Choosing the Right Portable Tank Mixer
Mixing equipment plays an important role in preventing water quality issues such as stratification, stagnation and the growth of harmful microorganisms in potable drinking water reservoirs. Choosing the right mixer for your tank can help ensure that your water system operates well and complies with regulations.
The type of mixer chosen depends on the viscosity of the liquid being mixed. The motor size and power rating is also a factor.
Top Mount
A top mount portable tank mixer is an invaluable tool for mixing a wide range of industrial fluids in large tanks. Known for their durability, low maintenance needs, and versatility, these industrial mixers are used to ensure product quality and aid in process consistency in many different industries. They are also designed to be integrated with advanced control systems for automated operation and improved efficiency.
The type of tank mixer to use depends on the desired mixing speed and intensity, as well as the material to be mixed. Some materials are sensitive to shear, which can cause damage or degradation. It is important to choose a tank mixer that can withstand the pressure and temperature requirements of the application. In addition, the material selected must be compatible with the chemicals being mixed to avoid chemical reactions that could lead to corrosion or contamination.
Depending on the type of tank, mixer mounting configurations vary. Drum and tote mixers thread directly into the bung opening on the vessel or have special brackets that are designed to mount on the drum portable tank mixer or tote. c-clamp and plate mount mixers are commonly used in larger, permanent installations, as well as sealed or pressurized tanks.
These portable mixers are primarily made of stainless steel, although some models are available in carbon steel or other corrosion-resistant alloys. They are designed to withstand harsh operating conditions and ensure longevity by using high-quality components that are resistant to corrosion and wear and tear. Regular inspections and lubrication are recommended to detect any potential issues early on.
Side Mount
For small mixing tanks up to 1,000 gallons (3,785.4 liters) the mixer is clamped to the side of the tank. Optimum mixing will be achieved when the mixer is angled from the tank wall, either off-center (figure 1) or on-center (figure 2). Angling off-center is preferred for good material turnover as in mixing a slurry. Angling on-center is desired when more gentle mixing is required and when vortexing must be minimized.
Larger agitators and mixers are commonly mounted using an external bracket or screwed through a threaded connection in the drum cover. Various mounting-clamp designs can be used to secure these types of mixers, with the liquid type and application dictating the best style of large tank agitator.
A popular choice for IBC tote tank mixing is the deluxe toggle clamp bracket mixer that easily connects to the top- or bottom-lifting eye on an IBC tote, which provides a simple and quick solution to fluid handling in industrial applications. ANSI flange and plate mount mixers are also effective choices when a more permanent installation is required.
For higher viscosity applications like blending (petro)chemical products, paper & pulp, or oil & gas, a side entry mixer is often recommended for optimum mixing results. These agitators can be mounted on the ANSI flange or plate of a tank or vessel and are typically designed to be installed with baffles to ensure proper mixing and prevent turbulence in the liquid. These high-performance agitators are available with both electric and explosion proof motors to meet the demands of a variety of industrial processes.
Bottom Mount
Like any other industrial equipment, portable mixers perform at their best when they are properly configured for the specific mixing and blending task. Many operational variables must be taken into account, including mixer type, fluid viscosity and rate of agitation.
Tank design and position of the agitator also play a significant role in defining the flow pattern of your mixture. Magnetic mixers are placed in the bottom of the tank creating a top to bottom vortex, while c-clamp or flange mount mixers can be positioned in the center of, or offset from the tank. This gives you more flexibility to create a more gentle and thorough flow pattern.
Propeller type and shaft length also impact the mixing performance of a portable tank mixer. A rule of thumb is to position the mixer propellers 1 to 2 propeller diameters from the tank bottom. This will determine shaft length and allow you to gauge proper mixing action.
It is also important to consult the mixer manufacturer to determine the prop’s pumping rate for the particular model and size at the various rpms it will operate. This information is normally provided in terms of the number of gallons per minute (GPM) that will be pumped. This will help you determine the appropriate agitation rate needed for your application — mild agitation is usually 1/2 to 1 tank turnover per minute, while vigorous agitation may require 2-1/2 or more turnovers.
Magnetic Coupled
For the most demanding sterile processing applications that require full containment of substances to be mixed, a bottom mount magnetic mixer is an ideal solution. This type of mixer eliminates the need for a shaft seal and significantly reduces the risk of product contamination.
Instead of relying on a mechanical seal to keep liquid from leaking out, a mag mixer uses a magnetic coupling to transfer torque between the motor and mixing impeller. The outer drive magnet of the mag mixer aligns with a set of magnets portable tank mixer manufacturer on the inner male bearing of the mixer, and they couple together to create an invisible connection between them. The external driver then generates a rotating magnetic field to rapidly spin the stir bar and mix the contents of the tank.
In addition to eliminating the need for a shaft seal, this magnetic coupling design makes flange-mounted mag mixers easier to clean and maintain. This means that a plant can remove the mag mixer from the tank and replace the male bearing without draining the process or using a solvent. Furthermore, these magnetic tank agitators can be used for longer periods of time because they do not wear as quickly as a traditional mechanical seal. This helps reduce maintenance costs and ensures that the mag mixer is ready for the next batch at any moment.