are

used they should be
positioned to work
together in the same
loop.

Blending in deep tanks

For complete mixing of different miscible components where no solids are present, the mixer
can be positioned at the bottom to minimize the risk of vortices.

The inflow is preferably added close to the propeller on the pressure side for instant
mixing.

Long tanks
For complete mixing, resuspending sediments,
preventing separation and stopping short-circuits
between inlets and outlets, a number of serial mixers
are needed (the maximum length one mixer can mix
is 2.5 times the greater value of width or depth).
These multiple mixers should be installed in series,
so as to work in the same loop.

The jet from the mixer expands at an angle of

approximately 1:2.5. To ensure circulation back to
the jet source, space for the return flow must be
available. The maximum length one mixer can
mix is therefore 2.5 times the width or depth.

To resuspend sediments, the mixers should be

directed along or towards the bottom.

To ensure sufficient space for the return flow, the propeller

diameter(s) should not be more than 1/3 of either the width or
depth (whichever is greater).

10
 Other solutions
Often the mixing situation is such that is not possible to locate the mixer exactly as in theory. Other positions can also
fulfill mixing requirements. Following are some arguments for different locations of two mixers in a rectangular tank.

Case 1. The standard installation. This positioning is advantageous from a homogenizing point of view, the bulkflow is
maximized, especially in deep and large tanks. Positioning the mixers together creates a pressure at the other side of the
tank, which creates top-to-bottom mixing also necessary in shallow tanks. This positioning creates an even return flow
which distributes the bottom shear stresses evenly hence minimizing the friction losses. Please note that in shallow tanks, the
inner mixer must have a clearance to the rear wall to ensure inflow to both mixers.
Case 2. This positioning is a good alternative to case 1 in shallow tanks. At small liquid levels the inner mixer must have a
significant clearance to the rear wall to ensure inflow and entrainment to both mixer jets. With this positioning a well
defined loop is created,, both vertically and horizontally, which ensures that all parts of the tank are well mixed. With a
small jet - tank wall angle, the jet attaches to the wall and reaches further than 2.5 times the greater of width or depth,
which can be utilized in long tanks to minimize the number of units. This is also a good solution in batch tanks when the
mixers operate during emptying. Two intensive mixing zones are also advantageous from a mix-up point of view; a
homogenous volume can be achieved faster than in case 1.
Case 3 is a good solution for bottom erosion, resuspend sediments, especially in deep tank to concentrate the bulkflow loop
at the bottom. The mixers in the corners will keep the corners sediment-free and the high intensities in the jets are utilized
for bottom shear stress. Also an alternative to the standard installation, case 1, though the risk for sediments along the
center line increase.
Case 4 is a position for a (long) tank with throughflow where a plugflow is required for the process. With this positioning a
virtual wall is created, very little longitudinal mixing which is advantageous in some processes. The tank is divided in two
parts with little mixing in between, only on the mixers (weak) suction side. The usual mixing requirement of the mixers is to
prevent sedimentation, resuspend sediments.
Case 5 is a good solution to create a good inflow and smooth running, although an expensive installation, as a bridge has to
be built.

11
 CIRCULAR TANKS
Recommendations for positioning mixers to fulfill the mixing requirements; complete
mixing, prevent separation and resuspend sediments, in other words homogenize the volume.
Other mixing requirements can be to break scum or stratification, which are described in the
Special applications chapter.
Guidelines for inlet / outlet considerations can be found in the Considerations in
throughflow chapter.
In all cases where large tanks and/or large number of mixers are involved, please consult
with an ITT Flygt application engineer.
Minimum clearances to tank walls, surface, bottom and other mixers should always be
checked.

To achieve the highest possible degree of homogeneity which is essential to achieve

the mixing requirements of complete mixing, to prevent separation and resuspend
sediments, the bulk flow in the tank should be maximized. By directing the jet
towards half the radius, 30 off-center, friction (head) losses are minimized and an
even shear stress over the bottom is obtained. With two units, the mixers should be
located together and angled at 1/3 and 2/3 of the radius respectively (perpendicular
to the jets), which is approximately 20 and 40 from the radius. This will distribute
the mixing capacity evenly over the wetted area (except the wall).
Losses at the bottom are positive, but losses at the wall are wasted from the
resuspending point of view.

In large tanks, when large flows and relatively shallow depths are involved (no entrainment into the jet from above or
below), the mixer should be located further out in the tank to ensure sufficient inflow into the jet as well as on the outer side
of the jet. To avoid high local losses in front of the propeller, a clearance between the propeller and the bottom is
recommended.

Shallow tanks
In tanks where the depth is smaller than the tank radius, the mixer should be positioned for
clockwise bulk flow rotation (viewed from above).
A minimum clearance between the propeller tip and the bottom is recommended to avoid
high local losses. The mixer should be installed with a clearance of 1-2 propeller diameters,
tank bottom to propeller tip. Two propeller diameters clearance when the tank depth is
approximately the same as half the tank length, and one propeller diameter when the tank is
very shallow. Large diameter mixers should be positioned with a clearance of 0.3-0.6 m (1-2
feet).

In very shallow tanks there must be a space between to the rear wall to ensure the inflow to
the propeller. See Minimum clearances.

12
 One unit
Direct the jet towards the midpoint of the radius, 30 off-center, and with clockwise bulk
flow rotation. See the drawing in the introduction to this chapter.

Two units
The mixers should be located together and
angled at 20 and 40 from the radius with
clockwise bulk flow rotation. The minimum
clearances to the wall and spacing between
the mixers must be considered to ensure
enough inflow to the propellers,
seeMinimum clearance chapter.

13
Semi-deep tanks with two units
When the depth is greater than the tank
radius but smaller than the tank diameter,
the mixers should be positioned as in the
diagram to create one single loop, which is
essential to maximize the bulk flow in the
tank.
With the mixers located diagonally but on different levels,
the mixers will try and create one bulk flow loop at the
bottom and another diagonal top-bottom loop. These two
loops will interfere, thus decreasing the bulk flow.
If the mixers are located on the same guide bar, but on
different levels, the same situation occurs and two bulk flow
loops are created. At the propeller inflow areas, in this case
with the guide bar located where it is, the flows are
competing, thus lowering the efficiency of the mixing
system.

14
 Deep tanks
Recommendations valid for tanks where the depth is greater than the tank radius (mixing
with two units, see alsoSemi-deep tanks .... above).

The mixer(s) should work in an anti-clockwise direction

(viewed from above) which increases the top-bottom mixing
due to the rotation of the jet. The (upper) should be positioned
as close to the surface as the required submergence permits for
a long jet path.

To prevent separation and solids suspension, at least one

(compact) mixer should produce a vertical flow for a top-to-
bottom mixing. To create maximum bulk flow, the mixer should
be angled vertically towards 1/4 the diameter at half depth.

When resuspending sediments is the critical

requirement, a lower mixer should be
positioned below.

Blending in deep tanks

For complete mixing of different miscible components where no solids are present, the mixer
can be positioned at the bottom to minimize the risk of vortices.

The inflow is preferably added close to the propeller on the pressure side for instant
mixing.

15
 RACETRACKS
Recommendations for positioning mixers to fulfill the mixing requirements; complete
mixing, prevent separation and resuspend sediments, in other words homogenize the volume.
Usually the mixers are located on a bridge in the middle of the racetrack. Note the minimum
clearances in the diagram.

The main objective with the mixer

is to create as strong a bulk flow
as possible. To utilize the
momentum source optimally, the
mixer should be positioned to
maintain good propeller
performance and to minimize the
total losses in the racetrack.

To achieve a good mixer

performance, the attacking flow,
the incoming flow to the propeller,
should be uniform. After the
upstream blend, the outgoing flow needs a distance over which to develop a uniform velocity over the cross section. Hence
the mixer(s) should not be located close to the upstream bend. The propeller jet also needs a distance over which to develop
before it enters the downstream bend so as to minimize the losses. Taking these into consideration, the mixers should
preferably be installed half way along the length of the racetrack. If the minimum clearances up- and downstream cannot be
fulfilled, it is better to maintain the minimum clearance at the upstream bend (behind the mixer).

The liquid will be homogenized better if the mixers are installed in series, on different bridges, as there will be several
intensive mixing zones where the flow is mixed over the whole cross section. This is especially important if the inlet and
outlet are both located at the outer wall. Otherwise there is a risk that the flow attaches to the wall and flows directly from
outlet to inlet, taking shortcuts. Incoming flow should be mixed instantly to start the process in the liquid immediately.

If a plugflow is needed and the mixing objective is to prevent sedimentation, the mixers can advantageously be installed in
parallel, on the same bridge. This is especially good if inlet and outlet are located at outer and inner walls. The flow will be
mixed over half the width only once every circulation, and it will take a flow element several circulations before it passes
from inlet to outlet, thus maximizing retention time. Parallel installation is the most common and economical solution.

Large diameter mixers, 4410/30, should be installed near the bottom to ensure bottom scour,
approximately 0.5 m (2 feet) clearance. In deep tanks the mixers can be positioned closer to
the mid-depth to reduce the zone above the mixer with recirculating flow (this zone is not
used in the process).

16
 RING CHANNELS
Recommendations for positioning mixers to fulfill the mixing requirements; complete
mixing, prevent separation and resuspend sediments, in other words homogenize the volume.
To resuspend sediments and keep the particles in suspension, a position as in the diagram is
recommended.

The special positioning objectives in ring channels are normally to distribute capacity evenly over the width and to avoid
wave actions around the channel. An inward angle is recommended, otherwise a concentrating of the jets towards the outer
wall will cause a big difference in velocity between inner and outer walls, where sediment can occur at the inner wall.
However, the jet should not hit the inner wall as this causes high local (friction) losses.

17
LARGE WIDE TANKS, LAGOONS
The mixers are advantageously located
together with enough spacing to ensure
entrainment of flow on both sides of the
jets. See also the recommended minimum
clearances.
In large and relatively shallow tanks, the mixers must be
positioned so as to achieve an even distribution of the
flow, and local high velocities, which are as small as
possible, throughout the tank. This positioning will also
prevent the flow from circulating in lanes without being
homogenized (over the width).
In all tanks there will be a rotational center where there
is very little movement and thus a risk of sedimentation.
Turning one mixer off changes the momentum (and the
velocity profiles) in the tank. The rotational center is
moved and earlier deposits resuspended. By running
one, or several, mixers intermittently, no deposits will
pile up and form a hard sediment.

To achieve the largest possible bulk flow and highest

homogeneity, the mixer(s) should be positioned so
the total added momentum of thrust, from the
mixer(s) is located at the radius midpoint. The
mixers should have a small angle, see the diagram,
so that the direction of the jet is changed smoothly
when it hits the wall.
With two mixers, one is positioned at 0.25 R and the
other at 0.75 R and the total momentum from them
will be at 0.5 R. Positioning the inner mixer at 0.25
will take care of resuspending sediments in the
center of the tank, the poorest mixing zone.

18
 CONSIDERATIONS IN THROUGHFLOW
TANKS
Complete mixing of (in)flows in general
In throughflow tanks (with a process including reactions), the mixers must be positioned so
that the incoming liquids are mixed quickly and to prevent short circuiting between inlet and
outlet. There should also be an all-over bulk flow to avoid inactive parts of the tank.
When different inflows are being mixed-in, as in denitrification zones, position the mixers:
for a circulation that creates the longest flow from inlet to outlet to achieve the longest
retention time.
to cut off the shortest distance between inlet and outlet.
for immediate mixing with the mixer jet close to the inlet (avoid the inflow being directly
aimed at the mixer which disturbs the propeller), to create an instant process start in the
liquid. In addition to a primary horizontal flow, a secondary spiral flow pattern reduces the
risk of short circuiting.

If the flow attaches to a wall and goes directly from outlet to inlet without being mixed
(shortcuts) the tank volume is not utilized efficiently, causing a low process result.
To avoid this, the inlet and outlet should be separated:
Horizontally
Vertically
At boundaries
See also Systems Engineering brochure "Anoxic Zones ....".

Positioning for plug flow conditions

When there is a detention time (or retention or mixing time) requirement it is often advantageous to mix the liquid instantly
at the inlet(s) and aim for a plugflow through the rest of the tank. The purpose of the mixers in these cases is usually to
prevent sedimentation and maintain contact between reactants. By locating the mixers for individual loops with several
separate mixing zones, a higher residence number is created. The residence number describes how close to a true plugflow
the hydraulic conditions are. Higher residence numbers can be achieved with higher numbers of mixing chambers.

Significant throughflow, > 0.05 m/s

Blending
When there is a requirement for complete instant mixing of different liquid components, for example additive blending, and
if the throughflow creates a significant velocity (>0.05 m/s, 0.15 ft/s) the mixer(s) should work in the same direction as the
flow. The different components will then be mixed in the intensive part of the jet, just downstream of the propeller. As the
throughflow passes through this intensive mixing zone around the propeller it will be well mixed over the cross section, but
there will be a poorly mixed zone beside the mixer where sedimentation can occur.

Resuspending sediments, keeping particles in off-bottom

suspension
To avoid sediments in long tanks with high throughflow (> 0.05 m/s, 0.15 ft/s) it is advantageous to have the mixers working
in the opposite direction to the throughflow. The jet from the mixer will push the throughflow around the mixer, which
increases the velocity.

19
 SPECIAL APPLICATIONS
Breaking crust or destratification. Direct the jet towards the most demanding part of the
tank, the surface.

In circulating channels, the mixers should be installed in

the narrowest section.

Mixers working along and close to walls should be placed at an angle of 10 with the wall for best mixing performance, e.g.
to avoid high losses along the wall. Wall shear stress does not give efficient mixing. When there is a need to extend the reach
of the jet (normally L > 2.5 W), the mixer should be directed parallel to the wall. The jet then attaches to the wall and the
mixing distance is increased.

If the medium being mixed is highly viscous, the body of the mixer and the accessories for its installation (guide bar system)
can significantly hinder the bulk rotation. Hence, fixed installations are preferred as they require no guide bars that could
interfere with the flow. Obstacles such as pipes can cause stagnant areas to occur, especially on the suction side. In more
viscous media, the propellers should be placed so that they push the mixture throughout the tank with ahy obstacles on the
pressure side.

When diluting in paper pulp applications, the water should be added upstream of (behind) the mixer to prevent a cavity
forming.

EFFECTS OF LIQUID CHARACTERISTICS

The capacity of the mixer must be sufficient to produce the desired flow and level of turbulence. Large diameter mixers
give lower intensities than compact mixers, and might not produce the required turbulence level in highly viscous media or
for suspension solids (slurry mixing). Therefore, as the viscosity of the liquid is significantly greater than that of water, the
capacity of the mixer must be greater.

High viscosity affects the flow in various ways. It increases the resistance to flow, reduces the production of turbulence
and causes the jet to expand radial at a greater angle. It is therefore often beneficial to use a prolonged jetring.

For all of the reasons described above, more power is required to mix highly viscous liquids. Normally the increase is less
than 15 %. If the liquid is denser than water (a specific gravity greater than 1), the input- and output power increase in
direct proportion.

Some viscous liquids can cause deposits to form on the propeller. Mixer performance can be adversely affected by
stickiness, fiber formation and large shear stresses in various ways and propeller vibration may be one result.

Other types of liquids are non-homogenous in that they contain solid particles, lumps, agglomerates, etc. These can cause
uneven loading on the propeller and can also lead to vibrations.

20
 MINIMUM CLEARANCES
This chapter is divided into General recommendations for compact mixers and large
diameter mixers, Recommendations for compact mixers and Recommendations for large
diameter mixers.

General recommendations for compact mixers and large

diameter mixers
These recommendations refer to circular tanks, rectangular tanks and racetracks. The
minimum recommended clearances upstream or clearances to the rear wall, in shallow tanks
are given here as Minimum rear wall clearances in shallow tanks.

Maximum mixing length

The jet from the mixer expands at an angle of 1:5. Before
the jet reaches the wall it has to turn back to ensure the
return flow. The maximum length one mixer can mix is
therefore 2.5 times the largest of width or depth.
Therefore multiple serial units must be used in narrow and shallow tanks.

Aeration equipment:
The distance to aeration equipment from the mixer should be at least
L > 1.5( + h )
upstream: min
propeller diameter, h propeller - bottom clearance

downstream:

circular tanks: Lmin > R/2 where R is the tank radius

racetracks and
annular tanks,
W
the greater L > N number of mixers
min N
value of:
L >H W lane width, H tank depth
min

21
rectangular tanks
the greater value of:
W
L > N number of mixers
min 2N
L >H W tank width, H tank depth
min

These recommendations for clearances in aeration tanks assume air bubbles rise with a
velocity of approximately 0.2 m/s (0.7 ft/s) and an attacking water velocity of approximately
0.3 m/s (1 ft/s).

Max propeller diameter in aerated tanks

Because of the risk of loads fluctuating on the propeller in conjunction with aeration, the
maximum recommended propeller diameter is 2.2 meters (7.3 ft), if the mixer is located
closer than 3 propeller diameters to the aeration equipment.

Racetracks
For best mixing performances the recommended clearances and spacings in the diagram
should be complied with. See also Minimum clearance for distance between propeller and
bottom.

22
 Minimum rear wall clearance in shallow tanks

There must be a certain area behind the mixer to ensure

the inflow to the propeller and to feed the jet on the
outside. To ensure this, the clearance to the rear wall
should be:

10 + W 5 H
youter > for the "outer" mixer
4
10 + 1.5W 5 H
yinner > for the "inner" mixer
4
is the propeller diameter, W tank width and H depth

23
 Minimum submergence requirement
Vortex formation
For approximate submergence, see tables for Submergence Recommendations for
compact mixers and ... large diameter mixers.

The following submergence is recommended for vortex suppression:

0 .7 Q F F
S= or S = 0.020 for mixers with jetring ; S = 0.018 for mixers without jetring
1.5 D D
D
Q is flow through propeller [m3/s] and F is mixer thrust in [N]

These values of submergence are minimum values. A vortex can be drawn down to the propeller at much larger depths
depending on installation and type of tank. Therefore, completely vortex-free operation cannot be guaranteed. Vortices on
large diameter mixers have less affect on performance and stability than those on compact mixers.

In more viscous liquids, such as sludge, manure, paper pulp, etc., a vortex will not form as easily as it does in water.
Minimum submergence for these can therefore be less. Nonetheless, the values given above are valid as a general
recommendation. (See also Systems Engineering brochure "Vortex suppression". )

NPSH (Net Positive Suction Head)

A submergence giving a certain NPSH is necessary in order to avoid cavitation. No other restrictions regarding NPSH affect
any Flygt mixer if the temperature remains below 70 C (160 F).
For temperatures between 70 C and 90C (160 F and 190 F) the following equation can be used for estimating minimum
submergence.

( )
2
S = T 10
3 5 n D
3
300
S is the submergence from surface to propeller tip in [m]
T C
n RPM
D Propeller diameter [m]

24
 Recommendations for compact mixers
These recommendations refer to mixers with a propeller diameter less than one meter.

Submergence:
The required submergence greatly depends on the flow conditions. With good flow conditions,
turbulent surface, viscous liquids, and/or a smaller propeller angle, the submergence can be
reduced. The following tables refer to low viscous liquids and the largest propeller angle for
each mixer type.

Recommended submergence without vortex suppressor plate

4630 4640 4650 4660 4670 4680

meters, 50 Hz 0.7 0.9 1.1 1.5 1.4 1.7
feet, 60 Hz 2.3 3 3.3 4.7 4.4 6.2

Recommended submergence with vortex suppresser plate

4630 4640 4650 4660 4670 4680

meters, 50 Hz 0.2 0.4 0.5 0.6 0.6 0.7
feet, 60 Hz 1 1.3 1.4 2 1.9 2.7

Side walls:
The clearance between the propeller and the side walls should be at least 0.5 times the
propeller diameter.

Bottom:
The distance between the center of the propeller and the bottom should be at least 1 propeller
diameter.

Rear wall:
The distance between the propeller and the rear wall immediately upstream should be at least
1.5 times the propeller diameter.

Distances:
Obstacles and walls downstream of mixer. The clear distance downstream of the mixer should
be at least 10 times the propeller diameter.

Note: If any of the foregoing conditions for clearances and spacing are not met, the system
will be less efficient (mixer performance will be decreased) and larger mixers (including large
power margin) will be required. If the clearance to the side wall and/or the bottom is less than
recommended, the distance to the rear wall should be increased, if possible, to avoid lower
efficiency. In shallow tanks for which bottom- and surface clearances are close to zero, a
vortex protection plate is recommended and the distance to the rear wall should be at least 3
propeller diameters.

25
 Recommendations for large diameter mixers
Submergence:
The required submergence greatly depends on the flow conditions. The minimum
recommended submergence is 0.5 m (1.7 ft) to the propeller tip. Under good conditions, with
no restrictions upstream (low velocities of incoming flow), the submergence might be
decreased to 0.3 m (1 ft). See also "Minimum Submergence Requirement".

Side walls:
The clearance between the propeller and the side wall should be at least 0.3 m (1 ft).

Bottom:
The clearance between the propeller and the bottom should be at least 0.3 m (1 ft).

Rear wall:
The distance between the propeller and the rear wall immediately upstream should be at least 1
propeller diameter. If parallel mixers are used, the space behind them must be enough to
produce a good supply of fluid to all mixers. See also Large wide tanks.

Distances downstream:
The clear distance should be at least 4 times the diameter of the mixer.

Approaching flow:
Mixers should be positioned parallel to the approaching flow or at the smallest angle
possible. If the angle is less than 20, mixer performance will not be reduced.

Racetracks:
Large diameter mixers 4410/30, installed in series, should have a distance of at least 5
propeller diameters between them. Mixers installed in parallel should not occupy more than
30 % of the channel area and the spacing between them should be at least 0.6 m (2 ft).

Small tanks:
The tank / mixer propeller diameter ratio should be at least 8 to avoid angled inflow to the
propeller.

Note: If any of the foregoing conditions for clearances and spacing are not met, the system
will be less efficient (mixer performance is decreased and life length reduced) and larger
mixers (large power margin) will be required. If the clearance or spacing in one dimension is
small, the other dimensions should be increased if possible, so as to compensate without undue
loss of power.

26
 MIXING PERFORMANCE

Measurable quantities
To be able to specify, control and adjust the overall process, mixing must also be
specified as it is a part of this overall system. Therefore measurable quantities related to
the mixing requirements should be specified during discussions with the enduser.
Measurable mixing quantities can also be guaranteed in addition to the usual mixer
performance guarantee.

Different mixing performances can be guaranteed and/or measured such as:

The power consumption of the mixer

Velocities (average bulkflow velocity only)
Settled material (normally in % of the tank volume)
Homogenization:
1) Degree of homogeneity as a function of time: % of the average concentration
(by weight) in some specified points after a given time. This is usually done
using Lithium tracer tests.
2) Degree of homogeneity, suspension: % of the average concentration (by
weight) in some specified points

In a throughflow tank, the concentration should be measured at the outlet since the
concentration differs in the tank (compare with a batch tank where the concentration is
constant after a certain time).
In each guaranteed case, the methods for measuring the guaranteed performance should
be agreed in advance.

Practical methods
The following are guidelines for judging the mixing performance according to the most
common mixing requirements for homogenization; get complete mixing, prevent
separation, prevent short-circuits and resuspend sediments.

Velocity
Velocity is not a mixing criterion itself but is commonly used to quantify the mixing
(though the velocity determines the homogenization). The following are some easy
methods on how to judge the velocity. For exact measurements, an Ott-mill is normally
used.

Select a representative place (neither too high nor too low). Clock a "flow follower" over
a measured distance, either on the surface or if possible, by means of a sunken "sail"
attached to a float (the float may be difficult to recapture). A velocity within 30 % of the
expected value is satisfactory. Perform the tests in a number of locations.

27
 Getting complete mixing
Do not judge the mixing on a violent surface behavior unless surface mixing is the
objective (such as scum layer break-up). Behavior at the bottom is usually more
important, to resuspend the sediments.

Movement on the surface

Once a steady state is reached, movement should be visible over the entire surface (in
"thick" media, any movement is enough). A small floating stick can be used and its
position registered every five minutes.

Degree of homogeneity, mixing time in batch mixing

Locate at least two poorly mixed areas. Take samples there and at the outlet after a
mixing period corresponding to the required mixing time. Evaluate differences by simple
estimation or if possible by laboratory tests. For more advanced tests, use tracer, such as
Lithium.

For throughflow tanks, see Preventing short-circuits.

Prevent separation
Movement within the whole tank especially close to the bottom (min. 0.5 m).
A "flow follower", heavy enough to sink and large enough to offset the effect of the
forces on the string, can be used to indicate movement. Register the angle the string
makes with the vertical. Tests A) and B) should be performed.

Degree of homogeneity, suspensions

1. Take a sample near the surface (preferably at a depth of about 0.5 m) and compare it
with a sample from the outlet. Determine the SG, weight concentration or simply make
an estimate of the consistency. More than 5 % difference between the two samples
should lead to new measurements and if consistent it should be recorded (if
homogenized conditions are expected).
2. Take samples at different locations within the tank (evaluate them as before).

Preventing short-circuits
Mixing in tanks with a through flow. Tracer tests should be performed with a tracer
added before inlet (the tracer should be well mixed within the inlet flow, before it enters
the tank). Take samples and compare with an ideally mixed tank. Ensure that the
retention time is long enough.

Resuspending sediments
With a long stick, feel where material has settled on the bottom (if you are inexperienced,
feel the material before the mixer is started). Such tests are only practicable in relatively
shallow tanks. In corners or near the periphery, a sediment layer greater than 25 % of the
depth is excessive. When the tank is emptied this would normally represent less than 5 %
of the volume.

28
 MIXER PERFORMANCE CHECKLIST
OBSERVATIONS POWER RESULT OF POSSIBLE REASON
CONSUMPTION
The liquid is not Very low RPM Propeller not
moving. fastened.

Very weak movement in High RPM The motor is running

the liquid. with only two phases.

Weak mixing action Higher than normal Clogging on Inadequately polished

over an unexpectedly and fluctuating propeller leading edge of
short distance. propeller. Bad shape
Vibrations. of swept leading edge
at one or more spots.
Sticky material which
propeller cannot
handle (can easily be
seen when mixer is
raised).

Weak mixing action Lower than usual but Air suction, Insufficient depth of
though violent flow fluctuating vortexing submergence.
close to the mixer. Unfavorable flow
Vibrations. conditions.

Lower velocities and Slightly higher than High Normal decrease in

less movement than normal viscosity performance due to
normal. and/or more viscous media.
consistency
Bad mixing. Surface Much higher but fairly Continuous If liquid is not very
movements more stable. clogging viscous, it could be
towards right. "stringy" material that
is thickened/
dewatered on leading
edge. Will not be seen
if mixer is raised.

Flow is too violent close Slightly higher than Liquid too Too viscous liquid
to the mixer and short normal viscous causing too much
circuiting back to the radial flow. Propeller
mixer. ceases to produce a
jet.

29
Mixing and mixer Varies slowly up and The The mixer starts in a
performance vary over a down consistency very viscous medium.
long time period of time of the As the medium is
(3-20 min). medium gradually
varies and homogenized, the
interacts liquid close to the
with the mixer is diluted. If a
mixer new batch of viscous
liquid enters, the
mixer has to work in a
viscous medium again
until the mixer has
homogenized it.

30