Energy Savings in Agitation

Introduction

Mixing technology serves as a linchpin in various industrial processes, facilitating tasks such as homogenizing liquids, suspending solids, dispersing gas, and ensuring efficient heat transfer. The latest advancements in mixing technology hold significant promise for enhancing the efficiency of stirring processes in terms of both energy consumption and production costs.

Long service life of agitators vs. short product life cycles

One of the key challenges in industrial mixing arises from the discrepancy between the longevity of agitators and the increasingly shorter product life cycles of the materials being mixed. While agitators can endure for many decades with proper maintenance, the properties of the materials being processed often evolve rapidly due to changing product demands. This misalignment presents an opportunity for energy savings. However, realizing this potential requires a systematic approach.

Key Factor: Process Verification:

Process verification stands as a crucial initial step in exploring energy-saving opportunities. Factors such as motor power, agitator-to-vessel setup, feed points, drain points, mixing zones, baffles, batch time, and product quality must be thoroughly examined. Additionally, considerations such as side reactions, mass transfer, and heating and cooling times play pivotal roles in optimizing energy usage.

Energy Savings – a holistic approach:

Energy savings can be achieved through various approaches:

-????????? Utilizing energy-efficient motors in conjunction with variable frequency drives can reduce power consumption during operation. Furthermore, advancements in impeller technology enable comparable mixing performance at lower power levels than traditional standards.

-????????? Additionally, optimizing gas handling capacities through specially designed impellers can minimize the power requirements of auxiliary equipment such as compressors.

-????????? Reducing operational hours and/or increasing yield while maintaining constant energy consumption further contribute to overall energy efficiency.

In a “Best Case”-Scenario, more than one approach is combined with another.

Mechanical Verification:

Mechanical verification is essential for any retrofitting endeavour to ensure the integrity of agitator components. This process involves a comprehensive assessment of various elements, including motor power, gearbox forces, calculated safeties of shaft, bearing housing and impellers. Also, the critical shaft speeds, and vessel nozzle loads need to be considered. Additionally, interfaces such as vessel nozzles, baffles, and piping must be carefully examined to account for loads induced by the agitator setup.

In essence, achieving energy savings in industrial mixing requires a holistic approach that addresses both operational and mechanical aspects. By leveraging advancements in technology and meticulously evaluating process parameters, industries can not only optimize energy consumption but also enhance productivity and reduce operational costs over the long term.

There is more information on this topic in the upcoming episode of our webinar series. The next planned webinar will take place on May 16th 2024. Register now for our free webinar .

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