Agitation tanks are at the heart of countless industrial processes—from chemical reactions and liquid blending to suspension of solids and thermal control. Whether you're in the chemical, pharmaceutical, food, dairy, or wastewater industry, the performance and longevity of an agitation tank rely heavily on thoughtful design and precision fabrication.
Below are the most critical design and fabrication aspects you must consider for reliable, high-performance agitation tanks.
1. Understand the Process Requirements
Before diving into design, align the tank’s specs with your operational needs:
Type of mixing: Suspension, dissolution, emulsification, or thermal regulation
Product characteristics: Viscosity, abrasiveness, pH, temperature sensitivity
Operating mode: Batch vs. continuous, pressure rating, heat exposure, and cycle time
2. Tank Geometry and Configuration
The shape and dimensions of your tank play a major role in mixing effectiveness:
Standard geometry: Cylindrical body with dished or conical bottoms
H/D ratio (height-to-diameter): Affects circulation zones and power draw
Bottom outlet design: Sloped or conical bottoms ensure complete drainage
Baffles: Reduce vortexing, increase turbulence, and promote homogeneity
3. Agitator Selection and Mounting
Your mixing goal determines the agitator design:
Types: Propellers (low-viscosity), turbines (general purpose), anchors (high-viscosity), high-shear mixers (dispersions)
Control: Variable Frequency Drives (VFDs) allow speed modulation
Mounting style: Choose between top-entry (most common), bottom-entry (better for CIP), or side-entry (for horizontal tanks)
4. Material of Construction (MOC)
Select MOC based on product chemistry, hygiene standards, and temperature:
Food & pharma: SS316L or SS304 with electropolishing
Water treatment & chemicals: MS with FRP, rubber, or epoxy lining
Extreme environments: Hastelloy, Duplex, or Titanium alloys for aggressive media
5. Thermal Control Features (Optional)
Maintain process temperatures with:
Jacketed walls, limpet coils, or internal coils
Heating/Cooling mediums: Steam, hot oil, glycol, or chilled water
Insulation & cladding: Retain energy and protect workers
Practical use: Pasteurization systems benefit from dual-zone jackets—one for rapid heating, the other for cooling.
6. Hygiene and Cleanability
Especially vital in food, beverage, and pharma applications:
CIP (Clean-in-Place) & SIP (Steam-in-Place) capabilities
Crevice-free welds and electropolished interiors (Ra ≤ 0.8 µm)
Accessible ports for inspection, swabbing, and maintenance
7. Instrumentation and Automation
Improve accuracy and control with:
Sensors: Level, temperature, pressure, pH, and RPM
Automation: SCADA/PLC integration for real-time monitoring
HMI panels: Program and track batch operations with ease
8. Structural and Safety Compliance
Ensure adherence to national and international codes:
Certifications: ASME, PED, GMP, FDA, BIS, EHEDG
Safety devices: Pressure relief valves, rupture discs, grounding points, flameproof motors
Documentation: Material traceability, welding records, and hydrostatic test reports
9. Fabrication Best Practices
Precision fabrication = performance + safety:
Welding: TIG/MIG with full penetration
Testing: Radiographic, dye-penetrant, and hydrostatic testing
Surface finish: Pickling, passivation, or electropolishing based on industry