Pfaudler Mixing Systems

Pfaudler Engineered Mixing Systems

for Glass-Lined Vessels
Pfaudler has been supplying mixing ProSol Process Solutions Using computational techniques and
systems and mixing applications assis- ProSol involves Pfaudler combining new agitation components, Pfaudler
tance for glass-lined reactors since the advanced computer modeling tech- can develop the optimum solution
1930s. These systems have always been niques with new mixing technology to whatever the complexity or degree of
combinations of glass-lined agitators custom-design the optimum solution difficulty of your reactor processing
and baffles, from the days of the for each reactor processing require- requirement. Problem solving is sup-
Retreat Curve Impeller (RCI) and ment. ProSol mixing systems mean ported by research and development
finger baffles used in the Pfaudler you can retain the benefits of glass- and resources at our pilot plant and
Agitative System to the world- lined equipment while matching the through Pfaudlers established team
renowned Cryo-Lock family of state-of-the-art effectiveness of alloy of experts. This ensures we can meet
impellers, ProSol, and state-of-the-art mixing systems in any application exacting quality control limits includ-
baffle systems like the concave baffle. range. With ProSol, Pfaudler is offering ing providing process guarantees and
The one constant through the years has a more effective baffle for all applica- your FDA requirements.
been Pfaudlers commitment to meet- tions, and expanded application range
ing customer process objectives with Pfaudlers Glasteel reactors equipped
where a glass-lined solution may not
well-manufactured, reliable glass-lined with Cryo-Lock now provide the exact
always have been considered the first
mixing systems. combination of attributes you need for
option. Now glass-lined is suitable for
broad-range mixing flexibility.
more uses in:
Pfaudler Mixers
gas dispersion Impeller/baffle combinations to
The different impeller configurations serve all basic mixing operations
in the Cryo-Lock family were designed transistion regime blending
by Pfaudler to meet the needs of differ- high viscosity blending Quick changeover reconfigures
ent process conditions and require- your glass-lined reactor for maxi-
ments, mixing operations, viscosity In addition to increasing the range mum flexibility
ranges, etc. of applications, Pfaudler ProSol can Unlimited impeller options
deliver core benefits to your process- custom designs can interchange
This inherent flexibility can be broad- ing needs. with standards
ened considerably by changing other improve the effectiveness of general Much less downtime and lower
factors of the mixing system, such as purpose mixing systems maintenance costs than conventional
the drive speed and baffle arrange-
improve the performance of existing one-piece glassed agitators
ment. Thus, most of the glassed
Cryo-Lock impellers may be used in solutions through retrofitting
This means you can respond to chang-
more than one of the five basic unit reduce process/mixing times ing market conditions by reconfiguring
operations: optimize product quality, yield and your Glasteel reactor, modifying or
throughput completely changing your mixing
Blending/Heat Transfer operation whenever necessary, and
maximize energy efficiencies
you can do it quickly, with minimum
Emulsification downtime.
Suspension

Gas Dispersion
High Viscosity
Blending

2
Cryo-Lock Family of Agitators

Curved Blade Anchor (ANC) Helical Ribbon

Turbine (CBT) Available in both (HLX)
The first Cryo-Lock single-hub and The HLX is a glass-
agitator introduced was a 4-blade turbine, two-hub designs, lined version of the
only two-thirds the diameter of the tradi- the anchor is some- traditional helical
tional one-piece Retreat Curve Impeller times used with ribbon mixer,
(RCI). However, the CBT is characterized higher viscosity fluids for crystallization, designed to handle high viscosity
by a higher power number. The net effect heat transfer and non-Newtonian prod- (>100,000 cP) blending.
is that the CBT delivers the same level of ucts. It is normally operated with narrow
power investment and bulk fluid motion wall clearance to produce a tangential flow. Multi-Flight
as the RCI, with the same low-level mixing The blade height of the one-hub anchor is
limited by the need to maneuver the shape Configurations
capability. Like the RCI, the CBT is a very
effective general-purpose impeller. through the man-way. Since the two-hub A single impeller
anchor does not have this restriction, its is often inadequate
Turbofoil (TBF) blades extend higher and, within the lim- to deal with high-
its of available torque, it can handle larger viscosity mixing,
The TBF is the only
batches in a given size reactor. homogeneous
glass-lined, high-
solids suspension,
efficiency impeller
the incorporation of
readily available in
the marketplace. Its high flow, low-torque Gas Dispersion floating solids, and
Turbine (GST) some multi-phase
characteristics make it an economical
applications requir-
choice for many blending and heat transfer The patent pending
ing a high level of power investment. This
applications in the turbulent flow regime. GST is a radial flow
inadequacy is most pronounced in vessels
It handles most liquid/solid applications impeller designed
with height to diameter ratios that exceed
effectively by providing a fluid velocity for gas dispersion applications. It provides
1.2. For these more demanding applica-
high enough to keep even heavy solids in superior uniformity and increased mass
tions, a multi-flight system is strongly rec-
suspension. transfer rate compared to a traditional flat-
ommended. To maintain low-level mixing
blade or disc-type turbine. The GST has
capability, a CBT is most often used as the
Pitched Blade significantly better gassed to ungassed
lower impeller. The upper flight is typically
Turbine (PBT) power characteristics than any other glass-
an axial flow impeller, a PBT when addi-
lined impeller on the market. Also, it can
This design is tional power investment is required; a
handle gas rates more than twice as high
often considered to be a general-purpose TBF when an increase in fluid motion is
as the VBT with Disc, CBT or PBT.
impeller system for conventional alloy desired. Multiple VBTs are sometimes used
mixers. The glass-lined version of the PBT for difficult gas dispersion applications.
is also quite flexible, but it cannot deal
MaxFlo Triple-flight systems are sometimes
effectively with small mixing volumes. Turbine (MXT) required for the most demanding
Because of its high pumping capacity and The patent pending applications.
moderate power requirements, it is often MXT is an axial
used in flow-oriented processes such as flow, high-
blending, solids suspension, heat transfer efficiency impeller designed to mix high
and light-duty emulsification. viscosity slurries (10,000 - 15,000 cP) or
solutions which cannot be handled by
Vertical Blade traditional high-efficiency impellers
When it comes to
Turbine (VBT) (e.g. TBF). The MXT gets its high flow to implementing and easily
The VBT is the power ratio through high flow coefficient.
classic radial-flow It is also effective at suspending solids. maintaining such a
impeller, with a high degree of energy dis-
sipation in the impeller zone and modest custom configuration,the
pumping capacity. With the appropriate advantages of the Cryo-Lock
baffle(s), it is best suited for multi-phase
mixing applications which require high system are obvious.
levels of power investment (i.e. gas
dispersions, demanding emulsifications).
With a PTFE disk sandwiched between
the two hubs, it becomes the only glass-
lined disk turbine readily available in the
marketplace.
3
Cryo-Lock Family of Agitators

Blending and Gas High Low-Level

Emulsification Suspension
Heat Transfer Dispersion Viscosity Mixing

Curved Blade Turbine

Excellent Good Good Adequate Adequate Excellent

Turbofoil

Excellent Adequate Good Adequate Poor Adequate

Pitched Blade Turbine

Excellent Good Excellent Adequate Good Adequate

Vertical Blade Turbine

Good Excellent Adequate Adequate Adequate Adequate

Anchor

Adequate Poor Adequate Poor Good Good

Gas Dispersion Turbine

Good Excellent Adequate Excellent Adequate Adequate

MaxFlo

Excellent Adequate Excellent Adequate Good Adequate

Helical Ribbon

Adequate Poor Poor Poor Good Poor

Multi-Flight Impeller

Excellent Excellent Excellent Excellent Excellent Excellent

4
The Basics Behind Baffling

When a center-mounted impeller The Concave Baffle is the latest Pfaudler baffles can also serve as a
is used in an unbaffled vessel, the design in glass-lined baffle technology. thermowell and can be provided
impeller imparts a high velocity swirl The revolutionary, patent-pending with a variety of temperature-sensing
and vortexing motion to the fluid, but design is characterized by a dramatic options including the traditional tanta-
very little mixing takes place. Baffles improvement in baffle effectiveness. lum encased RTD and our new TMI
are used to convert this swirling The premise behind the Concave Baffle temperature sensor. The TMI is a
motion to a more 3-dimensional flow is to maximize the drag coefficient of spring-loaded, dual element DIN RTD.
accompanied by turbulent dissipation, the baffle. For the Concave Baffle, the By using the TMI, the gasketed joint,
thereby promoting top-to-bottom drag coefficient is 2.3. For the flattened- which is present with the traditional
turnover and mixing. Placing a baffle pipe, it is 1.3. This results in increased threaded RTD, is eliminated. The
in an agitated vessel increases the power investment and improved Concave Baffle shown here is suitable
transfer of power from the impeller to uniformity of suspended particles. for a TMI temperature sensor.
the fluid. A visual indication of this The reaction which is related to this
transfer of power is a reduction in size increase in drag force results in an
of the free surface vortex, the magni- increase in both energy dissipation
tude of which is a function of the (power draw) and top-to-bottom
following: turnover within the vessel. Pfaudler
baffles are available in both flange-
1. Shape - The less streamlined the mounted and stuffing box designs.
baffle, the more effective it will be
(i.e., a flat plate is a more effective
baffle than a round pipe of equal
cross section).

2. Placement - The closer the baffle

is to the sidewall of the vessel, the
more effective it will be in converting
swirl to top-to-bottom turnover.

3. Size - The larger the projected

area of the baffle, the greater the
baffle effect.

A fully baffled condition (complete

vortex elimination, defined as 100%
baffle effectiveness) is produced by
four flat plates (shape) located at the
sidewall of the vessel (placement), of
width equal to 1/12 of the vessels
diameter (size). They typically extend
the length of the vessels straight side
and are spaced at 90 degree intervals.
While four sidewall baffles are gener-
ally used in alloy vessel construction,
they are not practical in glass-lined
reactors. Consequently, glass-lined
vessels typically have one baffle which
is supported from a top head nozzle. Various baffle types. (Four sidewall
Over the years several different styles baffles=100% effectiveness).
of glass-lined baffles have evolved,
each one providing improved baffle
effectiveness (i.e. vortex reduction)
over its predecessor.

5
Minimum Mixing Volumes for Standard
Cryo-Lock/Fin Baffle Configurations

Capacity Capacity Capacity

Standard
(gallons) (gallons) (gallons)
Reactor Series Reactor Size Cryo-Lock
to Bottom to Top to Bottom
Impeller
of Impeller of Impeller of Baffle

RA48 &RS48 300/500 23" CBT 17 59 96

RA60 & RS60 750/1000 29" CBT 35 100 181

RA78 & RS78 1500/2000 33" CBT 61 161 316

RA96 & RS96 3000/4000 41"CBT 96 336 619

The superiority of the System Innovation details of dip pipes, sparger assem-
and Integration blies, or in-tank filter elements, and
ProSol Pfaudler mixing When it comes to engineered mixing
provide an added degree of assurance
when it comes to the mechanical
system CBT with concave systems, Pfaudler innovation is not
integrity of these devices.
limited to Cryo-Lock impeller systems.
baffle over competitive The Quatro Pipe was developed in It is also worth noting that Pfaudler
standard offerings has been response to a demand for more effec- mixing systems are not limited to
tive use of limited top head nozzles. glass-lined construction. Pfaudler has
dramatically shown in By combining the functions of baffle, supplied alloy mixing systems for
dip pipe, sampling tube, and thermowell, years. The same glass-lined impeller
demonstration tests. Ask your the Quatro Pipe can potentially free at systems which provide effective
Pfaudler representative for least two nozzles for process piping or agitation at both low and nominal
instrumentation. batch volumes are also available in
more information. stainless steels and a number of nickel-
Glass-lined or Teflon-lined dip pipes
based alloys. The same skilled fabrica-
often play an integral role in the over-
tion techniques used to manufacture
all performance of a reactor system. By
the Pfaudler family of glass-lined
combining basic chemical processing
agitation systems can be utilized to
knowledge with information about
supply the same devices in polished
proposed or existing mixing systems,
stainless steel.
Pfaudler can assist in specifying the

6
Named Cryo-Lock The two-piece agitator comprises a
hollow, glassed shaft and a glassed
because it is based impeller. The shaft and the bore of
the impeller hub are precisely dimen-
on an application of sioned to create an interference fit
cryogenics, this with sufficient strength to handle all
mixing loads.
breakthrough development
The impeller and shaft are joined or
not only solved the 1 Removal starts with liquid separated by piping liquid nitrogen
nitrogen fed into hollow into the shaft, causing a cooling effect
problems related to agitator shaft. that shrinks the shaft enough in a few
one-piece agitator design minutes to release the interference fit
and allow the hub to slide on or off.
and maintenance, but When the shaft is allowed to return to
opened new realms of ambient temperature, it expands again
to form a rigid glass-to-glass joint.
operational flexibility
The precision dimensions that make
for glass-lined this cryogenic technique feasible are
accurately duplicated in the manufac-
agitated reactors. turing process, so Cryo-Lock impellers
2 Cryogenic cooling shrinks shaft and shafts are interchangeable off the
and loosens glass-to-glass joint. shelf. This makes it unnecessary to
Glass-metal and ceramic-metal replace a Cryo-Lock agitator shaft
composites are frequent materials of when only the impeller has suffered
choice for process vessels and other damage.
equipment handling products that
are highly corrosive, sticky or metal Since Cryo-Lock impellers are sized
sensitive. and shaped to fit through a reactors
manway, you can now change a dam-
Pfaudler developed the original glass- aged impeller inside the cleaned reac-
lined vessel construction a century tor, without having to remove the
ago, and for more than sixty years shaft, drive, motor and access cover.
we have designed and built mixing 3 Turbine slides off shaft onto This significantly cuts the downtime
systems of every type and variety, padded bottom head. required for changeover from days to
including glassed steel, for a broad hours in most cases.
spectrum of applications.

One result: our Glasteel agitated reac-

tors have for decades been the work-
horses of the specialty chemical and
pharmaceutical industries worldwide.

4 Separated turbine passes easily

through manway.
7
SB25-100-2

Pfaudler, Inc. Pfaudler-Balfour Ltd.

Rochester, New York Leven, Scotland

Chemical Reactor Services,

Ltd.
Glasteel Parts Bolton, England
and Services Bilston, England
Rochester, New York

Pfaudler-Werke GmbH
Schwetzingen, Germany

Pfaudler S.A. de C.V.

Mexico City, Mexico
GMM Pfaudler
Karamsad, India

Pfaudler Equipamentos
Industriais Ltda. Suzhou Pfaudler
Taubate, SP, Brazil Glass-Lined Equipment
Company Ltd.
Suzhou, China

The information contained in US Facilities Pfaudler-Balfour Ltd.

this bulletin is believed to be Leven, Fife, Scotland
Pfaudler, Inc.
reliable general guidelines for Tel: (44 1333) 423-020
Rochester, New York
consideration of the products Fax: (44 1333) 427-432
Tel: (1 716) 235-1000
and services described herein. 1000 West Avenue
Fax: (1 716) 423-9644 Pfaudler Equipamentos
The information is general in PO Box 23600
Industriais Ltda.
nature and should not be Glasteel Parts and Services Rochester, NY 14692-3600
Taubate, SP, Brazil
considered applicable to any Rochester, New York Tel: 716 235 1000
Tel: (55 122) 326-244
specific process or application. Tel: (1 716) 235-1010 Fax: 716 235 6393
Fax: (55 122) 326-301
Pfaudler, Inc. expressly Fax: (1 716) 235-7923 www.pfaudler.com
disclaims any warranty, Pfaudler S.A. de C.V.
expressed or implied, of fitness Worldwide Facilities Mexico City, Mexico
for any specific purpose in Chemical Reactor Tel: (52 5) 355-0100
connection with the infor- Services Ltd. Fax: (52 5) 355-0809
mation contained herein. Bolton, England Pfaudler-Werke GmbH
Copyright Tel: (44 1204) 862-777 Schwetzingen, Germany
Pfaudler, Inc. 2000 Fax: (44 1204) 577-484 Tel: (49 620) 2850 1999 Mt. Read Blvd.
A Unit of Robbins & Myers, Inc. Fax: (49 620) 222412
All rights reserved
Bilston, England PO Box 20857
Tel: (44 1902) 353-637 Suzhou Pfaudler Rochester, NY 14602
Glasteel and Cryo-Lock Fax: (44 1902) 495-696 Tel: 716 235 1010
are registered trademarks of Glass-Lined Equipment
Company Ltd. Fax: 716 235 7923
Pfaudler, Inc. ProSol is a GMM Pfaudler
trademark of Pfaudler, Inc. Karamsad, India Suzhou, China
Tel: (9126) 9230367 Tel: (86 512) 7239104
Fax: (9126) 9231935 Fax: (86 512) 7232903

12/00 3M Mech No. 634