ADVANCED PROCESS SOLUTIONS

Mechanical Design of
Agitators
Engineering Day Barcelona, October 18, 2022
Sven Hanselmann, Product Manager
Agenda
1. Mechanical Aspects
• Dynamic Loads and Frequencies
• Numeric Tools FEA

2. Mechanical Seals & Seal Supply

• Type of Mech Seals
• Design principles
• Product Overview

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Loads on Agitator Shaft
Mechanical interaction between mixing process and agitator shaft
The resulting force F acting at an impeller blade is the key design
parameter to size the agitator components such as the impeller blades and
the agitator shaft.

FN = normal force
FZ = tangential force
Fax = axial force
Fu = circumferential force
Axial
Circumferential force and axial Thrust
force are important to calculate
critical loads on the agitator shaft:
Shaft
Torque
Mt [Nm] = Shaft Torque
Mb [Nm] = Bending Moment Shaft
Fax [N] = Axial Thrust Bending
Moment

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Loads on Agitator Shaft
Mechanical interaction between mixing process and agitator shaft
The resulting force F acting at an impeller blade is the key design
parameter to size the agitator components such as the impeller blades and
the agitator shaft.

FN = normal force
FZ = tangential force
Fax = axial force
Fu = circumferential force
pulsating
loads Axial
Circumferential force and axial Thrust
force are important to calculate
critical loads on the agitator shaft:
Shaft
Torque
Mt [Nm] = Shaft Torque
Mb [Nm] = Bending Moment Shaft
Fax [N] = Axial Thrust Bending
Moment

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loads
Loads on Agitator Shaft
P (Process Design): P = Ne · r · n3 · d5
P (Mechanical Design): P = 2 · p · n · Mt

Shaft Torque: Mt = (Fu,1 + Fu,2 + Fu,3) · r

Bending Moment: Mb = FR · l

Radial Force: FR = Fu,1 + Fu,2 + Fu,3

Axial Force: 𝐹𝑎𝑥 = ෍ 𝐹𝑎𝑥,𝑖

𝑖

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Loads on Agitator Shaft
P (Process Design): P = Ne · r · n3 · d5
P (Mechanical Design): P = 2 · p · n · Mt

Shaft Torque: Mt = (Fu,1 + Fu,2 + Fu,3) · r

Bending Moment: Mb = FR · l

Radial Force: FR = Fu,1 + Fu,2 + Fu,3

Axial Force: 𝐹𝑎𝑥 = ෍ 𝐹𝑎𝑥,𝑖

𝑖

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Loads on Agitator Shaft
P (Process Design): P = Ne · r · n3 · d5
P (Mechanical Design): P = 2 · p · n · Mt

Shaft Torque: Mt = (Fu,1 + Fu,2 + Fu,3) · r

Bending Moment: Mb = FR · l

Radial Force: FR = Fu,1 + Fu,2 + Fu,3

Axial Force: 𝐹𝑎𝑥 = ෍ 𝐹𝑎𝑥,𝑖

𝑖

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Loads on Agitator Shaft
P (Process Design): P = Ne · r · n3 · d5
P (Mechanical Design): P = 2 · p · n · Mt

Shaft Torque: Mt = (Fu,1 + Fu,2 + Fu,3) · r

Bending Moment: Mb = FR · l

Radial Force: FR = Fu,1 + Fu,2 + Fu,3

Axial Force: 𝐹𝑎𝑥 = ෍ 𝐹𝑎𝑥,𝑖

𝑖

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Loads on Agitator Shaft
P (Process Design): P = Ne · r · n3 · d5
P (Mechanical Design): P = 2 · p · n · Mt

Shaft Torque: Mt = (Fu,1 + Fu,2 + Fu,3) · r

Bending Moment: Mb = FR · l

Radial Force: FR = Fu,1 + Fu,2 + Fu,3

Axial Force: 𝐹𝑎𝑥 = ෍ 𝐹𝑎𝑥,𝑖

𝑖

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 Agitated Reactors

Loads on Vessel / Internals

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Loads Acting on Vessel
Mechanical interaction of the agitator with vessel

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 Agitated Reactors

Dynamic Properties

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Resonance
The silent killer of your reactors…..
Every mechanical structure resonates at multiple
frequencies if excited at its natural frequencies.
Resonance will amplify vibration and will gradually cause Excessive shaft deflection
damage to welds, bolts, bearings. Most operators recognize at critical speed

the failures but are not aware of the root cause: resonance.

Critical Speed (rotating component)

shaft speed ≈ natural frequency of shaft

Structural Resonance (non-rotating component)

excitation frequency ≈ natural frequency

All relevant exciting and natural frequencies must be

calculated before manufacturing the vessel.

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Natural Frequency Measurement
Bump test to determine critical speed of an agitator shaft

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Excitation Frequencies Acting on Reactor Internals

Blade passing frequency: 𝒇𝒃 = 𝒏 ∙ 𝒛

𝑺𝒓∙𝒖
Vortex detachment frequency: 𝒇𝒌 = 𝒅

n = speed of revolution
z = number of impeller blades
Sr = Strouhal-Number
u = Flow Velocity Of Liquid
d = characteristic length

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Reactor Engineering

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Fatigue & Stress Calculations
Bottom steady bearing
Agitator flange

Heat exchanger supports

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CAE & Multi-Physics - Heat Exchanger

CAD Model CFD Mesh FEA Mesh

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CAE & Multi-Physics - Heat Exchanger
CFD Interface Subsequent FEA

Pressure distribution Interpolation i.e. deflections

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Dynamic Properties & Operating Conditions
Analyze & respect dynamic properties of
reactor over its full operating range
(agitator speed, filling level)

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Finite Element Simulations – Modal Analysis with FSI

Tube bundle heat exchangers Heat exchanger coil

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Finite Element Simulations – Modal Analysis of Baffles

Original design

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Finite Element Simulations – Modal Analysis of Baffles

Optimized design
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Finite Element Simulations - Modal Analysis

Agitator top part Vessel shell Vessel-agitator-system

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Summary

• An agitated reactor must be designed for process and

mechanical operation.
• Mechanical design follows the process design and is
essential for successful operation.
• Key design parameter are dynamic loads acting at the
impeller blades due to asymmetric fluid flow in the
vessel.
• Dynamic forces are acting at the vessel structure and
its internals such as baffles, heat exchangers…
• All relevant exciting and natural frequencies must be
calculated over the full operating range of the reactor
to avoid resonance vibration

ADVANCED PROCESS SOLUTIONS

Agenda
1. Mechanical Aspects
• Dynamic Loads and Frequencies
• Numeric Tools FEA

2. Mechanical Seals & Seal Supply

• Type of Mech Seals
• Design principles
• Product Overview

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Classification of Seals

Mechanical seal
Mode of operation / lubrication

Single acting Double acting Triple acting

mechanical seal mechanical seal mechanical seal

Product lubricated Buffer fluid Buffer fluid

seals lubricated seals lubricated seals

Dry running seals Gas buffered seals

Gas lubricated seals

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Seal Operating Principles

Rotating
parts

Sealing gap

Fixed parts

Radially operating Axially operating

lip-seal or stuffing box mechanical seal

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Main Parts
Clamp ring
Fixing segment transmits the pressure and torsion
keeps the shaft sleeve in forces from the shaft to the shaft sleeve
position during seal assembling

Grease nipple Bearing

transmits radial forces from the shaft
sleeve to the seal housing
Leakage port
Stationary seal ring
Shaft sleeve atmospheric side
carries the rotating seal rings
Rotating seal ring
Springs atmospheric side
pretension rotating seal rings

Sealing liquid Driving pins

sealing, lubrication, cooling connect the rotating seal rings

Flange attachment Rotating seal ring

vessel side

Flush fluid Stationary seal ring

vessel side

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Functioning of a Mechanical Seal (Fluid Lubricated)
Seal system (storage vessel installation with float switch)

Pressure
N2

Stationary seal ring

Atmosphere
Seal Liquid

Sealing gap
Vessel

OUT atmosphere

Rotating seal rings

▪ Sealing liquid supply from storage
vessel IN
▪ Pressure overlay e.g. with nitrogen Sealing gap vessel
(N2)
possible
Seal Liquid Stationary seal ring
Vessel room

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Seal Rings

Materials Applications

„hard“ materials • Silicon-Carbide (SiSiC) „hard / soft“ • high speed

• Tungsten-Carbide (WoC) combinations • with bad or without lubrication
• (Chrome steel) (dry running seal)
• (Aluminium oxyd) • high pressure
• (Stellite)
„soft“ materials • Carbon graphite „hard / hard“ • low speed
• Silicon carbon combinations • wear resistant
• Graphite • easy to clean (sterile conditions)
• low pressure

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O-Rings

O-Rings

Duty of the „secondary“ • seal all other leaking paths beside the seal faces
seals • mount the seal rings on the shaft sleeve and in
the seal housing
• chemical resistance to the medium

Standard materials • FKM (Viton) -20°C to +200°C

(* approx. Values)
• EPDM (Buna) -60°C to +150°C*
• FFKM (Kalrez, etc.) -30°C to +315°C*
• FEP/FKM (encapsulated) -20°C to +200°C*

Applications • FKM – standard O-ring material

• EPDM – seal liquid: condensate
• FFKM – high temperature, high chemical
resistance
• FEP/FKM High chemical resistance, low costs

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Selection Criteria for Mechanical Seals
Criteria Examples
Machine to be sealed / • agitator, pump, etc.
Orientation • top entry
• side entry
• bottom entry
Mechanical conditions • shaft diameter
• assembled condition
• bearing of the shaft
Physical conditions • pressure
• temperature
• speed (rpm)
• forces
Product to be sealed • corrosive medium/pH-index)
• solid particle content
• viscosity
Properties of the sealing liquid • viscosity
• thermal conductivity
• boiling temperature
• product compatibility
Specifications from customer / • directives from customer
guidelines • national guidelines (DIN, ATEX)
• international guidelines

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Product Overview

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Product Overview

Storage vessels Pressure compensators Supply systems

• for easy seal liquid supply • pressure control parts for • advanced seal liquid supply
• volume 1.5 - 6 liter mechanical seals systems
• pressure 1 - 16 bar • pressure 1 - 100 bar • safety, reliability and comfort
• level indicator optional • level indicator • plant solutions for refineries,
• automatic refilling minerals processing and
chemical industry
• refilling, cooling, flushing,
emergency systems
• flow through systems

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 Thank you Contact

very much for your Sven Hanselmann

Project Manager Sales

attention!
EKATO RMT
+49 7622 29 344
sven.hanselmann@ekato.com

© EKATO HOLDING GmbH

ADVANCED PROCESS SOLUTIONS