How to Calculate Tip Speed and Sweep Diameter of a Reactor Agitator
& Its Importance in API Industry
In the API (Active Pharmaceutical Ingredient) industry, the agitator’s tip speed and sweep
diameter play a critical role in ensuring efficient mixing, heat transfer, mass transfer, and reaction
uniformity.
1. Calculation of Agitator Tip Speed
Definition:
• Tip Speed (TS) is the linear velocity at the outermost edge of the agitator blade.
• It determines the shear force, mixing intensity, and mass transfer efficiency.
Formula:
Tip Speed (m/s) = π×D×N
Where:
• D = Sweep Diameter (m) (Diameter of the agitator blade)
• N= Agitator Speed (revolutions per second, rps)
o If speed is given in RPM (revolutions per minute), convert to RPS by dividing by 60.
Example Calculation:
• Sweep Diameter (D) = 0.5 m
• Agitator Speed = 120 RPM
• Convert RPM to RPS: N=120 / 60=2 rps
• Tip Speed = π × 0.5 × 2 = 3.14 m/s
Agitator Type Tip Speed Range (m/s) Application
Propeller 5 - 15 Low-viscosity mixing
Turbine (Rushton) 2 - 10 Gas-liquid reactions (hydrogenation)
Anchor/Paddle 0.5 – 2 High-viscosity mixing
High-Shear Mixer 10 - 25+ Emulsions, nanoparticle dispersion
2. Sweep Diameter of Agitator
Definition:
• Sweep Diameter (D) is the diameter of the circle traced by the agitator blade tips.
• It determines the mixing coverage inside the reactor.
Importance of Sweep Diameter:
• Larger Sweep Diameter → Better bulk mixing but higher power consumption.
• Smaller Sweep Diameter → higher shear but less bulk flow.
Industry Standards:
• Typically, sweep diameter = 0.3 to 0.6 × Reactor Diameter (Tank Dia, T).
o For low-viscosity: D=0.4×T
o For high-viscosity: D=0.6×T (to avoid dead zones)
How to Calculate Tip Speed and Sweep Diameter of a Reactor Agitator
& Its Importance in API Industry
3. Why Tip Speed & Sweep Diameter Are Critical in API Reactions?
A. Impact on Mixing Efficiency
• High Tip Speed → High shear, useful for:
o Emulsions (e.g., cream formation).
o Nanoparticle dispersion (e.g., liposomes).
• Low Tip Speed → Gentle mixing, ideal for:
o Crystallization (avoiding secondary nucleation).
o Shear-sensitive biologics.
B. Heat & Mass Transfer
• Higher Tip Speed → Better heat transfer (critical for exothermic reactions).
• Optimal Sweep Diameter → prevents hot/cold spots in the reactor.
C. Reaction Kinetics & Yield
• Gas-Liquid Reactions (e.g., Hydrogenation):
o Proper tip speed ensures gas dispersion for higher reaction rates.
• Solid-Liquid Reactions (e.g., Catalytic reactions):
o Prevents settling of solids, ensuring uniform contact.
D. Particle Size Control
• Crystallization & Precipitation:
o Tip speed affects nucleation & crystal growth.
o Too high → small crystals (may affect filtration).
o Too low → large crystals (may reduce purity).
E. Avoiding Dead Zones & Fouling
• Incorrect Sweep Diameter → Unmixed zones → Side reactions / impurities.
• Anchor agitators (large sweep) prevent material buildup on reactor walls.
4. Practical Considerations for API Manufacturing
A. Scale-Up Challenges
• Tip speed must be kept consistent from lab to commercial scale.
• Geometric similarity (sweep dia/tank dia ratio) must be maintained.
B. Shear-Sensitive APIs
• Biologics, proteins, vaccines require low-shear mixing (paddle/anchor).
C. Cleaning & Compliance (GMP)
• Large sweep agitators must allow CIP (Clean-in-Place) without residue.
How to Calculate Tip Speed and Sweep Diameter of a Reactor Agitator
& Its Importance in API Industry
Conclusion
• Tip Speed = π×D×N→ Determines shear & mixing intensity.
• Sweep Diameter → Affects flow pattern & reactor coverage.
• Optimal values depend on viscosity, reaction type, and API sensitivity.
• Incorrect selection → Poor yield, impurities, or failed batches.
For hydrogenation, crystallization, or nanoparticle synthesis, precise control of tip speed and sweep
diameter is essential for quality, efficiency, and compliance in API manufacturing.
