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Large low-RPM “submersible mixer” propulsors for a slow seastead (1–5 kW, ~2.5 m prop)
Using “submersible mixers / flowmakers” as ultra-low-speed seastead thrusters
High-level take
- Conceptually workable: big diameter + low RPM is exactly how you get efficient thrust at very low boat speed.
- Main risks: corrosion/seals/bearings in salt water, marine growth, safety guarding, and whether the unit is rated for continuous variable speed + frequent reversing (propulsion-like duty).
- If you can accept some engineering and prototyping, a large mixer/flowmaker can be a cost-effective “cheap azimuth-less thruster” for ~0.5–1.0 mph.
Reality check: does ~2,000 W for ~0.5 mph make sense?
A useful back-of-envelope relationship at low speed is:
P_shaft ≈ (T × V) / η
- Where
P_shaft is motor shaft power (W), T is thrust (N), V is boat speed (m/s), and η is overall propulsor efficiency (often 0.3–0.6 at very low speeds depending on prop/nozzle/installation).
At 0.5 mph = 0.223 m/s, with 2,000 W total and η = 0.4:
T_total ≈ P × η / V ≈ 2000 × 0.4 / 0.223 ≈ 3,590 N ≈ 807 lbf
- That’s roughly ~400 lbf per thruster if you use two.
Important: This only says what thrust you can “afford” at that power. Whether you actually need 400–800 lbf depends on your true hydrodynamic resistance (drag). Your 45° columns may reduce waterplane but can increase wetted area and form drag. A tow test or a CFD/empirical resistance estimate is worth doing early.
Are submersible mixers a “good plan” vs marine thrusters?
Pros
- Large prop diameters (2.3–2.75 m) at ~30–60 rpm are available off-the-shelf.
- Often good static thrust per kW because they are designed to push a lot of water in a tank.
- Industrial supply chain; used/refurb sometimes exists (municipal wastewater market).
Cons / engineering issues (the “gotchas”)
- Salt water suitability: many are cast iron with coatings intended for wastewater, not seawater. Long-term seawater needs correct metallurgy (316L/duplex), proper fasteners, anodes, seal materials, and coatings.
- Duty cycle mismatch: mixers are commonly “run at one speed for months.” Propulsion needs variable speed, reversing, and sometimes rapid changes.
- Cooling at low Hz: if you slow an induction motor far below rated speed using a VFD, motor cooling can suffer. Some mixers are fine; others need oversizing or forced cooling—manufacturer approval matters.
- Mounting / structure: you must design for several kN of thrust and bending loads, plus vibration. These units are heavy (200–400+ kg).
- Safety: a 2.5 m prop is extremely hazardous. You’ll want guards and operational rules. Also consider debris/line entanglement.
- “Thrust” ratings are not standardized for marine propulsion: mixer thrust (N) is usually measured in still water in a test rig; it’s a good starting point, but not identical to “bollard pull” standards used for marine thrusters.
Speed control: VFDs, variable power, reversing
Most low-speed mixers use 3‑phase induction motors. Variable speed is typically done by a VFD (variable frequency drive).
- Do these come with controllers? Often no—industrial mixers are frequently sold as “wet end + motor” and the integrator supplies the VFD, enclosure, breakers, cables, etc. Some premium systems (e.g., “adaptive mixers”) may have proprietary controls.
- Can they run at variable power levels? With a VFD, yes in principle—but confirm:
- Allowed frequency range (e.g., 30–60 Hz or wider)
- Whether continuous operation at low Hz is permitted (cooling)
- Whether continuous reversing is permitted
- Solar/battery integration: If you have a DC battery bus, you can feed a VFD that accepts DC bus input, or use a DC→AC inverter feeding a VFD (less ideal). Many integrators use an industrial VFD powered from an AC bus created by an inverter/charger system.
Typical VFD costs (order-of-magnitude)
| Item |
Typical budget range (USD) |
Notes |
| 3–5 kW industrial VFD (ABB/Danfoss/Schneider/Delta/etc.) |
$250 – $1,200 |
Basic drive only, not marine-sealed. |
| EMI filter / line reactor / dv-dt filter (optional but often needed) |
$100 – $600 |
Depends on cable length to thruster and EMC requirements. |
| NEMA 4X / IP66 enclosure + glands + disconnect + breakers |
$250 – $1,500 |
Salt air is brutal; sealed enclosure is strongly recommended. |
| Marine-grade cabling/connectors |
$200 – $1,000+ |
Depends heavily on length and current. |
Rule of thumb: if you buy an industrial mixer cheaply, plan on spending real money on the “electrical + corrosion + mounting” system around it.
Pricing: why Made-in-China prices are often unreliable & how to confirm
- List prices are often placeholders. The real price depends on material (cast iron vs 316 stainless), seals, cable length, coating system, and gearbox/motor brand.
- Confirm with:
- Written quotation with full model number, metallurgy, seal type, cable, and warranty
- Incoterms (EXW/FOB/CIF/DDP), shipping crate size/weight, and lead time
- Spare parts pricing (seals, prop, bearings) and availability
- Other ways to validate price:
- Ask 2–3 local wastewater equipment integrators for a quote on Flygt/Sulzer/Landia equivalents.
- Check used/refurb municipal equipment channels (surplus dealers, municipal auctions). Large mixers sometimes appear used because plants upgrade.
- Ask OEM for a list of distributors; distributors often give more realistic budget numbers quickly.
Comparison of the candidates you listed (focused on ~2.5 m, 1–5 kW, “push”)
| Vendor / model |
Prop dia |
Power |
Thrust / “push” |
Salt water suitability |
Variable speed (VFD) |
Budgetary price (each) |
Links |
| ShinMaywa (SM-VRTN / related) |
~2.5 m |
2–3.2 kW |
3200 N (~720 lbf) per your note |
Strong candidate if configured in stainless for seawater (you noted stainless + seawater OK) |
Likely VFD-capable (confirm frequency range, reversing, cooling) |
Likely mid/high (often far above “China pricing”); request quote |
Product page
PDF
|
| Flygt / Xylem 4410 / 4320 series |
Large (series-based) |
Varies |
Often excellent thrust/kW (but depends on exact configuration) |
Can be specified for aggressive environments; verify seawater package |
Many installations use VFDs; “adaptive” versions may have special controls |
High (commonly among the most expensive) |
4410
4320
|
| Sulzer ABS XSB 900–2750 |
Up to ~2.75 m |
Varies |
Model-dependent |
Industrial-grade; verify seawater metallurgy and coatings |
Typically VFD-integrated in plants (confirm limits) |
High |
XSB series
|
| PTM Phantom 2500 |
2.5 m |
Varies |
Depends on configuration |
Verify seawater materials |
Likely VFD-capable if 3‑phase induction |
You estimated ~$13k (needs confirmation) |
Phantom 2500 |
| Landia POPL-I |
~2.3 m |
1.5 / 2 / 4 kW |
Not shown in your linked datasheet (ask for thrust curve) |
Verify seawater configuration |
Likely VFD-capable (confirm) |
Likely mid/high |
Datasheet |
| Wilo EMU TR series |
Series-dependent |
Varies |
Model-dependent |
Verify seawater metallurgy |
Likely VFD-capable (confirm) |
Likely mid/high |
TR series |
| Chinese (VIVAMIX VML2500/3kW) |
2.5 m |
3 kW |
2090 N (~470 lbf) per your note |
Cast iron version is not ideal for seawater; stainless version cost unknown—verify grade (316L?) + fasteners + anodes |
Likely VFD-capable (3‑phase). Confirm insulation/seal rating for VFD use. |
You saw ~$2k (cast iron). Stainless likely significantly more. |
VML series page |
| Chinese (QJB/QDT 2500mm units) |
2.5 m |
3–5.5 kW |
Examples you listed: 1960 N (~440 lbf), 3840 N (~863 lbf) |
Often cast iron unless upgraded; seawater requires careful spec |
Likely VFD-capable; confirm |
Often low upfront but higher risk/unknown lifecycle cost |
(Examples)
QJB 2500 example
QDT 5.5kW example
|
Which looks “best” for your use case?
- Best technical fit (from your list): ShinMaywa if you truly can get the stainless/seawater-rated configuration you mentioned, because you already have a credible thrust number (3200 N / 720 lbf) at modest kW (2–3.2 kW).
- Best thrust-per-$ (likely): Chinese 2.5 m units if you can get a real seawater build (316L/duplex + correct seals + anodes) and you can accept reliability/QA risk.
- Best “known quality / lifecycle”: Flygt or Sulzer, but they are usually priced for municipal/industrial budgets.
Pragmatic recommendation: If cost is the driver, buy one low-cost unit first (in the exact material you would actually deploy in seawater), build a test mount, measure thrust (bollard pull), power draw, noise/vibration, and check seal temps and corrosion after a few weeks. Then scale to two units.
Do you need a nozzle (Kort nozzle / duct) to improve low-speed efficiency?
- A duct/nozzle can increase static thrust and protect the prop, which is valuable at ~0–1 mph.
- Mixers generally are “open prop” designs. Adding a duct is possible but must be engineered to avoid cavitation, vibration, and structural issues.
- If you can’t afford azimuth thrusters, a fixed-direction ducted prop + differential thrust steering is a sensible next-best approach.
Other manufacturers / product categories to investigate (additional links)
I can’t live-browse to verify every model’s maximum diameter/thrust, but these are commonly used industrial mixer/propulsor families worth checking for large low-speed units and seawater options:
- KSB (AmaProp / Amamix families in some markets) – industrial submersible mixers:
https://www.ksb.com/
- Invent Umwelt- und Verfahrenstechnik (Germany) – large mixing and flow generation systems:
https://www.invent-uv.de/en/
- JWC Environmental / IPEC (often integrates mixers; sometimes has “channel mixers” and flow solutions):
https://www.jwce.com/
- Tsurumi (Japan) – submersible mixers/agitators in some ranges (diameters may be smaller than 2.5 m, but check):
https://www.tsurumipump.com/
“Marine aquaculture pushers” (> 400 lbf) — what to look for
Many aquaculture “circulators” quote flow rate (m³/h) instead of thrust (N/lbf), which makes it hard to confirm “>400 lbf push” without a datasheet. The units most likely to exceed 400 lbf are the same large industrial “flow booster / low-speed mixer” products you already found.
Confirmed (from your list) at or above ~400 lbf
- ShinMaywa unit you cited: 3200 N (~720 lbf).
- VIVAMIX VML2500/3kW: 2090 N (~470 lbf).
- Chinese QJB 2500mm example: 1960 N (~440 lbf).
- Chinese QDT 5.5kW 2500mm example: 3840 N (~863 lbf).
Aquaculture-adjacent keywords that often lead to “pushers” with published thrust
flow booster, pond / lagoon flowmaker, low speed propeller mixer
raceway circulator, aquaculture current generator
submersible propeller pump (sometimes used for very large flows)
What to ask vendors so you don’t get burned
| Question |
Why it matters |
| Is this exact model warrantied for seawater immersion? What materials are wetted parts (prop, hub, fasteners, housing)? |
Cast iron + coatings often fail in seawater; fasteners can galvanically destroy the assembly. |
| Seal type (double mechanical seal?), seal face materials, oil chamber, leak detection options? |
Seal failure is the #1 killer in submerged rotating machines. |
| Can it run on a VFD? Allowed frequency range? Continuous at low Hz? Any special inverter-duty motor requirements? |
Some motors overheat or have insulation issues on VFDs. |
| Is reverse rotation permitted? Any limits on reversing frequency? |
For docking/positioning you may reverse often. |
| What is the test condition for the thrust number (N)? |
Ensures apples-to-apples comparisons. |
| Spare seal kit cost and lead time? Prop replacement cost? |
Lifecycle cost matters more than purchase price offshore. |
Budgetary pricing guidance (what I’d expect, not a quote)
- Premium European/Japanese large mixers (Flygt/Sulzer/Landia/ShinMaywa, large diameter): commonly five figures to tens of thousands USD each, depending on options and seawater package.
- Chinese 2.5 m mixers: often advertised a few thousand USD in cast iron; seawater-capable stainless builds can move into mid four figures to low five figures once properly specified (and shipping/crating included).
- VFD + enclosure per thruster: very roughly $600–$2,500 depending on how “marine” you make it.
Price uncertainty warning: Without a formal quote that specifies metallurgy + seals + motor/VFD duty, the “$2,000” class listings are frequently not realistic for seawater + propulsion-like use.
Next step if you want: I can turn this into a short “shopping spec”
If you tell me:
- Battery bus voltage (e.g., 48 V, 120 VDC, etc.) and whether you already have an AC inverter bus
- Maximum allowed draft / where you can mount props
- How many hours/day you want propulsion vs station-keeping
- Saltwater temperature range and fouling expectations
…I can output a one-page RFQ/spec sheet you can email to ShinMaywa/Flygt/Sulzer and 2–3 Chinese suppliers to get directly comparable quotes.
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