Blog

What is the working principle of the ROTAMIX mixing system?

The ROTAMIX mixing system is a tank mixing system that operates with a nozzle system connected to a VAUGHAN chopper pump, used for providing mixing in sludge digestion tanks.

The VAUGHAN chopper pump draws the sludge from the most accumulation-prone central point of the tank floor, passes it through its chopper system, and then pumps it to the nozzles. The nozzles are placed inside the tank in a specific number and design to achieve 90-95% homogeneous mixing. These nozzles spray the sludge at high pressure, ensuring mixing on both the inner surface and the tank walls, preventing sludge sedimentation in the tank. The nozzles are positioned to ensure high-speed, uniform flow on the inner surface and walls of the tank, and a vortex-like high-speed mixture at the tank center along the vertical axis. This placement is optimized according to the results of EAM (Electronic Flow Modeling) analysis to ensure the most efficient mixing.

What are the application areas of the ROTAMIX mixing system?

The ROTAMIX mixing system can be applied in wastewater treatment processes such as anaerobic digesters (primary digesters), sludge storage tanks, bio-sludge mixing tanks, balancing tanks, secondary digesters, anoxic mixing basins, aerobic digesters, lime stabilization, and final settling tanks. In the industrial field, it is used in applications such as solid suspension in mining, textile waste treatment, liquid fertilizer mixing, and the retention of refinery waste.

The ROTAMIX mixing system can be implemented in digester tanks with conical, cylindrical, or egg-shaped designs.

What are the advantages of the ROTAMIX mixing system?

The ROTAMIX mixing system provides several advantages. It ensures the optimal circulation and homogeneous heating of sludge in both directions within conical, cylindrical, or egg-shaped sludge digesters. The nozzle system of the ROTAMIX tank mixer ensures a 90-95% active sludge mixture rate and equal temperature distribution, creating the ideal conditions for methane bacteria. It maintains a temperature change of no more than +0.03°C from the average inside the tank. Over a five-year period, the system maintains a 90-95% active mixing rate, ensuring sustained performance and preventing sediment accumulation. The chopper pump, which prevents clogging, draws the sludge from the most accumulation-prone areas of the digester tank, breaks it up, and feeds it to the nozzles. This process significantly increases the effective mixing volume, providing a 90-95% homogeneous mixture. The ROTAMIX system eliminates any crust or foam that may form on the surface of the tank and ensures there is no solid sedimentation at the tank’s bottom or edges. The system does not require any moving equipment within the tank, which eliminates the need for repairs or maintenance. The system is designed to be maintenance-free, with a 10-year warranty on the nozzles against wear. The system’s operation is easily monitored through a pressure gauge. In addition, the system’s efficiency can be verified through process performance tests, flow modeling, temperature profiling, or concentration profiling to confirm a 90-95% active mixture rate.

What are the material properties of the ROTAMIX mixing system?

The material properties of the ROTAMIX mixing system include:

The conical nozzle design, which is 1″ thick for long-term protection against wear, is made from ductile cast iron with a glass coating and has a 74C Rockwell hardness. This design reduces friction, prevents struvite adhesion, and ensures durability against wear. All components of the nozzle are sandblasted and then coated with 3M™ Scotchkote™ FBE (Fusion Bonded Epoxy) for strong surface protection.

The VAUGHAN chopper pumps, which are connected to the nozzles, have a body made from ductile cast iron. All internal chopper components that come into contact with the fluid (fan, rear cutter, etc.) are made from heat-treated cast steel with an Rc 60 hardness, making them 16 times more durable against wear compared to other brands in the industry.

Stainless steel options can also be selected depending on the fluid content.

What are the capacity and other operating parameters of the ROTAMIX mixing system?

The ROTAMIX mixing system can be applied in all conical, cylindrical, or egg-shaped sludge digestion tanks or basins based on the acquisition of information such as tank dimensions and capacity values.