STANDARD PRACTICE CONFIDENTIAL Page 1 of 11

JGS 210-120-1-72E
STD-09-042 Rev. 0, Sep-03
INLINE MIXING
Rev.1September
DATE15,2003
JUL.-31-'95

CONTENTS
PAGE
1. SCOPE.............................................................................................................................................................. 2
2. WORK PROCEDURE ..................................................................................................................................... 2
2.1 Input to the Design .................................................................................................................................... 2
2.1.1 Preparation of Data Source................................................................................................................ 2
2.1.2 Operating Conditions ........................................................................................................................ 2
2.2 Output from the Design ............................................................................................................................. 2
2.3 Work Steps ................................................................................................................................................ 2
3. DESIGN............................................................................................................................................................ 3
3.1 Selection of Mixing Devices ..................................................................................................................... 3
3.2 Guidelines to Select a Suitable Mixing Device ......................................................................................... 3
3.3 Static Mixer ............................................................................................................................................... 3
3.3.1 Gas-Gas Mixing (Axial Type Mixer) ................................................................................................ 3
3.3.2 Liquid-Liquid Mixing(Radial Type Mixer)....................................................................................... 3
3.4 Injection..................................................................................................................................................... 4
3.4.1 Axisymmetric Injection..................................................................................................................... 4
3.4.2 Wall Injection .................................................................................................................................... 5
4. DEFINITIONS ................................................................................................................................................. 6
5. REFERENCES ................................................................................................................................................. 6
APPENDIX-1: DESIGN METHOD OF AXIAL -TYPE MIXER..................................................................... 11
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

1. SCOPE
Inline-mixing devices are used in refineries, petrochemical plants, gas plants and other similar plants. There
are many types of in-line mixing devices. In-line mixing devices fall into the following three groups:
(1) Static mixers
(2) Nozzle mixing such as axisymmetrical jet mixing or wall-injection mixing
(3) Common usage of other equipment as a mixing device (pump etc.)
This standard practice provides design guidelines for static mixers and nozzle jet mixing devices used mainly
in refineries and petrochemical plants. Namely, this practice deals with the above items (1) and (2).
Descriptions concerning the above item (3) and a steam mixer are not given here.

2. WORK PROCEDURE
2.1 Input to the Design
Data to be prepared for calculation are summarized below.
2.1.1 Preparation of Data Source
Data to be used will be obtained from the following documents:
Process Flow Diagram (PFD)
Piping & Instruments Diagram (P&ID)
Basic Engineering Design Data (BEDD) when necessary
Equipment Data Sheets
Piping Material Specification
2.1.2 Operating Conditions
(1) Fluid name
(2) Flow rate; normal or maximum
(3) Inlet pressure at normal or maximum flow rate
(4) Pressure drop across the Inline-Mixing Device at normal or maximum flow rate
(5) Operating temperature
(6) Physical properties at inlet conditions,
Density (kg/m3)
Viscosity (c.p)
2.2 Output from the Design
The following items are determined.
(1) Selection of mixing device
(2) Mixing length
(3) Pressure drop
2.3 Work Steps
Basic design work for Inline-Mixing will be conducted following the work steps described below.
(1) Select a mixer type in accordance with the section 3. DESIGN.
(2) Preparation of data sheet.
(3) Sizing of the mixer (by basic engineer or vendor).
(4) Check the vendor’s designs by taking account of such information as described in this BDM and elsewhere.
(4) Check the vendor’s designs by taking account of such information as described in this procedure
and elsewhere.
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

3. DESIGN
3. DESIGN
3.1 Sele ction of Mixing De vice s
T here
3.1 are three of
Selection major mixingDevices
Mixing devices or methods as listed below.
(1)Static
There are mixer (see Figs.
three major 3.1a,
mixing 3.1b) or methods as listed below.
devices
(1-1) Axial
(1)Static Mixing
mixer T ype3.1a,
(see Figs. (PDIL)
3.1b)
(1-2) Radial
(1-1) Axial Mixing T ype (Vendor)
Type (JGC)
(1-2) Radial Mixing Type (Vendor)
Fig. 3.1a shows typical static mixer vendors and their popular commercial static mixers for liquid-liquid
mixing. So-called KENICS static mixer shown in Fig. 3.1b is supplied by NORITAKE CO. in Japan.
(2)Axisymmetrical injection.
(3)Wall injection
Values of mixing length and pressure drop depend on each mixing device. The appropriate mixer type should
be selected considering such allowable values as pressure drop, length/diameter ratio, cost, etc.
3.2 Guidelines to Select a Suitable Mixing Device
Fig. 3.2a or Fig. 3.2b is helpful to select an appropriate mixing device. Fig. 3.2a and Fig. 3.2b are for gas-
gas mixing and liquid-liquid mixing, respectively. In case pipe length for mixing is long enough, static mixers
are unnecessary.
3.3 Static Mixer
3.3.1 Gas-Gas Mixing (Axial Type Mixer)
For gas/gas mixing, Axial Type Mixers are primarily to be employed because of the following advantages.

High mixing performance in spite of low pressure drop

Cheap and easy maintenance because of the simple structure
Many successful experiences are redundant.

This mixer comprises of two-stage Cross-Type lattices which are made of at least two small pipes. As is
shown in Fig. 3.1b, two and four pipes are used for the first and the second lattices, respectively.

The following important items, at least, are to be strictly observed in actual designs of Axial Type
Mixers.

Detail design procedure is shown on APPENDIX-1.

Axial Type mixers are recommended for mixing gases introduced through injection nozzles.
Injection nozzle ends must be located near the first mixer element and the injected gas jet must collide
with the center of the first mixer element.
This mixer is generally applied to mixing of gases from totally two pipes. However, in case that gases are
injected from two nozzles (that is three gases are involved ), first of all, the two gases must be well mixed
prior to final mixing of all the three gases.
Choose the gas whose flow rate is smaller than that of the other gas as the gas to be injected into the main
pipe through a branch pipe.
Standard mixing lengths are listed as follows:
(a) For gas injection zone, L1 ; L/D is 1.0.
(b) For mixer element zone, L2 ; L/D is 0.5.
(c) For gas mixing zone, L3 ; L/D is 3.0.

Pressure drop and mixing length can be obtained according to the Technical Report[1]. An appropriate value
of the total mixing length for this mixer is approximately 4.5 in terms of L/D (= mixer length/pipe inner
diameter ).
3.3.2 Liquid-Liquid Mixing(Radial Type Mixer)
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

Pressure drop and mixing length of a static mixer strongly depend on velocity and viscosity of the fluid.
Carefully check the vendor’s data using the following method. And pressure drop must be within the
allowance.
(1) Number of element
Guideline to decide number of element is as follows: (see Technical Report [2])

NE = 4 Re 10
=3 10 Re 1,000
=2 1,000<Re<2,000
=1 2,000 Re

where NE : number of element

Re : Reynolds number (-)
D V
=

D : inner diameter of pipe (m)

V : fluid velocity (m/sec)
: fluid density (kg/m3)
: fluid viscosity (kg/m/sec) = 0.001 (C.P)

(2) Mixing length (L/D)

Mixing length is determined by a vendor, and a designer can roughly estimate the mixing length using , for
instance, Figs. 3.2a, 3.2b.

(3) Pressure drop

Pressure drop is also calculated by a vendor based on its specific correlations.
However, the basic designer can check the submitted pressure drop values using Technical Report[2].

3.4 Injection
General relationship between Degree of Mixing and L/D for both (1)axisymmetrical injection and (2) Wall
injection, are presented in Fig. 3.4. The guideline for the degree of mixing M of the vertical axis in Fig. 3.4 is
as follows:

M = 0.85 for static mixers upstream from temperature measurement sensors.

= 0.99 for static mixers upstream from reactors.
3.4.1 Axisymmetric Injection
For axisymmetrical jet mixing, two modes of injection nozzle orientation exist as is shown in Figs. 3.4.1a and
3.4.1b. The definite criteria to select one of these two modes are not established so far. Since most literature
deals with the mode shown in Fig. 3.4.1a, the design procedure described later is concerned with this mode.
However, it should be noted that some JGC engineers have job experiences to adopt the method shown in Fig.
However, it should be noted that PDIL engineers have job experiences to adopt the method shown in Fig. 3.4.1b.
3.4.1b.
(1) Mixing Length
The basic engineer should take an appropriate value of L/D, taking account of a special value of Dj/D.Here
Dj and D are inner diameters of an injection nozzle and a pipe, respectively. (See Figs. 3(a) to (b) ).

The
T herequired
required mixing
mixing lengths
lengths were roughly 10
were roughly 10 to
to 15
15 in
in terms
termsof
ofL/D
L/Daccording
accordingto
to
the JGC experiments for Dj/D = 0.24, 0.125.
the PDIL experiments for Dj /D = 0.24, 0.125.
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

At present
At present preferable
preferable value
value of
of Dj/D
Dj/Disislarger
largerthan
than 0.125
0.125 based
basedmainly
mainly on
on the
the PDIL’s
JGC’s experimental
experimentalfindings.
findings.
TThe basicengineer,
he basic engineer,of
ofcourse,
course, should
should take
take account
account ofof otherfactors
other factorssuch
suchasasthe
thespecified
specifiedfluid
fluid flow
flow rate
rate
and the pressure drop limitation simultaneously.
and the pressure drop limitation simultaneously.

A representative value of L/D is 15 for the degree of mixing of 0.99.

2 5 for the degree of mixing of 0.85

(2) Pressure Drop

Pressure drop can be calculated using Technical Report[3].

3.4.2 Wall Injection

(1) Mixing Length
Fig. 3.4 gives the following required mixing length.

A representative value of L/D is 25 for the degree of mixing of 0.99.

10 for the degree of mixing of 0.85

(2) Pressure Drop

Pressure drops are calculated using other appropriate calculation correlations described in a handbook and
so on. Details are not described here. Examples of such calculation formulas for pressure drop are
presented in Technical Report[4].
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

4. DEFINITIONS
“Mixing Length”
Mixing Length is the required length of a static mixer or a pipe without static mixer in order that a specified
degree of mixing is attained. Usually the mixing length is represented in terms of L/D where L is the
required mixing length and D is pipe inner diameter.

“Degree of Mixing”
Definitions of index to express the degree of mixing of each fluid are different. Three definitions of “Degree
of Mixing”, “Mixedness”, and “Degree of Segregation” are frequently used. Sometimes, “Degree of mixing”
or “Mixedness” is used for mixing utilizing static mixers.
Degree of Mixing, M is defined as following.
when the fluids are completely mixed, M equals to 1.
when the fluids are completely segregated, M equals to 0.

5. REFERENCES
TECHNICAL REPORT
[1] M.Akatsu, ”Experiment Report on Lattice-Type Gas Mixer”, JGC’s Study Report
(1978) ( This report is filed by the R&D division. )
[2] S. Oguro, “Design of Radial Type Mixer”, Nov., ’95
[3] H. Shibuya, “Pressure Drop of Axisymmetric Injection” Nov., ’95
[4] Y. Suzuki “Pressure Drop of Wall Injection” Nov., ’95

BIBLIOGRAPHY
[1] N.Harnby, M.F.Edwards, and A.W.Nienow,”Mixing in the Process Industries”,
Butterworth & Co. Ltd. (1985)
[2] J. H. Perry et al., ”Chemical Engineers’ Handbook”, McGraw-Hill (1984)
[3] “Chemical Engineers’ Handbook(Japanese) 4th Ed.”, Maruzen (1978)

LITERATURE
(1) K. Ogawa and S. Ito,”Turbulent Mixing Phenomena in a Circular Pipe”, Kagaku
Kogaku, vol.38, No.11, p.815 (1974)
(2) J. W. Hiby,”Mischung in Turbulenter Rohrstromung”, vol.4, No.12, p.538 (1970)
(3) Y. Masuo, ”Fundamentals of Static Mixers”, Kagaku-Souchi, No.5, p.74 (1994)
(4) T. Ogura, PETROTECH, vol.18, No.1, p.72 (1995)
(5) T. Ishikawa, T. Kamiya, “Limits of Reynolds Number for Effective Use of Heat Transfer Promoters”,
Kagaku Kogaku Ronbunshu, vol.20, No.1, p.41 (1994)
(6) A. Quarmby and R.K.Anand,”Axisymmetric Turbulent Mass Transfer in a Circular Tube”, J. Fluid Mech.,
vol.38, p.433 (1969)
(7) N.Harnby, M.F.Edwards, and A.W. Nienow, “Mixing in the Process Industries”, translated by
K. Takahashi
Nikkan-Kogyo Shinbun, p.177 (1989)
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

(1) 2 elements

(2) 3 elements

Fig. 3.1a Typical commercial static mixer

(Radial-Type ; KENICS MIXER)

L1 L2 L3

d1 d2

Details of “A” Details of “B”

Fig. 3.1b Axial-Type Mixer

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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

PDIL Mixer

Fig. 3.2a Pressure drop vs. L/D for gas-gas mixing

Fig. 3.2b Pressure drop vs. L/D for liq.-liq. mixing

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STANDARD PRACTICE CONFIDENTIAL STD-09-042 Rev. 0, Sep-03
JGS 210-120-1-72E

0 : PDIL's Exp.
(Dj/D=0.24)

Fig. 3.4 Relation between L/D and M

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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

Fig. 3.4.1a Line mixing without mixing devices

Axisymmetrical injection

Fig. 3.4.1b Line mixing without mixing devices

Wall injection
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STANDARD PRACTICE CONFIDENTIAL JGS 210-120-1-72E
STD-09-042 Rev . 0, Sep-03

APPENDIX-1: DESIGN METHOD OF AXIAL -TYPE MIXER

1. Performance
- L/D : L/D = 4.5
- Pressure loss : 50 300 mmH2O

2. Limitation
- Fluid : Gas - Gas
- Reynolds number : 3×104 3×105
- Percentage of opening : 30 60 % (Cross zone)
30 60 % (Lattice zone)

3. Design Method
(1) Calculation of pressure loss
Fluid Conditions Stream along run : Main fluid side
- Flow rate of main fluid (m3/hr) Stream in branch : Injection fluid side
- Flow rate of branch line fluid (m3/hr)
- Flow rate of combined fluid (m3/hr)

Fluid Properties
- Density (kg/m3)
- Viscosity (kg/m/s)

Sizing of Main Pipe Size D1 : inner diameter of main pipe (m)

Sizing of Branch Pipe Size D2 : inner diameter of branch pipe (m)

D1 = Line Size
D2 < D1

Sizing of outer diameter of pipes constituting a cross. d1 : outer diameter of pipes constituting a
Sizing of outer diameter of pipes constituting lattice. cross (m)
d2 : outer diameter of pipes constituting
d1 = D2 lattice (m)
d2 = D2/2

Pressure drop calculation

(see Technical Report [1])