Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162

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Chemical Engineering & Processing: Process Intensification

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Investigation of power characteristics in a novel cup-shaped-blade mixer T

a a a a a a,b,⁎
Cuili Guo , Song Xue , Wei Li , Hongyun Qin , Junheng Guo , Jinli Zhang
a
School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, PR China
b
School of Chemistry and Chemical Engineering, Shihezi University, Shihezi 832003, PR China

A R T I C L E I N F O A B S T R A C T

Keywords: The impeller performance and energy utilization are closely related to the agitator design. In this article, the
Cup-shaped-blade impeller power characteristics of the novel cup-shaped-blade (CB) impellers were investigated by using the Newtonian
Power consumption fluid in a stirrer tank, considering the effects of shape parameters, angle of the blades, baffles, agitator speed and
Power correlation physical properties of working fluid. An accurate power correlation for the CB impellers was established. In
Computational simulation
addition, the CFD method was employed to simulate the power consumption and flow characteristics, and the
calculated power value fitted well with the experimental value. The obtained results could provide the basis for
the design and scale-up of the CB impellers.

1. Introduction
Mixing in stirrer tanks plays an important role in various industries
processes in the field of food, agrichemicals, cosmetics and beverage
industries etc [1]. The agitator is a key part in the mixing vessel which
directly determines power characteristics and the mixing performance
of the mixing system. It is widely recognized that the power con-
sumption is one of fundamental design parameters [2–4]. In recent
years, a lot of work has been done on the power consumption for dif-
ferent liquids using various agitators, adopting both experimental and
simulated techniques to carry the research on power characteristics. It
is desirable to design a new type agitator blade to fulfill the require-
ments of different situations, besides the applications of existing agi-
tators in multi-combination modes.
The modification of agitators has been reported recently. For ex-
ample, Roman et al. [5–7] studied the characteristics including power
consumption, complete suspension speed and gas-liquid transfer effi-
ciency of a modified blade Rushton turbine in different systems. They
found that the modified blade turbine was more efficient than the
standard turbine. Niedzielska et al. [8] investigated the power con-
sumption of a ribbon impeller with particular design and found that the
geometrical parameters had a significant impact on power consumption
and efficiency of agitator. On the other hand, for the high viscosity
system, with the first report by Schneider et al. [9], intensive researches
on the coaxial mixer were reported by the Canadian Tanguy's group
[10–15]. According to different mixed materials and working condi-
tions, they designed and studied a series of new multiple impellers. In
their research, the proximity impellers (helical ribbon, anchor) and
dispersing turbines pitched blade turbine (PBT), rushton turbine (RT)
were used together. The power consumption and mixing performance
of coaxial mixers were mainly studied. The results showed that these
multiple impellers exhibited excellent mixing performance in many
specific situations. At present, there are few studies on novel agitators
which have a simple structure but extensive applications. So far no
report has been found on the type of cup-shaped-blade (CB) impellers.
Computational fluid dynamics (CFD) has been widely adopted to
understand deeply the power consumption, flow field and the turbulent
kinetic energy in the stirred tank [16–20], with the precision increased
gradually. Thus, the objective of this paper is to study the power
characteristics of the novel CB impellers, in combination with the CFD
numerical simulation to predict the power consumption and flow pat-
terns. Experimental and simulation methods are performed considering
the different parameters, such as impeller geometry (impeller type and
blade angle), agitation condition (impeller speed and power) and pro-
cess condition (working fluid concentration).
2. Experimental materials and methods
2.1. Experimental setup
The experiments were carried out in a pilot-scale transparent tank
made from plexiglas equipped with flat bottom, with the agitators
mounted centrally. The mixer and the detailed geometrical dimensions
are shown in Fig. 1. In the experiments, the liquid height HL is equal to
the tank diameter T and corresponding to a liquid volume of 0.4 m3.
The distance C of CB impellers is T/4 whereas that value of PBT and RT

⁎
Corresponding author at: School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, PR China.
E-mail address: zhangjinli@tju.edu.cn (J. Zhang).

https://doi.org/10.1016/j.cep.2018.01.025
Received 16 October 2017; Received in revised form 24 January 2018; Accepted 29 January 2018
Available online 31 January 2018
0255-2701/ © 2018 Elsevier B.V. All rights reserved.
C. Guo et al.
is T/3. The four removable baffles are T/10 long, 5 mm thick, 83 cm
high and can be installed into the tank every 90°.
Fig. 2 showed the schematic diagram of cup-shaped blades pro-
duction and blades that were cut by the 90° stainless steel elbow with
an inner diameter of 56 mm. Three types of the cup-shaped-blades
(CB1, CB2, CB3) provided by FLUKO (China) were studied. The CB
impellers consist of three cup-shaped blades and the angles of blades
can be adjusted flexibly. Another two widely used impellers PBT and RT
were also investigated as comparisons. The impellers and detailed
geometrical dimensions are shown in Fig. 3 and Table 1.
2.2. Materials
Malt syrup (70–100 wt%) was employed as the Newtonian fluid, of
which the viscosity could be adjusted by adding the pure water [21,22].
The rheological properties of malt syrup were determined by rotational
viscometer (Brookfield DV-C). The density of the Newtonian fluids is
between 1000 and 1450 kg/m3, and the viscosity ranges from 0.001 to
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Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162
Fig. 1. Schematic diagram of the experi-
mental setup.
Fig. 2. Schematic diagram of the cup-shaped blades.
4.56 Pa·s. The measurements as well as experiments were performed at
29 ± 1 °C. Table 2 lists the specific experiment conditions.
2.3. Methods
The power number is a reliable design specification in the mixing
operation and has been widely used to predict the process results, fol-
lowing the first report of power consumption on 1934. Recently,
Chapple et al. [4] studied the power consumption of PBT, RT through
accurate torque measurement techniques and performed the generic
power number curves. Liu et al. [22] studied the power consumption of
a double inner impeller and the power curves under different condi-
tions. Tanguy et al. [10] studied the power consumption of the blade-
helical ribbon impellers at different speeds and performed a generalized
power curve.
To determine the power consumption, the motor has been coupled
to the torque sensor and the power could be calculated from the torque.
The net power consumption can be obtained by the following formula
C. Guo et al. Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162

Fig. 3. (a) Cup-shaped-blade impeller (CB2); (b) 45°-

pitched blade turbine (PBT); (c) Rushton turbine
(RT); (d) Schematic diagram of the cup-shaped-blade
impeller.

[15]. losses power measured without impellers attached.

The Reynolds number Re and power number Np are defined by the
P = 2π NM (1) following equations.

ρ ·N ·D2
Pnet = Pshaft − PL (2) Re =
μ (3)
Where P is power, N is rotational speed, M is the torque value, Pnet is the
net power consumption, Pshaft is the input shaft power measured under Pnet
Np =
normal operating conditions with malt syrup or water, and PL is the ρ · N 3 · D5 (4)

Table 1 Where μ is the viscosity, ρ is the fluid density, N is the rotational speed
Structure parameters of three different cup-shaped-blade impellers. and D is the agitator diameter.
Structures θ D(mm) d(mm) L(mm)
Table 2
CB1-0 0° 280 68 42 Physical parameters of malt syrup at different concentrations.
CB1-15 15° 280 68 42
CB1-30 30° 280 68 42 Number Concentration (wt Density ρ Viscosity μ Temperature (°C)
CB1-45 45° 280 68 42 %) (kg/m3) (Pa s)
CB2-0 0° 284 75 58
CB2-15 15° 284 75 58 M1 100 1400 4.56 28.0
CB2-30 30° 284 75 58 M2 90 1350 1.28 29.0
CB2-45 45° 284 75 58 M3 85 1338 0.95 28.5
CB3-0 0° 286 56 63 M4 82 1338 0.43 29.0
CB3-15 15° 286 56 63 M5 70 1312 0.09 29.5
CB3-30 30° 286 56 63 M6 50 1124 0.013 29.5
CB3-45 45° 286 56 63 Water 0 1000 0.001 28.0

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Fig. 4. The details of computational mesh of

CB2-15.

Table 3 Table 5
The gird numbers of different mixers. Comparison of the calculated torque values using three meshes without baffles.

Global Rotating-zone Stationary-zone Speed (rpm) Mesh type Torque (N m) Average value and Standard deviation

CB1-15 1945984 387621 1558363 175 M(1) 1.56 1.58 ± 0.02

CB2-15 1931067 381417 1549650 M(2) 1.58
CB3-15 1939740 387128 1552612 M(3) 1.60
CB2-0 1935148 386562 1548586
200 M(1) 2.04 2.02 ± 0.02
CB2-30 1945555 403506 1542049
M(2) 2.02
CB2-45 1938255 388933 1549322
M(3) 1.99

250 M(1) 3.05 3.10 ± 0.03

2.4. Numerical simulation M(2) 3.13
M(3) 3.11

2.4.1. CFD methodology

In order to understand the power consumption and mixing condi-
tions well, the flow field of three CB impellers operated at four angles standard k–ε model was used for turbulence model, suggesting a good
was simulated with k–ε model by Ansys Fluent14.0 [23–25]. agreement between experimental results and CFD predictions. They
In previous work, the k–ε model has been proved to be able to concluded that the single-phase and power characteristics could be
predict the power and flow pattern. For example, Singh et al. [26] in- accurately predicted through CFD simulations. Besides, CFD predictions
vestigated the power consumption of RT with novel blades while the for a new geometric and process configuration could be relied upon for
design purpose. Bashiri et al. [27] performed the research of mean
Table 4 velocity profiles and turbulent flow using the standard k–ε turbulence
Constants in the standard k–ε model. model and radioactive particle tracking (RPT) technique in the stirred
tank equipped with RT or PBT, showing a good agreement between
Cμ σk σε C1ε C2ε
experimental and predicted results in the tank. Thus the standard k–ε
0.09 1.0 1.3 1.44 1.92 model was also adopted in our research.

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the momentum equations, and the second-order implicit scheme for time
advancement. The mesh independence verification was performance and
results were shown in Table 5. Mesh (1), (2), (3) in Table 5 have
1813509, 1930171, 2610017 girds respectively. An iterative manner
was used to solve the transport equations through ANSYS-Fluent. For a
more accurate simulation, each normalized residual should be less than
10−5. The torque acting on the agitator and velocities near the impeller
region were monitored to judge the convergence of the simulations.
The following continuity and momentum equations were used to
describe the turbulent fluid flow in the tank] [26,27].
∂ui
=0
∂x i (5)

∂ui ∂P ∂ ⎛ ⎛ ∂ui ∂uj ⎞ ⎞

=− + + ⎟ − ρui′ u′j
ρuj
∂x j ∂x i
μ⎜
∂x j ⎜ ⎝ ∂x j ∂x i ⎠ ⎟ + Fi
⎝ ⎠ (6)
Fig. 5. Comparison of Np obtained by experiment and CFD simulation. where Fi represents the external body forces. The Reynolds stress terms
ρui' uj' and the turbulent viscosity (μt) can be expressed as below.
The stirrer tank was divided into a rotating regime and a stationary
∂u ∂uj ⎞ 2
regime. In order to take into account the complex structure of CB im- ρui′ u′j = −μt ⎛⎜ i + ⎟ + kρδij
⎝ ∂x j ∂x i ⎠ 3 (7)
peller region, the unstructured meshes were used to obtain a high
quality of grids. Further, the girds were refined based on converged
k2
velocity gradient around the impeller which has a complex flow pat- μt = Cμ ρ
ε (8)
tern. Fig. 4 shows the details of the computational mesh and the de-
tailed numbers of different area are given in Table 3. A mesh with 1.93
million cells was therefore finally used for simulation with a standard k- 2.4.2. Modeling verification
ε model with second-order accuracy. Fig. 5 shows the comparison of power numbers obtained respectively
The constants in the standard k–ε model are shown in Table 4. The by the CFD simulation and experiments. It can be seen that the deviation
temporal resolution of the simulations with multiple reference frame between them is not more than 20% in the presence or absence of baf-
method is such that one impeller revolution takes 400 time steps. The fles. The results confirm that the simulation results fit well with the
second order upwind scheme was used for the spatial discretization of experimental data. Therefore, CFD simulation with the k–ε model is

Fig. 6. Power curves of three CB impellers at

four angles and PBT, RT without baffles (a)
CB-0; (b) CB-15; (c) CB-30; (d) CB-45.

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Fig. 7. Velocity vector and velocity contour on the XY plane of Z = 210 mm in the turbulence regime without baffles (Re = 3.7 × 104) (a1)(a2)CB1-15; (b1) (b2) CB2-15; (c1) (c2) CB3-
15.

Fig. 8. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime without baffles (Re = 3.7 × 104) (a) CB1-15; (b) CB2-15; (c) CB3-15.

Fig. 9. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime of CB2-15 without baffles at different speeds (a) 100 rpm; (b) 200 rpm; (c) 300 rpm.

available to calculate the power consumption of CB impellers [3,28].
3. Results and discussion
3.1. Effects of blade shapes on the power consumption
In order to investigate the effect of the configuration of blades on
power consumption [4,29–32], three kinds of cup-shaped-blade im-
pellers (CB1, CB2, CB3) and other two impellers (PBT, RT) were studied
here.
Fig. 6 shows the experimental power curves of the CB impellers at
different angles and PBT, RT in transition and turbulence regime
(20 < Re < 5 × 105). It can be seen that the power consumption of
CB impellers is less than that of the PBT and RT in any case. The power

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consumption of the CB is slightly smaller than that of the PBT and much
smaller than that of the RT. The lower power consumption of CB may
attribute to the hollow tubular structure, so the liquid flows through the
blades without strong resistance.
Fig. 7 shows the velocity vector and velocity contour, and Fig. 8
shows the strain rate contour on the Z = 210 mm plane in the tur-
bulence regime (N = 300 rpm, Re = 3.7 × 104) of three CB impellers
at 15°. It can be seen that the velocity of the fluid on both inlet and
outlet sides of CB impellers are greater than that formed on the
downstream of the inlet. The area of the central high velocity zone
formed by CB2-15 is the largest while the downstream jets formed by
CB1-15 are the longest and most obvious. Fig. 9 shows the contour of
strain rate on the Z = 210 mm plane in the turbulence regime of CB2-
15 at different speeds without baffles. The strain rate increases sig-
nificantly as the speed increases, which can be proved by Fig. 11.
Fig. 10. Velocity distribution of three CB impellers at 15° without baffles Further, the velocity distribution and the average value of velocity
(Re = 3.7 × 104).
are given in Fig. 10. The differences among these three CB impellers
in the speed range of 0.5–1.5 m/s are relatively large. According to
the contour velocity, the great variations are observed in the central
region and the jet area.
Power consumption of CB2 is the greatest in three CB impellers,
probably attributed to the biggest inlet area of CB2, so the power
consumption might be related to the inlet area of the cup blades. In the
same situation, the power consumption of CB3 is minimal and the inlet
area is also the smallest. The order of the inlet area for three CB im-
pellers is consistent with the order in the required power under the
same working conditions. So the inlet area of cup-shaped blades has an
impact on the power consumption. Since the projected area of the inlet
varies with the blade angle, it is necessary to study the impact of the
blades angle changes on the power consumption.

3.2. Effects of blade angles on the power consumption

Fig. 11. Strain rate distribution of CB2-15 at different speed without baffles.
Previous literature indicated that blade angles could affect the

Fig. 12. Power curves for three CB impellers

at four angles and PBT, RT without baffles
(a) CB1; (b) CB2; (c) CB3.

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C. Guo et al.
Fig. 13. Velocity vector and velocity contour on the XY plane of Z = 210 mm in the turbulence regime without baffles (Re = 3.7 × 104) (a1) (a2) CB2-0; (b1) (b2) CB2-15; (c1) (c2) CB2-
30; (d1) (d2) CB2-45.
Fig. 14. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime without baffles (Re = 3.7 × 104) (a) CB2-0; (b) CB2-15; (c) CB2-30; (d) CB2-45.
Fig. 15. Velocity distribution of CB2 at four degrees without baffles (Re = 3.7 × 104).
power consumption [33–35], thus we studied the effect of the CB
impellers angles (θ) on the power consumption and flow character-
istics.
Fig. 12 shows the power curves of different angled CB impellers,
PBT and RT. The result shows that the power number increases with
the increase in the blades angle. Fig. 13 shows the velocity vector
and velocity contour, and Fig. 14 shows the strain rate contour on
the Z = 210 mm plane in the turbulence regime (N = 300 rpm,
Re = 3.7 × 104) of CB2 at four angles. The area and velocity of the
high-speed central area are gradually reduced as the blade angle
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Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162
increases from 0° to 45°. The velocity distribution and average value
of velocity are given in Fig. 15. There appear obvious differences for
CB2 impellers with four angles in the speed range of 0.5–1.5 m/s, in
particular, great variations are located in the central and the jet
regions.
For an impeller with the fixed blade diameter and width, the pro-
jected area increases as the blade angle increases. When the angle is
45°, there will be the largest projected area and the power consumption
is the greatest. When the angle is reduced to 0°, the power consumption
of CB-0 is minimal. The power curves of CB-15 and CB-30 are located in
the middle between CB-0 and CB-45.
3.3. Effects of baffles on the power consumption
Fig. 16 shows the power curves of the CB impellers at different
angles PBT and RT with four baffles in transition and turbulence re-
gimes (20 < Re < 5 × 105). The power consumption of CB2 is higher
than that of other two CB impellers at any angles, but smaller than that
of PBT and RT. Compared with the power curves without baffles in
Fig. 6, the power curves are very close at low Reynolds number
(Re < 1000). However, as the Reynolds number increases, the power
curves in the case of baffles become significantly bigger than that
without baffles.
Fig. 17 shows the velocity vector and velocity contour, and Fig. 18
shows the strain rate contour on the Z = 210 mm plane with baffles in
the turbulence regime (N = 300 rpm, Re = 3.7 × 104) of three CB
C. Guo et al.
Fig. 17. Velocity vector and velocity contour on the XY plane of Z = 210 mm in the turbulence regime with baffles (Re = 3.7 × 104) (a1)(a2)CB1-15; (b1) (b2) CB2-15; (c1) (c2) CB3-15.
impellers at 15°. Compared with the case of no baffles, the circumfer-
ential movement of the fluid is weakened and major vortexes in the
tank disappear. When the fluid hits the baffles, small vortexes will be
formed at the intersection of the baffle and the wall of the tank, and the
axial movement here will be enhanced. Fig. 19 shows the contour of
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Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162
Fig. 16. Power curves of three CB impellers
at four angles and PBT, RT with baffles (a)
CB-0; (b) CB-15; (c) CB-30; (d) CB-45.
strain rate on the Z = 210 mm plane in the turbulence regime of CB2-15
with baffles at different speeds. The shear rate also increases with an
increase of speed, as shown in Fig. 21. The velocity distribution and
average value of velocity are given in Fig. 20. The difference among
three CB impellers in the speed range of 0.5–1.0 m/s is relatively large
C. Guo et al. Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162

Fig. 18. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime with baffles (Re = 3.7 × 104) (a) CB1-15; (b) CB2-15; (c) CB3-15.

Fig. 19. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime of CB2-15 with baffles at different speeds (a) 100 rpm; (b) 200 rpm; (c) 300 rpm.

with the great changes in the central and the jet regions, which is
slightly different from the case without baffles.
Fig. 22 shows the power curves of CB impellers and PBT, RT with
four baffles in transition and turbulence regime (20 < Re < 5 × 105).
The power curves at different blade angles are very close and power
consumption increases with the increase of blades angle. Fig. 23 shows
the velocity vector and velocity contour, and Fig. 24 shows the strain
rate contour on the Z = 210 mm plane in the turbulence regime with
baffles (N = 300 rpm, Re = 3.7 × 104) of CB2 at four angles. Compared
to the case without baffles, CB2-0 and CB2-15 are different
significantly. The jet formed by CB2-0 became longer slightly, whereas
the jet almost disappears in case of CB2-15. The velocity distribution
and average value of velocity are given in Fig. 25. There exists great
differences for CB2 impellers with four angles in the speed range of
0.3–1.0 m/s.
3.4. Power correlation
For a new type of impeller, it is important to gain an accurate power
correlation which can guide the scale-up and industrial applications of

Fig. 20. Velocity distribution of three CB impellers at 15° with baffles (Re = 3.7 × 104).
Fig. 21. Strain rate distribution of CB2-15 at different speed with baffles.

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the impeller. In a classical agitated vessel with the impeller mounted
vertically and centrally, the power P depends on the physicochemical
properties of the liquid, the stirrer speed (N) and the agitator diameter
(D), for the given stirrer type and given installation conditions in-
cluding the agitator height (b), the liquid height (HL), the vessel dia-
meter (T), and the bottom clearance (C) [4,36].
Fig. 23. Velocity vector and velocity contour on the XY plane of Z = 210 mm in the turbulence regime with baffles (Re = 3.7 × 104) (a1) (a2) CB2-0; (b1) (b2) CB2-15; (c1) (c2) CB2-30;
(d1) (d2) CB2-45.
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Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162
Fig. 22. Power curves for three CB impellers
at four angles and PBT, RT (a) CB1; (b) CB2;
(c) CB3.
In order to establish a power correlation suitable for the cup-shaped-
blade impellers, on the basis of the classical Nagata correlation, shape
parameters (the length L of the lateral arc and the length d of the long
axis of the inlet section) were considered. The correlation Eq. (9) is
obtained for the transitional and turbulence regime (20 < Re <
5 × 105), where S is the area of the cup-shaped blades inlet, the values
C. Guo et al. Chemical Engineering & Processing: Process Intensification 125 (2018) 150–162

Fig. 24. Contour of strain rate on the XY plane of Z = 210 mm in the turbulence regime with baffles (Re = 3.7 × 104) (a) CB2-0; (b) CB2-15; (c) CB2-30; (d) CB2-45.

of L and d have been listed in Table 1, and three correlated coefficients

(a, b, c) are listed in Table 6. We compared the experimental and cal-
culated power numbers, as shown in Fig. 26, to verify the accuracy of
the correlated equation. The result shows that the largest deviation
between two power numbers is not more than 20% with or without
baffles, and the average deviation is 5.9% for the case without baffles
while 6.9% for that with baffles.

dL
445 d
S
Np = + (a + b)(Re )−0.18 (cos θ)−0.32 + c
Re D (9)

4. Conclusions

The power consumption of three type impellers including CB im-

Fig. 25. Velocity distribution of CB2 at four degrees with baffles (Re = 3.7 × 104).
pellers, PBT and RT in transition and turbulence regime was in-
vestigated and the power curves were performed. A new power corre-
lation for cup-shaped-blade impellers was put forward to calculate the
power number of CB with different shape parameters and angles. The
CFD simulation results fit well with the experimental data. Besides, the
Table 6
experimental and CFD results could provide the basis for further re-
The correlated coefficients in Eq. (9).
search on the performance of CB impellers.
Coefficients a b c

Without baffles 18.25 0.18 0.13 Acknowledgments

With baffles 6.99 0.13 0.42
This work was supported by the National Key R&D Program
(2016YFC1201503), the NSFC (21476158, 21621004), and the
Program for Changjiang Scholars and Innovative Research Team in
University (no. IRT_15R46).

Fig. 26. Comparison of experimental and calculated Np without baffles (a) and with baffles (b).

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