When designing an electric submersible agitator, many aspects must be considered to achieve excellent performance, efficient operation and long-term durability.

Impeller Design

Regarding the design of the impeller, it is the core component that drives the mixing of fluids. The design of the impeller is directly related to the overall performance, energy consumption and working efficiency of the mixer. When designing the impeller of a submersible mixer, the following key factors need to be considered:

Blade geometry: The shape and curvature of the blades affect the flow pattern and mixing effect of the fluid. Common blade shapes include flat blades, inclined blades and airfoil blades, each of which is suitable for different application scenarios.

The number of blades is selected based on the flow characteristics and viscosity of the mixed media. Low-viscosity fluids may use fewer blades to achieve high flow rates, while high-viscosity fluids may require more blades to enhance shear and mixing.

Impeller diameter and pitch (blade tilt angle) are related to the pumping capacity and energy consumption of the agitator. Increasing the diameter increases the flow rate, but energy consumption also increases. Adjusting the pitch angle affects the balance of axial and radial flow.

The gap between the impeller and the bottom or sidewall of the container affects the flow pattern and mixing effectiveness. Reasonable gaps help avoid dead spots and ensure that the fluid is evenly mixed in the container.

Computational fluid dynamics (CFD) software can be used to simulate and analyze to optimize the impeller design, adjust the design before making physical prototypes, and save development time and resources.

Material Selection

When selecting materials for electric submersible agitators, it is necessary to ensure that they can withstand long-term operation, maintain stable operation, and maintain high efficiency in harsh environments. When selecting, it is necessary to focus on the corrosion resistance, mechanical strength and cost-effectiveness of the materials. Special attention should be paid to the material selection of the following components:

Impeller: It needs to withstand the mechanical loads during operation and resist the erosion of the medium. Commonly used materials include:

Stainless steel (such as 316L, 904L), which is suitable for a variety of environments, such as wastewater treatment and chemical industries.

Duplex stainless steel, which has better strength and corrosion resistance than ordinary stainless steel, is suitable for more severe environments.

Fiber reinforced polymer (FRP), which is lightweight and corrosion-resistant, is suitable for specific chemical applications.

Titanium, although more expensive, has excellent corrosion resistance and strength-to-weight ratio, suitable for extremely corrosive environments.

Shaft: Responsible for transmitting power, and must maintain straightness and resist bending. Optional materials are:

Stainless steel, which is widely used due to its strength and corrosion resistance.

Duplex stainless steel, which has higher strength and corrosion resistance.

Alloy steel, with protective coating, provides an economical option for less corrosive environments.

Motor housing: protects the motor from the surrounding media, requiring good sealing and corrosion resistance. Available materials are:

Stainless steel, corrosion-resistant and durable.

Cast iron, with a protective coating, is suitable for less corrosive environments and is low cost.

Engineering polymers, corrosion-resistant and can reduce overall weight.

Seals and O-rings: prevent the media from entering the motor. Commonly used materials are Viton, EPDM or PTFE. When selecting, consider the chemical compatibility of the media and the operating temperature.

When selecting materials, consider specific operating conditions, such as the chemical properties of the media, temperature, pH value, and the presence of abrasive particles. Consult material compatibility data and perform necessary tests to ensure that the selected materials can operate stably during the expected service life of the agitator.

Fluid Dynamics Simulation

Fluid dynamics simulation technology has penetrated into the design and improvement process of electric submersible agitators and has become an indispensable part.Advanced computational fluid dynamics (CFD) software allows engineers to accurately predict and deeply analyze the fluid performance of the mixer before building a physical model. This approach brings the following significant advantages:

When it comes to design optimization, CFD simulation provides engineers with a fast and cost-effective way to test and optimize multiple agitator design options. By adjusting key elements such as impeller shape, rotational speed and vessel layout, engineers can quickly find the configuration that best suits specific application needs.

In terms of improving mixing efficiency, the simulation process can intuitively display the flow state of the fluid in the container, helping engineers to discover and solve problems such as uneven mixing or dead zones. Based on the simulation results, engineers can adjust the design or installation position of the agitator to ensure uniform mixing of the fluid in the container.

In addition, in terms of energy efficiency optimization, by comparing the energy consumption and mixing efficiency of different designs, engineers can design an agitator that has both efficient mixing and low energy consumption. This not only helps reduce operating costs, but also complies with the concept of sustainable development.

In terms of scalability assessment, CFD simulation can predict how the performance of the agitator changes with the change of container size, providing precise expansion guidance for applications from laboratory scale to industrial scale.

The typical process of fluid dynamics simulation includes the following key steps:

First, geometric modeling is performed, and engineers use CAD software to build a three-dimensional model of the agitator and container.

Then meshing is performed to divide the fluid area into multiple small units for numerical analysis. The fineness and shape of the mesh have an important impact on the accuracy of the simulation results.

Then the boundary conditions are set to clarify the key parameters such as the physical properties of the fluid (such as density, viscosity), the rotation speed of the agitator, and the size of the container according to the actual application scenario.

In the equation solving stage, CFD software will solve the basic equations of fluid dynamics (such as the Navier-Stokes equations) according to the preset boundary conditions to obtain the flow state of the fluid inside the container.

Subsequently, the simulation results are post-processed and analyzed, the obtained data is presented in a visual way, and the design of the agitator is evaluated and optimized by examining the core indicators such as the flow pattern, velocity distribution and mixing efficiency of the fluid.

In addition, with the continuous advancement of technology, simulation technologies such as multiphase flow, particle tracking and chemical reaction kinetics have been included in the scope of fluid dynamics simulation, aiming to more accurately simulate the mixing process in complex application scenarios.

However, it should be emphasized that although fluid dynamics simulation technology has many advantages, it still needs to be verified in combination with physical experiments in actual applications to ensure the accuracy of the simulation results and enhance the confidence of engineers in the design process.

About Tianjin Kairun Pump Co., Ltd.

Tianjin Kairun Pump Co., Ltd. specializes in the manufacture of electric submersible agitators and other pumping solutions. The company adheres to quality and innovation to become a preferred supplier of efficient and reliable mixing equipment for various industries.

Tianjin Kairun is committed to improving product quality and has obtained ISO 9001 quality management system certification. This international standard ensures that the company follows a strict quality control process from product design, manufacturing to testing. The company continues to optimize this system to meet customer needs and promote operational improvements.

In the design of electric submersible mixers, Tianjin Kairun considers key factors such as impeller design, material selection and fluid dynamics simulation. The engineering team uses advanced impeller design concepts, selects high-quality materials suitable for different applications, and uses fluid dynamics simulation technology to optimize product performance and efficiency.

For customers who need electric submersible mixers, Tianjin Kairun Pump Co., Ltd. provides customized solutions to meet the specific needs of different industries. The company's professional team is always ready to assist customers in selecting the right agitator to ensure the best mixing effect and service life.

For more information about Tianjin Kairun electric submersible agitators or to discuss specific needs, please contact us by email at catherine@kairunpump.com. With expertise and commitment to quality, Tianjin Kairun Pump Industry Co., Ltd. provides reliable mixing solutions for a wide range of industrial applications.

References

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3. Dickey, D. S., & Fasano, J. B. (2004). Mechanical Design of Mixing Equipment. In E. L. Paul, V. A. Atiemo-Obeng, & S. M. Kresta (Eds.), Handbook of Industrial Mixing: Science and Practice (pp. 1247-1332). Hoboken, NJ: John Wiley & Sons.

4. Hemrajani, R. R., & Tatterson, G. B. (2004). Mechanically Stirred Vessels. In E. L. Paul, V. A. Atiemo-Obeng, & S. M. Kresta (Eds.), Handbook of Industrial Mixing: Science and Practice (pp. 345-390). Hoboken, NJ: John Wiley & Sons.

5. Brennan, D. J. (2006). Process Industry Economics: An International Perspective. Oxford: Butterworth-Heinemann.

6. American Water Works Association. (2012). Water Treatment Plant Design (5th ed.). New York: McGraw-Hill.