How can you reduce energy consumption with a mobile optimised for industrial mixers?
In industrial sectors such as pharmaceuticals, food processing, petrochemicals, water treatment, etc., reducing energy consumption is a major concern. MARLLIN supports its customers in their drive to reduce energy consumption by designing and manufacturing innovative mobile units, including the brand new DisGaz turbine. Thanks to technological advances, this turbine reduces energy consumption by around 30% compared with conventional Rushton-type turbines.
THE DISGAZ TURBINE FROM MARLLIN
MARLLIN and AGITEC are leading the way in
Low Energy Consumption equipment by installing the DisGaz turbine on their mixers. Thanks to its new design, this turbine offers gas/liquid dispersion effects equivalent to those of a conventional Rushton-type turbine, while significantly reducing energy consumption. This latest-generation turbine can be used in new installations or to replace old, energy-hungry Rushton turbines.
The DisGaz turbine is mainly used for its significant centrifugal and dispersive action: the centrifugal effect facilitates gas/liquid dispersion. This mixture is particularly useful in processes such as aerobic fermentation. In addition, this turbine can be combined with one or more pumping propellers to supply liquid to the turbine during gas dispersion, for use in specific processes such as stripping.
REDUCE ENERGY CONSUMPTION WITH A NEW MOBILE FROM INDUSTRIAL MIXER MANUFACTURER MARLLIN
Industrial mixers are used for a wide range of applications, from simple homogenisation to the dispersion or absorption of gases in a liquid, from dilution to complex emulsions and heat transfer.
MARLLIN relies on AGITEC's Research & Development department to design new stirrer profiles. In this particular context, AGITEC has allocated an exceptional budget to further improve the performance of MARLLIN stirrers. As a result, our agitators will be increasingly optimised in terms of energy consumption.
Indeed, 2023 marks a turning point with the design of a range of handsets bearing the "Low Energy Consumption" label. Following improvements to the DisGaz turbine, other mobile units will be optimised over the coming years. "Our aim is to provide our customers with industrial mixer solutions that consume less energy".
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Mobile comparison: Ruston VS Disgaz (Fr)
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Rushton |
Disgaz |
| Power input (W) |
891 |
622 ≈ (-30%) |
A blade profile that limits surrounding losses to reduce energy consumption by an average of 30%.
After extensive testing, a new horizontal disc with 6 profiled blades was designed to maximise the penetration of the mobile into the liquid. Combs at the tip of each blade enhance the dispersing action. The innovative blade design limits the surrounding energy losses that were initially caused by the frontal impact of the liquid on the straight blades of Rushton turbines.
The penetration of the DisGaz mobile in the liquid is favoured and now offers an efficiency equivalent to a Rushton turbine while reducing energy consumption. On average, savings of 30% are achieved in gas/liquid dispersion with the new DisGaz turbine. This mobile is the first model in a range that will be extended over the coming years.
These technological advances will enable us to offer the biotechnology, chemical and food industries lighter, more energy-efficient solutions, while preserving their performance.
DISGAZ AND RUSHTON TURBINES: DIFFERENT BLADE DESIGNS
With their 6 vertical blades, Rushton turbines offer an excellent centrifugal effect and a very good shearing effect at maximum rotation speed. This type of impeller is particularly well suited to applications involving the dispersion and absorption of gases in liquids, and to stripping processes.
The evolution in the design of the blades on the new DisGaz impeller involves the addition of combs at the tip of the blades. The gas is scratched as it passes through the combs. With a liquid sheared in this way, the dispersion of the gas increases the gas/liquid exchange surface. This process also greatly encourages the formation of gas micro-bubbles. With this innovative agitator, gas/liquid exchange has become as efficient as with a Rushton turbine, with a significant reduction in energy consumption of around 30%.
EXAMPLE OF AN OPTIMISED INSTALLATION IN THE PHARMACEUTICAL SECTOR
For one of our customers, we supplied 10 new-generation DisGaz turbines. These mobiles replace the Rushton turbines installed around 30 years ago. The DisGaz mobiles are installed in 500 to 1000 m3 fermenters. These installations are powered by 1 to 3 MW (megawatt) motors. For this customer, reducing energy consumption was a matter of urgency.
Fluid mechanics engineers designed several blade prototypes. Fluid modelling software calculated both the mechanical forces and the power consumed during gas/liquid dispersion operations. The results were compared with the hydrodynamic efficiency of each prototype. Installed for more than 2 years, at identical efficiency levels, the new DisGaz mobiles deliver energy savings of around 30% each year.
With the same efficiency, 30% energy savings is a real advantage for all types of industrial installations. With this first "Low Energy Consumption" mobile, gas/liquid dispersion operations are more economical. In the near future, we will be offering our customers more energy-efficient solutions for homogenisation, dilution and complex emulsion operations.
