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How to choose a reactor agitator
There are several classification methods for agitators, primarily based on their design, function, and flow characteristics.
1) **Based on Blade Structure**: Agitators can be categorized into flat-blade, inclined (folded) blade, curved blade, and spiral surface types. Flat and inclined blades are commonly found in slurry and turbine agitators, while propellers, screws, and ribbon blades typically feature a spiral structure. Additionally, agitators can be classified as either integral or split types, depending on installation requirements. The split type allows for easy attachment to the stirring shaft without removing other components like couplings, making it more convenient for maintenance.
2) **Based on Application**: Agitators are also divided into those used for low-viscosity and high-viscosity fluids. Low-viscosity applications often use propellers, slurry, open turbines, disc turbines, Brumag, plate-and-frame, and three-leaf agitators. For high-viscosity fluids, anchor, frame, serrated disc, and ribbon agitators are more suitable.
3) **Based on Flow Pattern**: Another classification is by the direction of fluid movement—axial, radial, or mixed flow. Axial flow agitators, such as propellers, move fluid vertically, while radial flow agitators, like straight-blade disc turbines, push fluid outward. Mixed flow agitators, such as inclined-blade turbines, combine both axial and radial movements.
Selecting the right agitator involves two key factors: the result must be reasonable, and the method should be simple. These two goals are often difficult to achieve simultaneously.
Viscosity plays a major role in determining the appropriate agitator. A common approach is to match the agitator type with the viscosity range of the medium. Propellers work best for low-viscosity liquids, while turbines, slurry, and eventually anchor and ribbon agitators are used for higher viscosities. However, these ranges often overlap. For example, slurry agitators are simple in design and can improve flow patterns with baffles, making them useful even at low viscosities. Turbines, due to their strong circulation and shear capabilities, are widely used across many applications.
The choice of agitator also depends on the mixing purpose and the resulting flow state. In some regions, certain types are preferred over others, so local practices may influence the selection.
Agitators are generally divided into fast and slow types. Fast agitators operate in turbulent conditions, while slow ones work in laminar flow. Selection is based on mixing objectives, flow pattern, and viscosity. Each type has recommended viscosity, speed, and tank capacity ranges.
A detailed selection table helps guide the process by matching agitator types to specific mixing tasks. This ensures a more accurate and tailored choice.
For low-viscosity homogeneous mixing, propellers are ideal due to their high circulation and low power consumption. Turbines, though powerful, may not be efficient for large volumes because of limited circulation.
In dispersion processes, turbines with flat blades are preferred for their high shear force. Propellers and slurry agitators are less suitable unless low shear is required. Baffles are often used to enhance shear effects.
For solid suspension, turbines are the most effective due to their ability to mix liquid above and below the blades without obstructions. Propellers are less suitable for high-solid-content mixtures, where careful baffle placement is necessary to avoid particle accumulation.
Gas absorption is best achieved with disc turbines, which create stable gas distribution. Propellers and slurry agitators are rarely used for this purpose unless only small amounts of gas need to be absorbed.
Crystallization processes require careful control. Small-diameter, high-speed turbines are suitable for fine crystals, while large-diameter, slow agitators like slurry are better for larger crystal growth.