Horizontal Paddle Agitator for High-Load / Hybrid Biogas Reactors
Horizontal Paddle Agitator for High-Load / Hybrid Biogas Reactors
Horizontal paddle agitators from Premix Technologies are engineered for high-load and hybrid biogas reactors handling viscous substrate, fluctuating fill levels and high dry-matter content inside the reactor. The horizontal paddle principle provides smooth immersion, strong thrust and efficient substrate movement while treating the bacteria population gently for stable gas generation.
Introduction: Horizontal Paddle Agitator for High-Load / Hybrid Biogas Reactors
Horizontal paddle agitators from Premix Technologies are engineered for high-load and hybrid biogas reactors handling viscous substrate, fluctuating fill levels and high dry-matter content inside the reactor. The horizontal paddle principle provides smooth immersion, strong thrust and efficient substrate movement while treating the bacteria population gently for stable gas generation.
Design Features
Built for high-load and hybrid reactors: suitable for steel or concrete fermenters, secondary digesters and fermentation residue storage tanks.
High-solids mixing capability: selected for reactor dry-matter content up to 15% and difficult feedstock movement; feed substrates can be much higher before dilution depending on process design.
Floating and settling layer control: the paddle principle helps break floating layers, lift settled material and improve substrate degassing.
Seal monitoring and gas-tight service: seal arrangement can be configured for operation in gas-tight zones with controlled filling-level reduction below the shaft.
Maintenance-focused bearing system: inner bearing materials are selected for wear resistance and low maintenance, while outer bearings absorb axial and radial loads.
Replaceable service parts: relevant components can be designed for replacement without draining the complete reactor or changing the agitator shaft.
Typically 15 kW standard; higher power such as 22 kW can be selected for demanding duty
Speed
Low-speed operation around 10 RPM, adjusted to reactor duty
Torque
High-torque selection for viscous substrate and floating-layer breakup
Installation Height
Project-specific axis height, commonly from 2,600 mm to 8,000 mm
Agitation Diameter
Approx. 4,200 mm standard concept; special diameter possible
Number of Paddles
6 paddles standard concept; 12 paddles or custom arrangements possible
Shaft Length in Reactor
Application-specific, commonly around 5,000 mm
Material
Structural steel, structural steel with special coating, SS316 / V4A or project-specific MOC
Operating Conditions
Substrate temperature up to +55 C and pH range around 6 to 8 when suitable for the process
Explosion Protection
ATEX / hazardous-area motor and gearbox options can be selected as per project requirement
CFD Assisted Agitator Engineering Review
Computational Fluid Dynamics (CFD) is used as an engineering support method to understand liquid circulation, velocity distribution, turbulence, vortex tendency and possible dead zones before finalizing agitator configuration. This helps our team match impeller type, RPM, shaft position, baffle arrangement and motor power with the actual process requirement.
For industrial agitators, CFD review is useful for blending, solid suspension, heat transfer, gas dispersion, slurry handling, fermentation and high-viscosity mixing duties. It gives customers a clearer view of how the mixer will perform inside the vessel, especially where tank geometry, viscosity, solids loading or batch quality is critical.
Engineering Points We Review
Flow pattern, circulation path and tank turnover
Dead zones near the wall, bottom dish and process nozzles
Impeller tip speed, shear level and velocity profile
Baffle requirement to reduce vortex and improve mixing
Power draw, torque and gearbox loading for reliable operation
Scale-up behavior from pilot trials to production vessels
Customer Benefits
Better agitator selection for the real process duty
Improved mixing uniformity and batch consistency
Reduced risk of sedimentation, floating layers and unmixed pockets
More confidence in motor, shaft, impeller and seal selection
Useful technical support for new tanks and retrofit applications
CFD flow visualization used for agitator selection, impeller performance review and mixing improvement.
Related Products
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Paddle, propeller, turbine, anchor, rushton turbine, gate, disperser, helical ribbon and hydrofoil impellers for industrial mixing duties.
Premix Technologies supported us with a reliable dosing system and quick technical response. The equipment quality and installation support were very professional.
Water Treatment Client
Google Review★★★★★
The agitator supplied by Premix is performing smoothly in continuous operation. Their team understood the process requirement and suggested the right configuration.
Chemical Process Customer
Google Review★★★★★
Good product finishing, timely communication and dependable service. The dosing pump package was delivered as committed and worked well after commissioning.
Industrial Utility Project
Google Review★★★★★
We appreciate their practical engineering approach and support after supply. Premix is a good partner for agitators, dosing pumps and chemical dosing systems.
