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Lightnin mixersgene ral overview
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For more than 85 years SPXs Lightnin
brand has been recognized as the leader
in Mixing Technology. Our extensive
knowledge base and dedication to
continuous product development ensure
ecient and reliable plant operations
around the world. With our unsurpassed
process application expertise, and state
o the art analytical design tools we can
solve virtually any mixing challenge no
matter how complex.
Based in Charlotte, North Carolina,
SPX Corporation (NYSE: SPW) is a global
Fortune 500 multi-industry manuacturing
leader. The companys highly-specialized,
engineered products and technologies
serve customers in three primary strategic
growth markets: inrastructure, process
solutions, and diagnostic systems.
Many o SPXs innovative solutions are
playing a role in helping to meet rising
global demand, particularly in emerging
markets, or electricity, processed oods
and beverages, and vehicle services. The
companys products include thermal heat
transer equipment or power plants;
power transormers or utility companies;
process equipment or the ood &
beverage industry; and diagnostic tools
and equipment or the vehicle service
industry. For more inormation, please visit
http://www.spx.com/.
Lightnin Mixers
AdvAnce d SolutionS for opti m iZ e d proceSS
performAnce
At the heart o SPXs continuous development program is its dedicated,
industry leading research center. Used on a daily basis to support its
customer base, the extensively equipped acility is manned by highly talentedresearchers and engineers, producing innovative solutions or dicult mixing
applications, ensuring that the Lightnin brand remains at the oreront o
Mixing Technology.
ldv las d v
Ecient mixing is at the heart o most successul process operations. OurLaser Doppler Velocimeter (LDV) allows us to accurately establish a given
impellers perormance. Power, speed and shat loading measurements are
taken simultaneously with the fuid fow data, allowing a ull understanding o
each impellers unique operating characteristics to be established.
cfd caa f dyas swa
LDV data and scale model testing is augmented by state o the art
Computational Fluid Dynamics (CFD) sotware. CFD models the combineddynamic eects o impeller design, vessel geometry and fuid properties.
This powerul capability allows quick evaluation o existing process mixing
problems, and signicantly reduces the cost o pilot scale experiments and
ull scale trials.
Sa ts abay, hh sa sa
We can test your process rom laboratory, through pilot scale to ull scale
production. SPXs Lightnin laboratory is ully equipped to model test any
mixing application whether it be liquid-liquid, liquid-solid, gas-liquid, or
gas-liquid-solid. Whenever possible we preer to test your actual material,
or to use a suitable simulant which mimics the rheological properties o
your process. Our dedicated Explosion-Proo laboratory area can be used
or hazardous materials testing. Our testing capability ranges rom 200 ml
to 2000 m3 (8 f.oz. to over 500,000 US gal.). Using SPXs proven scale
up / scale down techniques and experience, we can condently predict ull
scale equipment design requirements.
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Application Knowledgeengine ered productS ASSuredoperAtion
The depth o technical knowledge gained rom more than 85 years o
operating experience and an installed base exceeding 1 million units
is supported by state o the art analytical design tools.
Finite Element Analysis (FEA) is oten employed to carry out
mechanical, thermal and vibration analysis. We can look at stresslevels, structural defections, vibration modes and harmonics. We have
the know-how and ability to analyze the mixer, its mounting structure
and the vessel to ensure total system integrity.
proceSS conSulting
You can leverage the resources and knowledge base o Lightnin
by optimizing your mixing processes and solving any mixing
problems. Lightnins Process Technology Lab enables this support
to be eciently executed to minimize your costs. Lightnin will
evaluate your existing mixer design and process goals to determine
opportunities or improvement. Lightnin will team with yourtechnical group to reduce the time and expense or developing
new mixer applications. Lightnin can assist in the specication o
mixer design, tank internals, eed stream locations and product
draw-o position to optimize your operation. Lightnin has extensive
experience in scaling up lab designs and achieving guaranteed ull-
scale perormance.
Lightnins consulting work starts with a discussion o your needs
and process inormation. Then a proposal is created to dene the
project scope, responsibilities, deliverables, cost and schedule. Apath orward is then concisely and clearly written and agreed to by
both parties. Bidirectional condentiality agreements are requently
a necessary and common course or doing business.
liquid-liquid
Solvent Extraction o Copperand other Metals
Continuous pH control inpotable water or efuenttreatment
Blending o additives andingredients in ood andbeverages
liquid-solid
Petroleum blending and drillingmud suspension
Blending o additives andingredients in ood and
beverages Drat Tube Crystallisers, used in
the production o Alumina
Suspension o Slurries in LargeTanks at Slurry Pipeline acilities
gas-liquid
Flue-Gas Desuplurization ormunicipal and industrial powerplants
Hydrogenation or chemical andpharmaceutical Industries
gas-liquid-solid
Pressure Oxidation and HighPressure Acid Leach AutoclaveMixers
Fermentation, a key processstep in many Biopharma andBiouel plants
Surace Aeration and AnoxicMixing Basins at Industrial andMunicipal Water/Waste WaterTreatment Plants
fluidmotion
Milk storage and Cream Agingor dairies
Homogenization o storagetanks
SPX has a process solution or a wide variety o mixing
applications. Mixing applications can be broken downinto the ollowing mixing duties: liquid-liquid, liquid-
solid, gas-liquid, gas-liquid-solid and fuid motion. Many
applications are oten a combination o these duties
and thus having a ull understanding o each o these
areas is crucial to recommending an optimized design
that is also economical.
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Reliability By DesignSPX understands that when it comes to ecient process plant operations, equipment reliability is o paramount importance. As
a long-standing member o AGMA (American Gear Manuacturers Association) SPXs Lightnin brand recognizes that multi-
purpose commercial gearboxes are poorly suited to Agitator service. For more than 50 years the Lightnin products have utilized
proprietary, purpose designed agitator gear drives to ensure dependability and lowest cost o ownership. With more than 1
million units in the eld our operating experience is unsurpassed.SPXs agitator drive designs which are continually evolving to take advantage o latest materials technologies and
manuacturing techniques, range rom 125 W (0.17 HP) to units greater than 2500 kW (3350 HP).
Portableand fixed mount
The Enhanced Classic Line (ECL) are xed mount and portable mixers that
oer the highest perormance and quality, giving our customers an even
stronger and more versatile product.
series 10
Durable, versatile, cost eective, the eld proven series 10 unit was designed
with minimal maintenance in mind. The largest taper roller bearings in a mixer
o this class help produce an B10 lie o 100,000 hrs or greater, the integrated
drywell and casing design eliminate the risk o oil leakage over the tank or
into the product.
series 70 / 80
The workhorse o the Lightnin mixer drive range with over 40,000 placed
in service since its introduction in 1970, the 70 series mechanical design
technology is the industries most proven agitator drive technology.
series 98
A parallel shat all helical gear design provides enhanced installation fexibility
where there are space limitations on top o the vessel
series 780/880
From 15 kW (20 HP) to 1000 kW (1350 HP) the 780/880 series drive rangeis designed specically or the most arduous large scale mixing applications.
With thousands o drives operating globally on some o the most demanding
duties, reliability is assured.
series 7000
Series 7000 custom designed agitator gear drives can be ound on some
o the worlds largest and most complex mixing applications with power
requirements in excess o 1000 kW (1350 HP).
Vsf
Purpose-built agitators or harsh FGD environments. The rugged gearbox is
designed with a high service actor or long lie, while removable couplings
make maintenance easier. An FGD Slurry seal is designed to urther lengthen
the availability o the unit in operation.
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a310 /a 510
l b s h, c scs b s
susps ppcs:
Varying tip chord angle allows or urther optimization o mixer selection
Maximizes fow generation while minimizing fuid shear and minimizing loads on the agitator drive
The A310 is standard or all Lightnin gear drive portable mixers
Generates the same fow as a pitched bladed turbine (A200) or 60% o the power and 50% othe torque
a320
Hh s h s c hh scs b ppcs:
High eciency wide bladed impeller design with high fow/power ratio
Improved axial fow at low Reynolds numbers (Nre
< 500) reduces power requirements up to 50%over a pitch bladed turbine (A200) or equal blending perormance
Can be successully used or gas handling applications
a315
Hh s h s c squ sps ss
s ppcs:
High blade solidity improves gas handling by up to 3 times that o a conventional hydrooil impellersuch as the A510
Generates strong axial fow which reduces staging that occurs with radial fow impellers in tallreactors
Can improve mass transer by 30% compared with a Rushton impeller (R100)
Operates at lower torque than a conventional radial fow impeller, thus reducing capital costs
r130
rc hh sh x s sps ppcs:
Hal pipe shaped blades improves gas handling over R100 impeller while reducing torquerequirements by up to 40%
Radial design provides shear to achieve good contacting or liquid-liquid and gas-liquid dispersionsand emulsions
r135
Pbc p c hh sh x s sps
ppcs:
Optimized parabolic blade shape improves gas handling ability by 20% and reduces torquerequirements by 40% over an R130
Radial design provides shear to achieve good contacting or liquid-liquid and gas-liquid dispersionsand emulsions
a333 Clean e dg e
Spcfc s s -s x p:
Unique blade design resists ragging, making it suitable or low viscosity applications where raggingmaterial is present such as in Waste Water Treatment
Produces strong axial fow in low viscosity fuids with similar fow/power perormance as an A510hydrooil
a620
rc -n s b, h rs ubs
b 50 500:
Optimal two bladed design creates down fow in the center and up fow at the wall, creating acomplete turnover o tanks contents
Provides similar blend time or less power than traditional open impellers (A320, A200) and lesstorque (lower cost) than traditional close clearance impellers (A400, R400)
Operates at high impeller diameter/tank diameter ratios, which improves heat transer at the wall
Bolted construction available or tanks with small diameter manways
Core Technology Impellers
New & Specialty Impellers
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CHemiCalS PetroCHemiCalS
World class chemical and petrochemical companies around the globe rely on the
mixing expertise and experience behind the Lightnin brand to maximize process
eciency and minimize operating costs. Reliability and low cost o ownership are
assured rom standard equipment o 125 W (0.17 HP) through to custom designed
equipment or critical process operations in excess o 2500 kW (3350 HP).
exs xpc acc ac vCm
Blending, high and low viscosity,Newtonian & non-Newtonian
Crystallization
Dispersion, Dissolution
Heat Transer
Polymerization: bulk, condensation,emulsion, solution, suspension
Reaction and Mass Transer: Liquid-Liquid, Liquid-Solid, Gas-Liquid, Gas-liquid-Solid
Solids Suspension
mineralS ProCeSSing
With Lightnin products SPX has pioneered many o the mixing techniques now
considered standard or minerals recovery. From individual agitators or simplesolids suspension applications; the exacting demands o High Pressure Oxidative
leaching to the design o complex systems or counter-current solvent extraction;
our unique understanding o mixing requirements coupled with purpose designed
agitator drives ensure optimum process perormance and long term reliability.
Pcss xps au Uu Zc
Leaching, Conventional Leach,Carbon in Leach, Carbon in Pulp,Bio-Leach (Bio-Oxidation),
High Pressure Oxidative Leach
Precipitation
Crystallisation
Digestion
Solvent Extraction Mixer Settlers
Attrition Scrubbing
PHoSPHateS & Fertil iZer
Phosphates, Phosphoric Acid and Fertilizer production processes are recognized
as some o the most arduous mixing applications requiring exceptionally rugged
equipment design and a high level o process expertise. SPX has supplied
hundreds o Lightnin brand agitators or general Phosphoric Acid Attack Tank and
Reactor duties and is the largest supplier o the highly sophisticated drat tube
type circulators or Isothermal reactors.
Working closely with process licensors SPX is a key supplier o agitation
systems or both hot and cold crystallizers or the production o Potash and otherspecialized ertilizers.
FlUe gaS de SUlPHUri Zat ion
Since the rst installation o its kind in the mid 1960s, more than 1000 Lightnin
brand Top and Side Entering Agitators or FGD process operations have been
successully applied around the world.
SPX has extensive experience in the design and supply o Gas Sparge Systems
or Mass Transer in many dierent markets and applications. Specically a lance
system has been developed or the Lightnin brand to provide the required mass
transer or FGD Absorbers. The technology has proven successul in Europe,
the US and China, and allows Scrubber suppliers and Utilities to optimize their
Oxidation systems or maximum eciency.
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Food & Beverage
Mixing, stirring and blending o products are undamental operations in Food &
Beverage processing. Oten a product consists o components that are either
dissolved or contain a dispersion o particles o dierent sizes; such as milk which
consists o at, protein, carbohydrates, minerals and water.
Whether you need a standalone mixer or a complete mixing and blending
system, SPX oers market-leading solutions rom Lightnin. We help you
determine the best solution or your mixing and blending needs to achieve the
results you want.
While some manuacturers may consider mixing and blending a commoditized
process, we know that there is a good deal o engineering that goes into nding
the right solution. We have decades o experience and the broadest line o mixing
options in the industry to back it up.
You can be condent in Lightnin Mixers or versatility to allow recipe changes
and new product ormulations, consistency, reduced mixing times, increased
production. Lightnin Mixers comply with Food Saety Regulations 3A, FDA and CE
standards.
C ppcs cu:
Milk
Yogurt
Juice
Sot drinks
Vegetable oil
Chocolate
Beer & Spirits
Sauces & Salad dressing
PHarmaCeUtiCalS
Utilizing our experience and technical expertise, we engineer products to meet
your demands. For virtually any pharmaceutical, biotech, personal care, animalcare, or medical application rom a ew liters to ermentation reactors in excess o
120 m3 (31,700 gal), we have impeller and drive solutions to meet your needs.
We recognize the importance o material traceability and can provide a
comprehensive QAD package with the mixer. We can include: MTRs, FDA
Conormity, CE Conormity, PMI, Quality Plan, Welder Qualications and Surace
Finish Certicates.
As the world leader in mixing technology, SPX with their Lightnin brand
recognizes the need or geometrically accurate lab scale impellers, to allow or
precise scale up rom lab to plant scale. We have innovative designs which allow
ull clean-in-place and sterilize-in-place eatures to be provided.
envir onm ental water and waStewater
treatment
We understand every phase o water and wastewater treatment and apply
Lightnin Mixing techniques and process know-how to optimize results. Just
about every step in the water and waste water process depends on suspending
solids, or ow streams being mixed uniormly with a liquid or gas. The right
degree o uid motion and shear stress is critical during each stage. Highly
efcient impeller systems minimize running costs, while purpose built agitator
drives minimize maintenance and ensure long term reliability.
appc xps cus;
Aeration
Equalization
Flash Mixing
Flocculation
Neutralization
Sludge Mixing & Digestion
Activated Carbon
Chemical Makeup and Storage
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Technical ServicesThe Lightnin brand dedicated Ater Sales support teams are on hand to oer advise and support.
With more than 85 years experience in the manuacture and supply o agitation equipment, we know what parts need to be on
hand to support our customer base so that your downtime is minimized.
Our team o highly experienced eld service engineers are on call to support the on-site servicing o equipment, or supervise andtrain your maintenance sta in best practice care o equipment.
inStallat ion and CommiSS ioning
Proper installation o your Lightnin mixer is critical to its long term
perormance and reliability. To ensure that installation procedures are
ollowed, a certied technician will provide the ollowing services:
Audit the shipment to make sure all equipment is present and meetsstandards o compliance
Supervise job-site contractors in accordance with set up procedures
Perorm a nal inspection to ensure successul start-up and optimalperormance
ServiCe SUPPort & reFUrBiSHment
The Equipment audit is specically designed to identiy potential mechanical
problems beore they occur.
Detect and predict ailure without halting production
Schedule planned maintenance to minimize downtime
Eliminate secondary damage
Reduce operating costs
Reduce total cost o ownership
Original warranties can be extended
Using state o the art vibration diagnostic equipment and drawing on our
mixer manuacturing experience, our technicians can identiy the onset
o bearing and gear ailures, misalignment and system vibration problems
without the need to interrupt production.
Factory gearbox exchange and reurbishment programs oer a ast and cost
eective route to extending equipment lie.
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Manuacturing Technology or the Future
SPX manuactures and assembles its Lightnin mixing equipment using the latest
tooling technology. With locations around the world producing mixers in every
region, we know we can meet your mixing requirements and meet your time lines.SPXs Lightnin brand is one o only a ew mixer manuacturers that design,
machine and assemble their own gearboxes which ensures the drives used in our
mixers meet the rigorous demands o arduous agitator duties.
CNC machining o our cast gearboxes produces the required accuracy and
repeatability required or robust gearbox manuacture.
Machining capabilities allow the production o single piece shats o 13 m (44 t)
in length in solid bar or in pipe , longer shats can be abricated.. Mixer shat
production is critical to the perormance and reliability o any mixer. SPX uses
specially produced machinery to ensure that shat straightness is maintained dur-
ing the manuacturing process.
High capacity press tools and specially produced dies ensure accuracy and
repeatability o blade orms at any scale. Our accuracy ensures reliability andrepeatability in your plant process.
We recognize that process plant operators value quality and mechanical integrity
highly when investing in mixing equipment.
Our investment in modern machine tools and specialist equipment enables us
to meet these needs and oer the right mixer while meeting your documentation
needs or modern plant processes.
SPX is committed to quality. Our ISO9001:2008 accreditatio n in all our opera-
tions assures our customers that our products and documentation will meet all
their needs.
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Global locations
Lightnin mixers
general overview
SPX Flow teCHnology
135 Mt. Read Blvd., Rochester
Rochester, NY 14611, USA
P: (888) 649-2378 (MIX-BEST), (U.S. and Canada) or +1 (585) 436-5550
www.lightninmixers.com
SPX reserves the right to incorporate our latest design and material changes without notice or obligation.
Design eatures, materials o construction and dimensional data, as described in this bulletin, are provided or your inormation only and should not be relied upon unlessconrmed in writing. Please contact your local sales representative or product availability in your region. For more inormation visit www.spx.com.
The green > is a trademark o SPX Corporation, Inc.
ISSUED 2012/01 B-937
COPYRIGHT 2012 SPX Corporation
am e r iCa S
SPX Flow teCHnology BraZi l
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P: +55 11 2127 8278
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Providencia - Santiago
Chile
P: +56 2 8969 320
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P: +52 55 5293 9048
emea
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P: +44 161 249 1170
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midd le eaSt FZe
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The Galleries 4
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P: +971 4 8143400
aPaC
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P: +61 2 9763 4900
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2F, Treasury Centre
No. 1568 Huashan Road
Shanghai 200052, China
P: +86 (21) 22085889
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