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    ABSTRACT: Stirred tank reactors are used for variety of applications at different scales of operation. The conventional impellers
    tend to develop regions having nonuniform energy dissipation rates in the stirred reactor. In this work, we propose a novel fractal
    impeller, which helps in reducing such nonuniformities and help develop a uniform randomness throughout the reactor. The
    impeller geometry is discussed in detail. Experimental measurements of the power consumption, mixing time, suspension quality,
    and the ability for gas dispersion were carried out, and the performance is compared with the conventional impellers. The impeller is
    seen to have a low power number, and it can generate a uniform suspension of particles even at relatively lower impeller speeds and
    can efficiently disperse gas into liquid to yield relatively higher gas hold-up values. The Fourier analysis of the power consumption
    time series data indicates that no specific prominent frequency events exist in the reactor, and the spectrum showed several
    frequency events to exist in the reactor with almost identical prominence.Published: April 18, 2011
    1. INTRODUCTION,4521
    Stirred tank reactors (STR) form an integral component of
    chemical, pharmaceutical, and the fermentation industry. These
    types of reactors are in operation for last several decades and a
    number of investigators have analyzed them in detail to optimize
    the designs based on the power consumption, mass and heat
    transfer, and the internal hydrodynamics. In the stirred reactors,
    the energy is supplied in the form of a kinetic energy by rotating
    the impeller at desired speed. STRs are largely used for (i)mixing
    or blending of two miscible liquids, (ii) generation of dispersions
    for gasliquid and liquidliquid reactions, (iii) keeping the
    solid particles in suspension to facilitate the solidfluid contact
    to achieve solid dissolution, (iv) crystallization, etc. The energy
    requirement of these processes forms a significant part of the
    total energy and contributes toward major expenses. Thus, the
    efficiency of a stirred tank reactormainly depends on the impeller
    design and its location in the stirred reactor. The variations in the
    design and operational protocols make the fluid mechanics
    prevailing in a STR complex, and hence the design procedures
    have largely been empirical. However, over the years detailed
    experiments and theoretical analyses have contributed to some
    extent in making the operation of a STR more efficient.
    1
    In
    general, the industrial inclination toward following the efficient
    design procedures or using efficient impellers has increased,
    while a large fraction of the industry still believes in stirring hard
    to achieve desiredmixing with the same old generation impellers.
    Typically (except for the highly viscous fluids), the system
    operates in turbulent regime. Usually, the distribution of energy
    dissipation is considerably heterogeneous. Thus for instance, for
    a paddle mixer, 90% of the input energy is dissipated below the
    impeller while the remaining 10% is dissipated above the
    impeller.
    2
    Also, for a pitched blade downflow turbine (PBTD),
    30% energy is dissipated in the impeller region, 57% below the
    impeller and just 13% above the impeller.
    3
    Usually, the impeller
    region is the most active zone of the reactor and also a region
    yielding high transient shear gradients. Thus, uniform spatial
    distribution of energy is difficult to achieve in the conventional
    STRs and this implies that it is necessary to look for alternatives
    that would make the entire reactor active in a hydrodynamically
    similar manner. Also, for achieving uniform temperature
    throughout the reactor while operating it at lower impeller speed
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