Choosing a suitable static mixer is a crucial aspect from the viewpoint of getting the right mixing results. Accordingly, are you looking for a static mixer? The broad array of static mixers may make you wonder how to choose a suitable static mixer? Well then, this blog can help, as it helps you consider a few essential factors while selecting the suitable static mixer for your needs.
What is a Static Mixer?
A static mixer helps manipulate the miscibility of various fluid streams. It is inserted into a process vessel or a pipeline to separate, spread, combine or disassociate a particular fluid mixture.
As the name suggests, static mixers do not have moving components. Typically, static mixer components include polypropylene, stainless steel, CPVC, and PVC. Lately, materials like glass-lined steel have also been introduced.
The pipeline industry terms static mixers inline mixers. Static mixers comprise a tube containing moulded parts. These parts ensure that the flow profile is influenced in a way that everything is mixed into one homogenous mixture.
Applications of a Static Mixer
Static mixers have widespread applications across various sectors. One of the typical applications is to mix nozzles for two-component adhesives. Static mixer finds uses in other applications, including chemical processing and wastewater treatment as well. Additionally, you can use static mixers in refineries and oil and gas industries. Besides, static mixers are also used in polymer production to enable the polymerization reaction to facilitate admixing of liquid additives.
Advantages of Static Mixer
Some of the common advantages of static mixers include the following.
- Efficient mixing
- Low energy usage
- Considerable chemical savings
- Low maintenance as there are no moving parts
- Ease of installation
- Compact enough to accommodate in smaller spaces
- Available in custom sizes, depending on the manufacturer
- Available in multiple materials of construction
5 Factors to Consider While Choosing the Right Static Mixer
Now, let’s come to the focus topic, which is how to select the right static mixer. Well, selecting the right static mixer is vital from the viewpoint of the mixing result. Of course, choosing a static mixer isn’t rocket science. But it requires you to evaluate the mixer across a few essential parameters and make an informed, effective and sustainable choice. Let’s look at what those factors are.
1.The Dispensing Method
2.The Material to be Mixed
- PU Foam: 10-24 elements
- Acrylic: 8-20 elements
- Silicone: 20-30 elements
- Epoxy: 15-24 elements
3. Viscosity of the Material and the Desired Flow Rate
4. The Mixer Attachment
- Bayonet: These mixers have a straightforward twist-and-lock system. They are suited for 9-50mL cartridges.
- Bell: These mixers offer a broad array for round, square and rotary connections.
- Integral Nut (threaded): Bell mixer’s use involves 200mL cartridges or larger than that.
5. Application of the Material
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The way you want to dispense your material is a significant factor to consider while selecting a static mixer. The material you use will help you decide the mixer based on the nozzle’s pressure limitation, the expected flow rate and the acceptable back-pressure/ retained volume.
Cartridge applications restrict your working volume. Accordingly, retained volume will play a significant role in determining the type of static mixer. It also refers to the fact that you will need a comfortable handling back-pressure.
The material to be mixed plays a direct role in determining the range of elements required to mix the material into a homogenous one. Some materials are significantly difficult to mix. Hence, you must have the right number of elements in the mixer to get the desired type of mixture you require. The element range required for each of the separate material includes the following.
Viscosity and material ratio are two elements that can signify the use of a number greater than the higher range. If two elements have two different viscosities, you will potentially require a higher number of elements.
On the other hand, your material ratio will also determine the number of elements required to achieve the desired level of mix.
You must also know the viscosity of the material to be mixed to determine the element diameter in use. The slenderer the material, the smaller the diameter to get a proper mix. Similarly, a thicker material would demand a larger diameter to get the desired degree of homogenous mix. You can refer to the below to decide the mixer’s diameter range.
| Range of Viscosity | Diameter Range of the Mixing Element |
| Thick (>50,000cps) | >0.366” (9.3mm) |
| Medium (5,000 – 50,000cps) | 0.212” – 0.314 (5.4 – 8mm) |
| Thin (< 5,000cps) | 0.093” – 0.25” (2.36 – 6.35mm) |
This factor will enable you to determine the connection style/ inlet to be used with the mixer. The three primary connection types include,
Now, the last concern is for what you are going to use the static mixer. The below chart can prove helpful in this regard.
| Material Application | Mixer Outlet |
| Hole extension | Extension outlet to reach through holes |
| Small bead | Slip Luer Outlet for 3/16”, 1/4” bell and bayonet mixers |
| Increase onsite output | Stepped Outlet (for 8mm, 3/8”, or ½” bell mixers) |
| Spread out w/ Pro-Tip accessories | A detail outlet |
| Through tubing at the mixer’s end | Barbed outlet |
| Maximum output | Full bore outlet |
| Precise placement w/ needle tip and jacket | Snap hub or h-tapered outlet |
S-Cube is one of the top manufacturers of a broad array of efficient static mixers. Relatively young, S-Cube is a team of energetic and passionate professionals with several decades of cumulative experience across mass transfer technology.
The company manufactures static mixers to suit the liquid mixing needs of various domains. It includes pharmaceuticals, power plants, energy, natural gas processing, pollution control, pulp and paper processing, minerals and ore processing, vegetable oil processing, reverse osmosis feed pre-treatment, etc.
S-Cube believes in product excellence and complements the approach to manufacturing excellent products with outstanding and comprehensive customer service. The company’s clientele includes many reputed companies across the globe, delighted with its products and customer service.
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