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Process Design

Slurry Blending (Two-Stream) Calculator

This calculator combines two slurry streams into one using a volume and mass balance. For each stream you enter the volumetric flow, the slurry density, and the percent solids by mass; the calculator returns the total volumetric flow, the total slurry/solids/liquid mass flows, the blended slurry density (total mass flow ÷ total volumetric flow), and the blended percent solids by mass. Supplying the solids and liquid densities additionally returns the blended percent solids by volume. It is a preliminary two-stream mixing estimate only — not a full plant mass balance, thickener model, or process simulator.

TypeInteractive engineering calculator

Calculator

Stream A

0–100 %

Optional — for volume basis

Stream B

0–100 %

Optional — for volume basis

Result
Stream A
Slurry mass flow122.96 t/h
Solids mass flow36.888 t/h
Liquid mass flow86.072 t/h
Stream B
Slurry mass flow55 t/h
Solids mass flow8.25 t/h
Liquid mass flow46.75 t/h
Blended stream
Total volumetric flow150 m³/h
Total slurry mass flow177.96 t/h
Total solids mass flow45.138 t/h
Total liquid mass flow132.822 t/h
Blended slurry density1186.4 kg/m³
Blended percent solids by mass25.3641 %
Blended percent solids by volume11.3664 %

Formulas

Stream slurry mass flow
ṁ_slurry = Q × ρ_slurry
Stream solids mass flow
ṁ_solids = ṁ_slurry × Xs
Stream liquid mass flow
ṁ_liquid = ṁ_slurry × (1 − Xs)
Total volumetric flow
Q_total = Q_A + Q_B
Blended slurry density
ρ_blend = (ṁ_slurry,A + ṁ_slurry,B) / Q_total
Blended mass fraction solids
Xs_blend = Σṁ_solids / Σṁ_slurry
Blended volume fraction solids
Cv_blend = Σ(ṁ_solids/ρ_solids) / [Σ(ṁ_solids/ρ_solids) + Σ(ṁ_liquid/ρ_liquid)]

Diagram

Two-Stream Slurry BlendStream AQ_A, ρ_A, Cw_AStream BQ_B, ρ_B, Cw_B+BlendQ, ρ_blend, Cwmass and volume conserved across the blend

Worked example

Stream A: 100 m³/h at 1229.6 kg/m³ and 30% solids by mass. Stream B: 50 m³/h at 1100 kg/m³ and 15% solids by mass. Solids density 2650 kg/m³, liquid density 1000 kg/m³. What is the blended stream?

  1. 01ṁ_slurry,A = 100 × 1229.6 = 122,960 kg/h = 122.96 t/h; solids = 36.89 t/h; liquid = 86.07 t/h
  2. 02ṁ_slurry,B = 50 × 1100 = 55,000 kg/h = 55.00 t/h; solids = 8.25 t/h; liquid = 46.75 t/h
  3. 03Q_total = 100 + 50 = 150 m³/h; Σṁ_slurry = 177.96 t/h; Σṁ_solids = 45.14 t/h; Σṁ_liquid = 132.82 t/h
  4. 04ρ_blend = 177.96 t/h ÷ 150 m³/h = 1186.4 kg/m³
  5. 05Xs_blend = 45.14 / 177.96 = 25.36% by mass
  6. 06solids vol = 45,140 / 2650 = 17.03 m³/h; liquid vol = 132,820 / 1000 = 132.82 m³/h
  7. 07Cv_blend = 17.03 / (17.03 + 132.82) = 11.37% by volume
Result

Total 150 m³/h; slurry 177.96 t/h; solids 45.14 t/h; liquid 132.82 t/h. Blended density ≈ 1186.4 kg/m³, blended solids ≈ 25.36% by mass (≈ 11.37% by volume).

FAQ

What is the minimum input I need?
For each stream: the volumetric flow, the slurry density, and the percent solids by mass. That gives you the total flow, the combined slurry/solids/liquid mass flows, the blended slurry density, and the blended percent solids by mass. Supplying the solids and liquid densities additionally unlocks the blended percent solids by volume.
How is the blended density calculated?
By conserving volume and mass. The total slurry mass flow is the sum of each stream’s mass flow (volumetric flow × slurry density), and the total volumetric flow is the sum of the two volumetric flows. The blended density is the total mass flow divided by the total volumetric flow — it is a flow-weighted result, not a simple average of the two densities.
Why is the blended density not just the average of the two densities?
Because the streams carry different flows. A denser stream at a lower flow contributes less to the blend than a lighter stream at a high flow. The density is weighted by volumetric flow through the mass balance, so the blend always lands between the two inputs but closer to whichever stream carries more volume.
Can this balance a whole plant or more than two streams?
No. This is a two-stream blend only. Multi-stream reconciliation, recycle loops, thickeners, cyclones, and recovery models are out of scope — use a full mass-balance tool and plant data for that.
Does it model reactions, settling, or entrained air?
No. It assumes mass and volume are conserved with no reaction, dissolution, precipitation, settling, foaming, or air entrainment. It is a preliminary mixing estimate for two homogeneous slurries; validate with plant samples and qualified review before using it for design.

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