Mixing (process engineering)

In industrial process engineering, mixing is a unit operation that involves manipulation of a heterogeneous physical system with the intent to make it more homogeneous. Familiar examples include pumping of the water in a swimming pool to homogenize the water temperature, and the stirring of pancake batter to eliminate lumps (deagglomeration). Mixing is performed to allow transfer of heat or mass, or both, to occur between one or more streams, components or phases. Modern industrial processing almost always involves some form of mixing. Some classes of chemical reactors are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas into another solid, liquid or gas. A biofuel fermenter may require the mixing of microbes, gases and liquid medium for optimal yield; organic nitration requires concentrated (liquid) nitric and sulfuric acids to be mixed with a hydrophobic organic phase; production of pharmaceutical tablets requires blending of solid powders. The opposite of mixing is segregation. A classical example of segregation is the brazil nut effect.

The mathematics of mixing is highly abstract, and is a part of ergodic theory, itself a part of chaos theory.

Mixing classification The type of operation and equipment used during mixing depends on the state of materials being mixed (liquid, semi-solid, or solid) and the miscibility of the materials being processed. In this context, the act of mixing may be synonymous with stirring-, or kneading-processes.

Liquid–liquid mixing Mixing of liquids occurs frequently in process engineering. The nature of liquids to blend determines the equipment used. Single-phase blending tends to involve low-shear, high-flow mixers to cause liquid engulfment, while multi-phase mixing generally requires the use of high-shear, low-flow mixers to create droplets of one liquid in laminar, turbulent or transitional flow regimes, depending on the Reynolds number of the flow. Turbulent or transitional mixing is frequently conducted with turbines or impellers; laminar mixing is conducted with helical ribbon or anchor mixers.

Single-phase blending Mixing of liquids that are miscible or at least soluble in each other occurs frequently in engineering (and in everyday life). An everyday example would be the addition of milk or cream to tea or coffee. Since both liquids are water-based, they dissolve easily in one another. The momentum of the liquid being added is sometimes enough to cause enough turbulence to mix the two, since the viscosity of both liquids is relatively low. If necessary, a spoon or paddle could be used to complete the mixing process. Blending in a more viscous liquid, such as honey, requires more mixing power per unit volume to achieve the same homogeneity in the same amount of time.

Gas–gas mixing

Solid–solid mixing Dry blenders are a type of industrial mixer which are typically used to blend multiple dry components until they are homogeneous. Often minor liquid additions are made to the dry blend to modify the product formulation. Blending times using dry ingredients are often short (15–30 minutes) but are somewhat dependent upon the varying percentages of each component, and the difference in the bulk densities of each. Ribbon, paddle, tumble and vertical blenders are available. Many products including pharmaceuticals, foods, chemicals, fertilizers, plastics, pigments, and cosmetics are manufactured in these designs. Dry blenders range in capacity from half-cubic-foot laboratory models to 500-cubic-foot production units. A wide variety of horsepower-and-speed combinations and optional features such as sanitary finishes, vacuum construction, special valves and cover openings are offered by most manufacturers. Blending powders is one of the oldest unit-operations in the solids handling industries. For many decades powder blending has been used just to homogenize bulk materials. Many different machines have been designed to handle materials with various bulk solids properties. On the basis of the practical experience gained with these different machines, engineering knowledge has been developed to construct reliable equipment and to predict scale-up and mixing behavior. Nowadays the same mixing technologies are used for many more applications: to improve product quality, to coat particles, to fuse materials, to wet, to disperse in liquid, to agglomerate, to alter functional material properties, etc. This wide range of applications of mixing equipment requires a high level of knowledge, long time experience and extended test facilities to come to the optimal selection of equipment and processes.

Solid-solid mixing can be performed either in batch mixers, which is the simpler form of mixing, or in certain cases in continuous dry-mix, more complex but which provide interesting advantages in terms of segregation, capacity and validation. One example of a solid–solid mixing process is mulling foundry molding sand, where sand, bentonite clay, fine coal dust and water are mixed to a plastic, moldable and reusable mass. This is used for molding and pouring molten metal to obtain sand castings to make metallic parts for automobiles, machine building, construction or other industries.

Mixing mechanisms In powder two different dimensions in the mixing process can be determined: convective mixing and intensive mixing. In the case of convective mixing material in the mixer is transported from one location to another. This type of mixing leads to a less ordered state inside the mixer, the components that must be mixed are distributed over the other components. With progressing time the mixture becomes more randomly ordered. After a certain mixing time the ultimate random state is reached. Usually this type of mixing is applied for free-flowing and coarse materials. Possible threats during macro mixing is the de-mixing of the components, since differences in size, shape or density of the different particles can lead to segregation. When materials are cohesive, which is the case with e.g. fine particles and also with wet material, convective mixing is no longer sufficient to obtain a randomly ordered mixture. The relative strong inter-particle forces form lumps, which are not broken up by the mild transportation forces in the convective mixer. To decrease the lump size additional forces are necessary; i.e. more energy intensive mixing is required. These additional forces can either be impact forces or shear forces.

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