Pfaudler Mixing Systems Reduce processing times and save costs R E A C T O R S Y S T E M S
Reduce processing times and save costs with Pfaudler Mixing Systems PFAUDLER-BALFOUR - a worldwide leader in the manufacture of process equipment -produces mixing systems to meet any application, process condition, mixing operation and viscosity range. TYPICAL FLOW PATTERNS Pfaudler-Balfour can recommend the optimum mixing system for specific requirements and show how it can be modified or changed. If required, a custom impeller or agitator can also be designed and built. Significant cost savings can be achieved by mixing and matching impellers to: optimise product quality and yield reduce mixing/process times optimise the agitation process maximise energy efficiencies ensure performance effectiveness respond to changing market conditions Curved Blade Turbine Pfaudler Mixing Systems improve product quality and yield while minimising costs. Optimal agitation process The Cryo-Lock option is a complete all in one mixing system based on a single reactor with a wide variety of interchangeable agitator blades. This flexibility means blade configurations can be altered to best suit the requirements of each product. For all mixing systems, Pfaudler can also produce computer simulations to maximise the efficiencies in each of the five basic processes: mixing/blending suspension gas absorption/dispersion emulsification heat transfer Turbofoil Impeller
Pfaudler Mixing Systems - improve product quality and yield while minimising costs Reduced process times With some products, switching to a turbofoil blade from a standard fixed agitator can lead to mixing times being reduced by half while pumping capacity is almost doubled. 1 1,0 0,8 Reduced mixing time 2,5 2,0 Increased pumping capacity 2 3 0,6 0,4 1,5 1,0 4 0,2 0 RCI 1100 CBT 835 PBT 890 TBF 990 0,5 0 Blade Type P/V=Constant RCI 1100 CBT 835 PBT 890 TBF 990 5 6 7 Cryo-Lock Family of Agitators Blending Heat Emulsion Suspension Gas Transfer Dispersion 1 ANC Anchor 2 PBT Pitched Blade Turbine 3 FBT Flat Blade Turbine 4 MFI Multi-Flight Impeller 5 RCI Retreat Curve Impeller 6 TBF Turbofoil 7 CBT Curved Blade Turbine
Performance characteristics 1 2 3 ANC anchor low shear tangential flow high torque for higher viscosity fluids can operate at low liquid levels PBT Pitched Blade Turbine moderate shear (higher flowto-shear ratio) combined radial and axial flow relatively high drive speed FBT Flat Blade Turbine high shear load pure radial flow Unlimited impeller options Impeller and baffle configurations can be adapted to serve all basic process operations. In addition, other factors, such as drive speed and baffle arrangement, can be altered to enable most impellers to be used in more than one of the five basic unit operations. 4 MFI Multi-Flight Impeller where single impeller is inadequate for high viscosity fluids lightweight solids in narrow vessels 5 6 7 RCI Retreat Curve Impeller versatile, general purpose design high radial flow wider baffling required insensitive to viscosity variations suitable for low liquid levels, small batches TBF Turbofoil low shear forces high axial flow at relatively low baffling low torque low power-consumption CBT Curved Blade Turbine high shear radial flow wider baffling required with low viscous fluids
Improve power and energy efficiencies Increased energy efficiencies Effective system design means power input can be reduced by achieving: optimum heat transfer uniform dissipation of energy and low energy demand. Energy savings of up to 35 per cent have been achieved. Power applications and advantages Homogenisation A high performance agitator Turbofoil (3.2kW) needs 35% less energy compared to an Impeller (5.1kW). On the basis of BE 6300, SG = 1.3 and viscosity = 20cp. Gas-Dispersion Replacing an Impeller (RCI) with a standard agitator (CBT) can triple gas-absorption rates. On the basis of 1 kw/m3, 630 m3/h instead of 220 m3/h. Agitator Power (KW) Power Diagram AE/BE/CE 6300 for SG = 1.3 and viscosity = 100cp 12 10 8 6 4 2 0 0 20 40 60 80 100 120 140 Agitator Speed (rpm) Impeller TBF Drive VSO 8/100 Drive VSO 16/100 Suspension For solid particles distribution needs, the Pitched Blade Turbine (PTB) at 4.2 kw can lead to energy savings of 3.7 kw over the Impeller (RCI), representing a considerable cost saving during the year Crystallisation Replacing the anchor (ANC) with the double stage Turbofoil can increase output by 30%.
Minimise downtimes and maintenance costs Safety and environmental protection The dismountable system is corrosive resistant and considerably reduces the risk of leakage caused by splitting vessels and replacing gaskets. Cryo-Lock enables gasket sizes for BE 6300 vessels to be reduced by 2,500 mm compared to the CE 6300 versions, resulting in a 60% reduced leakage rate at vacuum conditions. Performance effectiveness Further cost efficiencies result from Cryo-Lock s unique dismountable design which means the single shaft stays in place so only the blades are changed. Liquid nitrogen cooling enables the blade to be easily accessed and removed quickly. Cryo-Lock impellers in a BE vessel can be changed in less than two hours compared to two days or more for standard impeller in a CE vessel design. There is also no need to replace a Cryo-Lock agitator shaft when only the impeller has suffered damage. This can be changed inside the cleaned reactor without removing the shaft, drive, motor or access cover. Replacement agitators can also be stored economically. Pfaudler s Glasteel reactor technology means vessel and agitator life is maximised for mixing corrosive substances. All these factors contribute to minimal downtimes and maintenance costs. The perfect complement to Pfaudler Mixing Systems. Pfaudler-ProSol Next generation mixing systems Pfaudler In-Line Drives For glass and alloy mixing systems Total Flexibility Pfaudler-Balfour s mixing technology offers total flexibility. You can respond immediately to changing market conditions by: reconfiguring your Glasteel reactor modifying or completely changing the mixing operation To find out how Cryo-Lock can save costs by optimising product quality and yield contact: Pfaudler-ProSol See Technical Data Bulletin No: 97-07-01 Pfaudler In-Line Drives See Technical Data Bulletin No: 97-02-01 Pfaudler-Balfour Leven, Fife, Scotland, KY8 4RW. Tel: (01333) 423 020 Fax: (01333) 427 432 Email: mailus@pfaudlerbalfour.co.uk Website: www.pfaudlerbalfour.co.uk R E A C T O R S Y S T E M S TECHNICAL DATA BULLETIN NO: 97-01-02