Introduction to Technology

A static mixer, also known as a motionless mixer, is a device that is installed into a housing or pipeline with the goal of modifying fluid streams as they travel through the mixer to divide, recombine, accelerate/decelerate, spread, swirl, or form layers. Mixture components are brought into close contact as a result of these changes in fluid flow. As a result, static mixers are used not only for precise mixing but also for reaction processes. There are a variety of designs available, but most consist of plates or baffles positioned at exact angles to direct flow, produce turbulence and achieve mixing. Static mixer sizing and selection, like any other process equipment, requires a mixture of empirical observation/experience and analytical modelling. 

     The best static mixer is one that provides the desired mixing quality at the lowest pressure drop, at the lowest installed cost, and in the smallest amount of area. Testing the mixing capabilities of each of the numerous types available with the actual materials to be processed would be ideal. When working with two-part fluids, appropriate mixing is essential for achieving the best results. Static mixers work are an efficient, cost-effective, and dependable way to mix these materials, but there are several considerations that make choosing the right mixer difficult.

Designs OF Static Mixer

Chemical reactions can be carried out in plug flow and loop reactors with static mixing devices under finely controlled conditions, which is especially crucial for extremely exothermic and endothermic processes. In addition to quickly mixing and/or dispersing feed components, S-Cube mixers create plug flow and significantly increase heat transfer both within the fluid and with contacting surfaces for temperature control.

Dispersions are generated when the relevant components are immiscible and a liquid component forms the continuous phase. To create the proper mean drop size and narrow drop size distribution, uniform energy dissipation in the total mixer volume and simultaneous distribution of the components over the full pipe cross-section are used.

A wide variety of firms have developed static mixers over the years, all based on the notion of circulating streams radially via a set of metal baffles. Metal twists, corrugated sheets, parallel bars, small-diameter channels, or tabs protruding from the wall are examples of baffles. Depending on the design, these are essentially connected flow devices with a limited amount of back mixing.

The way you need your materials distributed is a key component in deciding which s mixer is right for you. Based on the pressure limitation of the nozzle, the allowable back-pressure/retained volume, and the expected, or desired flow rate, the materials you’re utilizing will assist you to decide your mixer.

The best static mixer is one that provides the desired mixing quality at the lowest pressure drop, at the lowest installed cost, and in the smallest amount of area. Testing the mixing capabilities of each of the numerous types available with the actual materials to be processed would be ideal. In practice, however, this is not achievable. Relying on advice and information from several mixer vendors is required.

Because static mixers rely on external pumps to transfer product across the mixer parts, the pressure drop is frequently used to determine which static mixer is best. In many circumstances, the kind and number of mixer elements are chosen to achieve the best possible mixing while staying within a pressure drop limit.

A wide variety of firms have developed static mixers over the years, all based on the notion of circulating streams radially via a set of metal baffles. Metal twists, corrugated sheets, parallel bars, small-diameter channels, or tabs protruding from the wall are examples of baffles. Essentially, they’re connected flow devices with a tiny amount of back mixing, depending on the design.

For more than a decade, the S-Cubes SCM-MX mixer has been the industry standard in static mixing applications. It is made up of a grid of inclined bars in a variety of sizes. This design divides the ingredients to be blended into layers and distributes them across the pipe’s full cross-section.

Corrugated plates produce open, crossing channels in which flow is separated into multiple substreams in the SCM-MV mixer. These mixers are most commonly utilized in transitional and turbulent flow regimes to increase mass transfer between immiscible liquids. Gas mixing applications are the best fit for these mixers. 

Benefits of Static Mixer

  1. Material is directly moulded into mixing parts, resulting in efficient mixing with little energy use.
  2. In a short amount of time, proper distribution of fluid streams and additives into short pipe sections can be accomplished.
  3. In terms of viscosity, color, and texture of the product outlet, this is the most consistent type of mixer in the segment.
  4. Handling is simple and adaptable. Quick adjustments to the mixture or stream ratio are possible.
  5. The mixer is shaped and sized to perfection. Unlike large mixers, it does not need to be updated or revalued.
  6. All industrial applications are compatible.

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