Agitated tanks are indispensable in mineral processing, facilitating mixing, leaching, flotation, and slurry homogenization. With varying designs tailored to specific operational needs, selecting the right agitation tank significantly impacts efficiency, recovery rates, and overall process stability. This article explores eight specialized types of agitated tanks: standard agitation tanks, high-efficiency agitation tanks, high-temperature agitation tanks, pulp lifting agitation tanks, high-concentration pulp agitation tanks, cone-bottom agitation tanks, chemical agitation tanks, and pickling agitation tanks. Each type addresses unique challenges—whether optimizing mixing intensity, handling corrosive media, or managing dense slurries—ensuring seamless integration into diverse mineral processing workflows.
1. Standard Ordinary Agitation Tank
The standard agitation tank is the most basic mixing equipment widely used in industries such as mining, chemical processing, and wastewater treatment. It is primarily employed for mixing and suspending low-to-medium-density slurries to prevent solid particle sedimentation. Its simple structure and low cost make it suitable for conventional applications with moderate mixing requirements.
Core Functions
- Achieve uniform liquid-solid mixing.
- Prevent sedimentation and maintain suspension.
Working Principle
The motor drives impellers (e.g., pitched-blade or turbine-type) to rotate, generating radial and axial flows, which create circulation within the tank for homogenization.
Basic Structure: Cylindrical flat-bottom or slightly sloped tank with standard impellers.
Improvements:
- Variable-frequency motor adjusts speed for different viscosities.
- Optional baffles enhance turbulence (prevent vortexing).
Key Features
- Cost-Effective: Low manufacturing and maintenance expenses.
- Versatility: Suitable for low-viscosity fluids (e.g., water, diluted slurries).
The standard agitation tank remains a fundamental industrial choice due to its affordability and reliability, though less efficient than advanced types in demanding conditions.
2. High-Efficiency Agitation Tank
Optimized for superior mixing performance and energy savings, this tank is ideal for applications requiring high uniformity, such as flotation reagent dispersion or metallurgical leaching.
Core Functions
- Rapid homogenization.
- Energy-efficient operation with minimized dead zones.
Working Principle
Combined impellers (axial + radial flow) and draft tubes or CFD-optimized flow patterns ensure synergistic mixing for shorter blending times.
Structure: Draft tube with multi-stage impellers; parabolic-shaped bottoms are possible.
Improvements
- CFD-designed impellers tailored for specific fluids.
- Low-shear configurations protect flocs (e.g., mineral processing).
Key Features
- 30–50% Energy Savings: Compared to conventional tanks.
- Faster Mixing: Critical for time-sensitive processes.
Balancing energy efficiency and mixing precision, high-efficiency tanks are ideal upgrades for fine chemical and mineral processing industries.
3. High-Temperature Agitation Tank
Designed for extreme conditions (150–300°C), it supports thermal leaching, petrochemical reactions, and other high-heat processes with robust sealing and corrosion resistance.
Core Functions
- Stable agitation under high temperature/pressure.
- Uniform thermal distribution.
Working Principle
Mechanical agitation paired with jacketed heating (steam/electric) and high-pressure seals ensures leak-proof operation.
Structure: Double-layered jacketed vessel made of alloys (316L/Hastelloy).
Improvements: Magnetic couplings replace mechanical seals in extreme cases.
Key Features
- Heat/Pressure Resistant: Sustains harsh environments.
- Safety-Centric: Explosion-proof designs.
Indispensable for high-temperature reactions, reliability and material durability are critical selection factors.
4. Pulp Lifting Agitation Tanks
Specifically designed for slurry lifting, it prevents solid settling through strong axial flow and is suitable for processes requiring vertical circulation, such as cyanide leaching in gold mining.
Core Functions
- Enhances vertical slurry flow.
- Prevents bottom sedimentation.
Working Principle
Upward-angled impellers (e.g., 45° inclined blades) propel slurry from the bottom to the top, creating an upward-dominant circulation flow.
Structure: Offset impeller or integrated guide sleeve.
Improvements: Low-speed, high-torque motor for high-density slurries.
Key Features
- Reduced sedimentation risk: Extends equipment lifespan.
- Energy optimization: 20% more energy-efficient than screw agitators.
The pulp-lifting agitator tank resolves sedimentation issues inherent in traditional agitation, making it particularly suitable for high-density mineral slurry processing.
5. High-concentration Pulp Agitation Tanks
Designed for paste slurries with 40%–75% solids content, achieving homogenization through high-torque shear for applications such as tailings concentration and paste filling.
Core Functions
Breaks agglomerated particles while maintaining flowability in high-solids slurries.
Working Principle
Low-speed rotation (20–60 RPM) of wide impellers generates high shear forces, complemented by scrapers to prevent cone-bottom buildup.
Structure: Parabolic/conical bottom + heavy-duty shaft assembly.
Improvements: Asymmetric impeller design (e.g., three-blade swept-back configuration).
Key Features
- Handles extremely high solids content: Up to 75%.
- Reduces flocculant dependency: Achieves natural homogenization.
The high-concentration agitator tank is critical equipment for tailings processing and paste preparation, with its heavy-duty design overcoming high-viscosity challenges.
6.Cone-bottom Agitation Tanks
The conical bottom structure enables complete discharge, ideal for materials prone to settling (e.g., pigments, ceramic slurries), with easy cleaning and maintenance.
Core Functions
- Residue-free discharge.
- Prevents bottom accumulation.
Working Principle
Gravity-assisted + agitation synergy: Material slides down the cone wall to the bottom valve for centralized discharge.
Structure: Cone angle ≥45° + side-entry agitator.
Improvements: Pneumatic vibrator for discharge assistance (viscous materials).
Key Features
- 99% discharge efficiency: Minimizes waste.
- Time-saving cleaning: Dead-zone-free design.
The conical-bottom agitator tank delivers high-efficiency solutions for fine chemical and food industries, particularly suited for batch production.
7.Chemical Agitation Tanks
Corrosion-resistant design with integrated temperature control and sensors for complex chemical reactions in hydrometallurgy, pharmaceuticals, and other industries.
Core Functions
- Precise control of reaction conditions (temperature/pH).
- Resistance to strong acid and alkali corrosion.
Working Principle
Mechanical stirring enhances mass transfer, combined with reagent dosing and real-time monitoring to optimize reaction efficiency.
Structure: PP/FRP lining + titanium alloy impeller.
Improvements: Vacuum seal (volatility prevention).
Key Features
- Material safety: Withstands pH 0–14.
- Process flexibility: Supports oxidation, polymerization, and more.
Chemical agitator tanks are the preferred choice for corrosive reactions, with a modular design that adapts to diverse process requirements.
8. Pickling Agitation Tanks
Specifically designed for strong acid environments (e.g., sulfuric acid, hydrochloric acid) used in metal surface pickling or lithium/cobalt leaching, requiring an integrated exhaust gas treatment system.
Core Functions
- Promotes a reaction with acid solutions on metal surfaces.
- Controls acid mist dispersion.
Working Principle
Agitation accelerates the penetration of acid solutions into metal surfaces, while the exhaust extraction system collects the acid mist.
Structure: PTFE lining + side exhaust ports.
Improvements: Tantalum components (hydrofluoric acid resistant)
Key Features
- Environmental compliance: Acid mist recovery rate >95%.
- Exceptional corrosion resistance: pH <1 operating conditions.
Acid pickling agitators balance corrosion protection with production efficiency, serving as core equipment for new energy battery recycling and steel processing.
From standard ordinary agitation tanks to specialized pickling agitation tanks, each design serves a distinct purpose in mineral processing. Factors like slurry density, temperature sensitivity, and chemical reactivity dictate tank selection, emphasizing the need for precise engineering solutions. By understanding the strengths of high-efficiency, high-temperature, pulp lifting, and other variants, operators can enhance mixing uniformity, reduce energy consumption, and prolong equipment life. As innovation continues, advanced agitation systems will further refine mineral extraction efficiency, solidifying their role as the backbone of modern processing plants. Whether for leaching, flotation, or chemical conditioning, the right agitated tank ensures optimal performance at every stage.