Benefits of Static Mixers in the industrial processes

A static mixer, also called as motionless mixer is a device inserted into a housing or pipeline with the objective of disturbing or manipulating fluid streams to divide, influence, recombine, accelerate/decelerate, spread, swirl or form layers as they pass through the mixer. As a result, these alterations in the two or more fluids in mixer, components get enough driving force to have an intimate contact. Therefore, Static mixers are widely utilized not only for strictly mixing requirements but also in processing reactions. Flow in pipe produces some degree of radial mixing but not as required, that’s why adequate mixing can be simply achieved by an impractical length of pipe. Inserting a static mixer enhances the flow of fluids and significantly accelerates inline mixing or reaction. This technique is essentially desirable whenever a continuous, economic and fast operation is required. Since there are no moving parts in the motionless mixer, it’s a maintenance-free and can be installed quickly and easily as any piece of pipe.

A static mixer is designed such that which consists of a tube element which having moulded parts known as mixing elements, which ensure that the flow is drive in disturbed mannerto get influenced mixing and homogenised mixture out. In a process, various external components can be used, such as a pump, which provides the forced feed to the mixer. Main Advantage of static mixer is there are no moving parts in it. That’s why, a static mixer does not require any kind of maintenance and its energy consumption is also very low while there are no electrical components that can consume energy.

Determining the accurate implementation and optimizing number of moulded parts of mixer required to a particular application requires a lot of knowledge and complex calculation, models and various simulation software are used to determine correct efficient mixing. Whenever there is mixing, two mixing principles are always followed from the flow theory, whereby mixing is created from a laminar or turbulent flow.

 

Use of Static Mixers in Process Industries -

 

Mostly the use of Static Mixers in the process industry is categorised as,
1. Blending of Miscible Fluids - Laminar & Turbulent Flow

2. Immiscible Fluids - Interface Generation- Gas/Liquid, Liquid/Liquid, Solid/Liquid

3. Heat Transfer - Homogenization &Efficient Heating Operation

4. Solid Blending

 

Various Industrial Applications -

· Blending different grades of oil or gasoline · Mixing two or more liquid resins · Dilution of concentrated solutions · Water and wastewater treatment · Gas-liquid dispersions · Pipeline reactions · Oil/water and water/oil emulsification · Biodiesel production · Blending anti-oxidants and other additives · Chlorine dioxide bleaching of pulp · Inline addition of flocculants · Homogenizing process streams for sampling · Adjusting viscosity · Chemical suspensions · pH control

 

Based on flow theory,

1.  Laminar Flow

·    High Viscosity Mixing

·    High – Low Viscosity Mixing

·    Heat Transfer Enhancement

·    Plug Flow Reactors

2.  Turbulent Flow

·    Low Viscosity Liquids Mixing

·    Gas Mixing

·    Dispersion of Immiscible Liquids

·    Gas-Liquid Contacting

 

Benefits of Static Mixers -

1.    Injection moulding -

Static mixers precisely and continuously mix fluids and gas streams with injection moulding. So, products are maintained in a certain environment until they are applied especially benefit from their use. Adhesives, sealants, chemical processing, and wastewater treatment are some of the most popular applications in industry.

2. Homogenization and consistency -

This includes proper control over texture, temperature, colour, viscosity of the fluids, distribution of additives and raw materials also. They ensure that your product is delivered with the same way and accuracy throughout the application process.

3. Controlling application process -

Because the mixing is being done is a very small area/section of pipe, changes to the mixture ratio or materials can be made quickly and efficiently unlike large mechanisms and not need to revaluation and alteration of entire vat or container.

4.  Precision shaping -

This gives exacting application of the mixer for given material. This allows for a tighter seal and greater control.

5. Accuracy -

Follows absorption, reaction, and heat transfer to ensure that the materials are being delivered according to industry standards.

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