Collaboration blog between Venwiz and Rahul Engineering Global Pvt. Ltd. sharing valuable insights on how to choose an agitator for your plant
Powerful agitators actively churn and mix liquids, individually or in combination, for diverse industrial processes. They play a crucial role in various industrial processes, including those in the chemical, pharmaceutical, food processing, grease manufacturing, metal extraction, paint production, adhesive manufacturing, water treatment, and cosmetics industries. Read on to find out how to choose the perfect agitators for your plant. Read on to learn how to choose agitators for your plant.
Components of an Agitator
Motor Components: The motor component drives the agitator assembly, producing torque to control flow and shear in media. The power requirement of an agitator depends on factors like viscosity, specific gravity, solid content, impeller speed, diameter, power number, and number of impellers.
Shaft component: The shaft component, connected to the motor’s driveshaft, transmits torque to the impeller. To ensure seamless operation and eliminate material buildup, manufacturers carefully construct it using couplings, end caps, and seals.
Impeller component: The impeller is a crucial component of agitators, determining the flow pattern, efficiency, and mixing parameters.
As it spins, the impeller directly transfers energy to the materials being mixed, generating fluid flow and intricate shear patterns. A central hub, connected to a shaft key and grub screw, forms the core of the impeller, with blades securely attached. Welding or screwing secures the blades to the hub, offering a hygienic advantage by preventing material buildup on fasteners and fittings.
The number of impellers depends on the type of impeller, maximum height of media, vessel diameter, and specific media gravity. Impellers can be classified as open- or disc-type.
- Open-blade impellers have blades connected to the shaft, making cleaning easier.
- Disk-type impellers consist of a disc with attached blades, creating a more uniform radial flow and used in gas dispersions.
Applications of agitators
Agitators are indispensable equipment in various industrial settings and play a critical role in different processes. Applications of agitators include:
- Homogenizing solutions and suspensions: Manufacturers use agitators to break down large particles and disperse them evenly in liquid or mixture for uniform consistency. This is critical for achieving a smooth texture and preventing the separation of components.
- Uniform mixing: Agitators maintain a constant motion in the mixture, preventing solids from settling down or the formation of concentration gradients, and ensuring even distribution of all components.
- Dispersing gases: Agitators are essential for dispersing gases into liquid solvents, creating a stable dispersion or solution. This is crucial for processes like the aeration of beverages, the oxygenation of wastewater, and the production of emulsions.
- Promoting chemical reactions: Agitators enhance chemical reactions by bringing reactants into close contact, accelerating the reaction rate, and improving the efficiency of chemical processes.
- Maintaining consistent temperature: Agitators facilitate heat transfer within vessels, ensuring uniform temperature distribution and preventing localised hot spots or cold zones.
- Enhancing heat transfer to jackets: Agitators promote heat transfer from jackets to liquid mixtures by increasing the surface area available for heat exchange.
Types of agitators
Paddle Agitators
Paddle agitators excel in tasks where high levels of axial and radial flow are not needed, utilizing their two flat, paddle-shaped blades that reach the tank walls. They produce a laminar, low-shear flow pattern, making them ideal for mixing low-viscosity liquids, crystallization, dissolution, and heat transfer. Paddle agitators typically operate at low speeds, generating a predominantly tangential flow. For more viscous materials, secondary blades can be added to the paddle blades for enhanced mixing.
Anchor Agitators
Anchor agitators boast distinctive impeller blades, mimicking the anchor in shape.These blades typically follow a U-shaped design, conforming to the contour of the tank. For tasks requiring both tangential and axial flow, anchor agitators can be customized with angled blades attached to their horizontal supports, introducing a potent axial flow element.
Helical Ribbon Agitators
Helical ribbon agitators have distinctive impeller blades that resemble a helical ribbon fixed to the shaft. These agitators serve as an alternative to anchor agitators, offering an efficient alternative for generating laminar flow. Unlike anchor agitators, helical ribbon agitators produce an axial flow pattern, effectively moving fluids along the length of the tank. Their design typically incorporates a larger fluid contact area, making them particularly well-suited for mixing fluids with higher viscosities.
Double Helical Ribbon Agitators
These agitators are designed with two counter-rotating blades. Double-helical ribbon agitators are perfect for mixing viscous liquids and heat transfer. They are the top choice for high-viscosity laminar flow applications, sometimes with low clearance to the tank wall.
Agitators with screw impeller
Agitators with screw impellers have a close clearance design and a helical flight directly attached to the impeller shaft. This unique design ensures exceptional top-to-bottom turnover, facilitating thorough mixing throughout the entire tank. Screw impeller agitators are particularly well-suited for blending high-viscosity and shear-sensitive media, effectively preventing the formation of dead zones, and minimizing damage to delicate materials.
Propeller impeller
Propeller agitators can produce both axial and tangential flow patterns. The impeller blades draw fluid towards them, imparting a longitudinal acceleration and displacing the fluid. The degree to which the fluid is deflected depends on the inclination of the impeller blades. To minimize centrifugal force and maximize axial flow, the impeller blades are tapered towards the shaft.
Turbine agitators
Turbine agitators strike a balance between propeller agitators and paddle agitators, combining centrifugal and rotational motion to achieve efficient mixing. They typically have larger diameters than propeller agitators, enabling them to handle a wider range of material viscosities while maintaining high mixing efficiency. Turbine agitators can be further classified into:
- Straight-blade turbine impellers
- Pitch blade turbine impellers
- Rushton blade turbine impellers
- Smith blade turbine impeller
- Curved-back turbine impeller
Comparing different agitators
| Agitator type | Applications | Advantages | Disadvantages |
| Paddle Agitator | Mixing low-viscosity liquids, crystallization, dissolution, and heat transfer | Simple and inexpensive design, low shear mixing, effective for laminar flow | Limited mixing capacity for high-viscosity fluids |
| Anchor Agitator | Blending and heat transfer of highly viscous liquids and shear-sensitive media | Efficient mixing for viscous fluids, low mixing, suitable for rounded or conical tank bottoms | Limited axial flow, not ideal for high-speed mixing |
| Helical Ribbon Agitator | Mixing highly viscous fluids, heat transfer | Efficient mixing for viscous fluids, gentle mixing action, effective heat transfer | Complex design, higher cost |
| Double-helical ribbon agitators | Mixing highly viscous fluids, heat transfer | Enhanced mixing capacity compared to single helical ribbon, improved axial flow | More complex design and higher cost than single helical ribbon |
| Agitator with Screw Impeller | Mixing highly viscous and shear-sensitive media | Efficient mixing for viscous fluids, gentle mixing action, effective heat transfer | Not suitable for low-viscosity fluids |
| Propeller Agitator | Mixing and blending fluids of various viscosities, emulsification and dispersion processes | Versatile for axial and tangential flow applications, efficient mixing, energy-efficient | Limited mixing capacity for high-viscosity fluids |
| Turbine Agitator | Emulsification and dispersion processes, mixing materials with a wide range of viscosities | Effective emulsification and dispersion, versatility for various viscosities, high mixing efficiency | High shear forces, higher energy consumption |
Choosing the right agitator for your industrial application
Selecting the appropriate industrial agitator for a specific application involves careful consideration of various factors, including:
Compatibility with Materials:
- Phase: Determine whether the process involves single-phase (liquid, gas) or multiphase (slurry, suspension) mixing, as different agitator types excel in different scenarios.
- Viscosity: Assess the bulk material’s viscosity (low, high, or intermediate) to ensure the agitator’s design and power match the material’s flow behaviour.
- Chemical Properties: Identify any corrosive or flammable properties to select agitators constructed with appropriate materials and safety features.
Process Requirements:
- Function: Define the specific function needed (blending, dissolving, dispersion, heat exchange, chemical reaction, crystallization, emulsification, suspension, etc.) to choose an agitator aligned with the desired outcome.
- Mixing Cycle: Consider the batch size, agitation duration, and material addition sequence to ensure the agitator can handle the intended process conditions effectively.
- Desired Outcomes: Clearly outline the desired characteristics of the final product (uniform consistency, specific temperature, etc.) to guide agitator selection.
Material Characteristics:
- Initial and Final Viscosities: Assess viscosities at both the start and end of the mixing process to ensure the agitator can manage potential changes during operation.
- Solubility of Solids: Understand solid solubility and concentration levels to prevent settling and achieve uniform distribution.
By carefully considering these selection criteria, you can choose the most suitable industrial agitator for your specific application, ensuring optimal performance and safety.
Industries using agitators
| Industry | Type of agitator used | Why is it used? |
| 1.Speciality Chemicals 2. Fertiliser 3. Pharmaceuticals 4. Dyes & Pigments 5. Food & beverages 6. Paints & Polymers 7. Adhesives 8. Power 9. Paper & Pulp etc. | Anchor type | Used where the process required both pumping and shearing action |
| Pitch blade turbine type | Efficient turbulent flow, Used for Blending and suspending solids applications, | |
| Narrow-blade Hydrofoil | Used where the process required both pumping and shearing action | |
| Double Helix | Generally operates at slow speed, Used for homogenisation & heat transfer applications, high viscous liquids | |
| Paddle Type | General purpose, economical type, low viscous mixing, basic applications | |
| Wide-blade Hydrofoil | Efficient turbulent flow, Used for Blending and suspending of solids applications, |
Venwiz: Your source for high-performance agitators
At Venwiz, we understand the importance of sourcing the right equipment for your project. We are India’s leading digital platform for capex procurement and are committed to connecting businesses with leading agitator manufacturers like Rahul Engineering Global Pvt. Ltd.
Rahul Engineering Global Pvt. Ltd
Rahul Engineering Global Pvt. Ltd., established in 2005, specializes in manufacturing and exporting high-quality agitators, heat exchangers, storage tanks, vacuum chambers, pressure vessels, winery tanks, and brewery equipment for various industries.
With over 100 people and a manufacturing capacity of 1200 MT per annum, the company has grown from a small factory to two state-of-the-art facilities in Chakan, Pune. With a CE label, their products satisfy EU regulations for environmental protection, health, and safety. It is by consultants approved by several Engineering, Procurement, and Construction (EPC) firms and consultants.
Products manufactured by Rahul Engineering Global Pvt. Ltd.
Noteworthy projects
| S.No | Client Name | Industry/Sector |
|---|---|---|
| 1 | UPL ltd | Chemical |
| 2 | Deepak fertilizers | Chemical |
| 3 | HikalAmul | PharmaMixing of chocolates |
Manufacturing capabilities
- Capable of manufacturing laboratory size to large-scale energy-efficient agitators
- Expertise to offer any special MOC, including MS, SS, Titanium, Hastelloy, etc.
- NDT testing like UT, PMI, Dye penetration test, Vibrations, Noise levels, Tachometer, temperature, geometrical parameter instruments, etc
- Motors (FLP, Ex’d, Non-flip,), Gearbox ( Inline helical, Bevel Helical, Planetary ), Shaft sealing ( Single/ Double mechanical seal, Lip seal, and Gland packing)
Guest Author
Rahul Chhajed is the managing director of Rahul Engineering Pvt. Ltd. A mechanical engineer from Pune University, he has over 18 years of experience as a designer and manufacturer of process equipment.
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