Mixing quality characterization in separations process tanks

An experimental study has been performed on distribution of a dilute immiscible organic liquid dispersed in an aqueous phase contained baffled, paddle-agitated vessel, fitted with cooling coils. Acceptable total liquid levels in the vessel and minimum impeller speed were established for plant scale operation. Axial and radial distributions of the dispersed organic phase as functions of total liquid height, impeller speed, and the number of impellers were examined and some recurring trends were identified. Four stages of dispersion of organic phase in predominantly aqueous phase were identified with increasing rotational speed of impeller(s). The stages were: (1) non-dispersion stage in which the organic layer was undisturbed, (2) the organic layer was decreasing with impeller speed until complete but nonuniform dispersion was attained, (3) the non-uniformity of the completely dispersed mixture decreased with increasing rotational speed of impeller(s), and (4) a grossly uniform dispersion in which the local volume fraction of dispersed phase (organic) in mixture was the same throughout the vessel. Scale-up relations were developed for reproducing a defined mixing quality on two geometrically similar scales of operation, for the attainable condition of complete but non-uniform dispersion. The mixing quality was observed to decrease with increasing liquid depth over acceptable range, but variations in the overall concentration of organic liquid appeared to have only slight effect on the mixing quality