Custom static mixers are unique and specially designed mixing devices that are created to meet specific requirements or preferences of a client or application. These mixers are tailored with distinct geometries, materials, and features to optimize mixing efficiency and performance for the intended use.
Characteristics of a custom static mixer may include:
Bespoke Geometry: The internal elements of the mixer can be custom designed in terms of size, shape, and arrangement to achieve the desired level of mixing intensity and homogeneity.
Specialized Materials: Custom static mixers can be fabricated from a wide range of materials such as stainless steel, PVC, exotic alloys, or composite materials to ensure compatibility with the fluids or gases being processed.
Unique Configurations: The configuration of the static mixer, including the number and arrangement of mixing elements, can be customized to meet specific flow rates, viscosities, temperature ranges, and pressure conditions.
Optional Features: Tailored static mixers can incorporate additional features like flow straighteners, specialized fittings, injection ports, or monitoring sensors to enhance functionality and performance.
Application-Specific Design: Custom static mixers are engineered with a focus on the specific application requirements, whether it be in the food industry, pharmaceuticals, water treatment, chemical processing, or other industrial sectors.
By engaging with manufacturers or experts in static mixing technology, clients can collaborate to design and manufacture a custom static mixer that perfectly aligns with their unique needs, ensuring optimal mixing results and operational efficiency in their processes.
Custom static mixers are intricate and specialized devices employed across industries to blend fluids and gases effectively. It is also used for powders by inducing turbulence and intermixing within a stationary housing. Also, Unlike dynamic mixers that rely on moving parts like impellers or agitators. Moreover, for static mixers utilize the physical design of the mixer itself to achieve thorough mixing without any mobile components. Finally, this characteristic makes them particularly suitable for applications prioritizing low maintenance. This will help with minimal energy consumption and precise control of mixing processes. Tailored to meet specific application requirements, a custom static mixer considers factors such as flow rate and viscosity. Along with temperature, pressure, and mixing objectives during its design phase. The efficacy and efficiency of the mixing process heavily rely on the design of the static mixer.
One common type of custom static mixer is the plate-type static mixer, comprising multiple layers of crisscrossed plates or elements within a cylindrical housing. As the fluid or material passes through the static mixer, the geometric arrangement of these plates disrupts the flow, inducing eddies and folds essential for thorough mixing. You can customize the number, shape, and configuration of the plates to achieve the turbulence and mixing intensity required for specific applications. Another variant of static mixer is the helical static mixer, characterized by helical or spiral elements within the mixing chamber. The fluid, as it moves through the twists and turns of the helical elements, undergoes intense shearing and folding, resulting in effective mixing and blending. You can fine-tune the pitch, diameter, and orientation of the helical elements based on the desired mixing performance.
Customer Static Mixers Materials
We design custom static mixers from materials like stainless steel, PVC, Teflon, and other corrosion-resistant alloys to suit a wide range of industries and applications. Selecting the right material is crucial for ensuring compatibility with the substances being mixed and maintaining the durability and longevity of the mixer in various operational conditions. The applications of custom static mixers span various sectors including chemical processing and water treatment. Moreover, industries like food and beverage production, pharmaceutical manufacturing, petrochemicals, and environmental engineering also utilize static mixers. In chemical processing, static mixers are instrumental in blending multiple components, fostering chemical reactions, or facilitating heat exchange processes. Water treatment plants leverage static mixers to blend coagulants and disinfectants. They are also used for pH-adjusting chemicals to maintain water quality standards.
Custom static mixers offer numerous advantages. They provide precise control over mixing processes, enabling uniform distribution of components and efficient blending of materials. Notably, static mixers are energy-efficient due to their self-sufficient operation without external power sources. Moreover, they are straightforward to install and entail minimal maintenance requirements. In addition, they occupy minimal space, rendering them ideal for space-constrained applications. In conclusion, a custom static mixer epitomizes a sophisticated and tailored mixing solution that delivers efficient and effective blending of fluids and gases. Additionally, also used for powders in a broad array of industrial applications. With their customizable design, material versatility, energy efficiency, and precise mixing capabilities, custom static mixers stand as indispensable tools. Tools for attaining optimal mixing performance and enhancing process efficiency across diverse industries.
Three criteria are needed to determine the pressure drop across a static mixer.
Reynolds Number – Re
Pressure drops in an empty pipe of the same length as the Mixer elements.
A flow coefficient, or friction factor correction factor for the static mixer.
Reynolds Number can be calculated – See Reynolds # section.
Pressure Drop in an Empty Pipe
For calculation of the pressure drop in an empty pipe, use the standard Darcy equation, and the Darcy friction factor.
The equation for the pressure drop is as follows:
Where D PP = pipe pressure drop (kPa)
Where D PP = pipe pressure drop (psi)
f = Darcy friction factor
f = Darcy friction factor
l = Element length (mm)
l = Element length (inch)
Q = Flow rate (m3/h)
Q = Flow rate (gpm)
r = Density (kg/m3)
sg = Specific Gravity
D = Pipe I.D (mm)
D = Pipe I.D (inch)
An estimation of the friction factor can be made from the equations below: –
Re>2000
Re<2000
Where e is the surface roughness and D is the pipe diameter in consistent units.
If this equation were to be used, the recommended value for e would be 0.0457 mm (0.0018 inches).
The flow coefficient is a correction factor to compensate for the increased pressure loss caused by the mixer elements compared with that of an empty pipe.
The coefficient is given as separate equations for flow regimes.
The following shows the relevant equations for both 1.5:1 and 1:1 pitch elements.
Flow Condition
1.5 : 1 Pitch (D<12″)
1 : 1 Pitch (D>=12″)
Re<10
Re<1000
upon request
upon request
upon request
Note that the Pitch is shown as the element length compared with the ID of the pipe. A 1″ element for example would have a 1.5:1 Pitch as standard and an ID of 1.049″. The element length should therefore be 1.5735″. Also, the equations are based on elements of standard thickness. Changes in either the pitch or the element width from such things as coatings will affect the flow coefficient and therefore the pressure drop.
Installation
Installing a static mixer involves careful planning and execution to ensure optimal performance and integration into your existing system. Follow these steps for a successful installation:
Preparation
Review Specifications: Ensure that the static mixer is compatible with your system’s flow rate, pressure, temperature, and substance requirements.
Gather Tools and Materials: Have the necessary tools and materials ready, including wrenches, gaskets, seals, and any additional fittings required.
Shut Down and Safety
Power Down System: If applicable, turn off the power to the system to avoid any accidents during installation.
Depressurize System: Ensure that the system is depressurized and drained of any fluids to prevent leaks and ensure safety.
Inspect the Mixer
Check the Mixer: Inspect the static mixer for any damage or defects before installation.
Verify Components: Ensure that all components, including the mixer and flanged connections, are present and in good condition.
Install the Mixer
Align the Mixer: Position the static mixer between the existing piping flanges or connections. Ensure that it aligns properly with the flow direction indicated on the mixer.
Install Gaskets and Seals: Place gaskets and seals as required to prevent leaks. Ensure that they are properly seated and undamaged.
Secure the Mixer: Bolt the mixer to the flanges or connections, tightening the bolts in a crisscross pattern to ensure even pressure and a secure fit. Follow the manufacturer’s torque specifications for the bolts.
Check for Proper Alignment: Ensure that the mixer is aligned correctly and that there is no undue stress on the piping system.
Connect Piping and Electrical
Reattach Piping: Connect any additional piping or hoses as needed. Ensure all connections are secure and free from leaks.
Electrical Connections: If the mixer has any electrical components or sensors, connect them according to the manufacturer’s instructions.
System Testing
Inspect for Leaks: Before powering up the system, inspect all connections and joints for leaks. Address any issues before proceeding.
Test Operation: Gradually introduce the fluids or materials into the system and observe the mixer’s operation. Check for any signs of improper function or leaks.
Verify Performance: Ensure that the mixer is performing as expected and providing the desired mixing results.
Documentation and Final Checks
Document Installation: Record the installation details, including any modifications made, to keep track of the system configuration.
Final Inspection: Perform a final inspection of the installation to ensure everything is in place and functioning correctly.
Training and Maintenance
Operator Training: If applicable, train operators on the proper use and maintenance of the static mixer.
Maintenance Schedule: Establish a maintenance schedule based on the manufacturer’s recommendations to ensure long-term reliability and performance.
By following these steps, you can ensure that your static mixer is installed correctly, operates efficiently, and meets the requirements of your system and application.
Maintenance
Regular maintenance is essential to ensure the long-term performance, reliability, and safety of your static mixer. Follow these procedures to keep your mixer in optimal condition:
Routine Inspection
Visual Check: Regularly inspect the mixer for any signs of wear, damage, or leaks. Look for cracks, corrosion, or any unusual wear on the mixer and associated components.
Connection Review: Ensure that all connections, flanges, and bolts are secure and free from leaks. Tighten any loose bolts as needed.
Cleaning
Scheduled Cleaning: Clean the mixer according to the frequency recommended by the manufacturer or based on the process requirements.
Cleaning Agents: Use appropriate cleaning agents that are compatible with the materials of the mixer. Avoid harsh chemicals that might cause damage.
Cleaning Procedure: Follow a systematic cleaning procedure:
Flush the Mixer: Rinse the mixer with a suitable solvent or cleaning solution to remove residual materials.
Disassemble: If necessary, disassemble the mixer for a more thorough cleaning. Ensure you follow safety procedures and keep track of all components.
Scrub and Rinse: Scrub internal surfaces gently to remove any buildup, then rinse thoroughly to remove all cleaning agents.
Checking Performance
Performance Monitoring: Regularly monitor the mixer’s performance to ensure it meets the required specifications. Check for consistent mixing results and any changes in performance.
Flow Rate and Pressure: Measure and verify that the flow rate and pressure are within the designed parameters. Adjust as necessary.
Inspection of Internal Components
Disassembly: Periodically disassemble the mixer to inspect internal components, especially if there is a history of problematic performance.
Examine Components: Check mixing elements for signs of wear or damage. Look for any blockages, corrosion, or buildup that might affect performance.
Replace Parts: Replace any worn or damaged parts with genuine components as needed. Follow manufacturer recommendations for part replacements.
Lubrication and Sealing
Gaskets and Seals: Inspect gaskets and seals regularly for signs of wear or damage. Replace any compromised seals to prevent leaks and maintain sanitary conditions.
Lubrication: If the mixer has moving parts or requires lubrication, apply lubricant as specified by the manufacturer. Avoid over-lubrication or using incorrect types of lubricant.
Calibration and Adjustment
Check Calibration: For mixers with integrated sensors or controls, ensure that they are properly calibrated and functioning correctly. Adjust as necessary to maintain accuracy.
Performance Adjustments: Make adjustments to the mixer settings if there are changes in the process or if performance is not meeting expectations.
Documentation
Maintenance Records: Keep detailed records of all maintenance activities, including inspections, cleaning, part replacements, and performance adjustments. This helps track the condition of the mixer and plan future maintenance.
Incident Reporting: Document any issues encountered during maintenance and report them to the appropriate personnel for further action.
Training
Operator Training: Ensure that operators are trained in the proper use and maintenance of the mixer. Provide them with guidelines and procedures to follow.
Ongoing Education: Keep up with any updates or changes to maintenance procedures from the manufacturer.
Safety Checks
Safety Protocols: Always follow safety protocols during maintenance activities. Use appropriate personal protective equipment (PPE) and follow lockout/tagout procedures if required.
Emergency Procedures: Be familiar with emergency procedures in case of equipment failure or accidents during maintenance.
By adhering to these maintenance procedures, you can ensure the longevity and efficient operation of your static mixer, minimizing downtime and maintaining product quality.
Q&A
Q: What are the main advantages of opting for a custom static mixer over a standard or off-the-shelf mixer?
A: Custom static mixers offer optimized mixing performance tailored to specific application requirements, enhanced efficiency, application specificity, and durable designs using high-quality materials.
Q: How can a custom static mixer improve the efficiency of my mixing process?
A: By customizing the mixer’s geometry, elements, and features to match your specific process conditions and fluid properties, a custom static mixer can significantly improve mixing efficiency, reduce energy consumption, and minimize waste.
Q: What factors should be considered when designing a custom static mixer?
A: Factors to consider include application requirements, flow rates, fluid properties, mixing objectives, material compatibility, and the operating environment to ensure the custom mixer meets your specific needs effectively.
Q: What materials are commonly used in the construction of custom static mixers, and how do they impact performance?
A: Materials such as stainless steel (e.g., 304SS), PVC, PTFE, and other alloys are commonly used in custom static mixers. The choice of material influences factors such as corrosion resistance, durability, and compatibility with process fluids, impacting the mixer’s performance and longevity.
Q: What maintenance considerations are important for custom static mixers?
A: Custom static mixers may have specific maintenance requirements, including cleaning procedures, periodic checks for wear or fouling, and adjustments to maintain optimal performance. Adhering to recommended maintenance practices is essential for the long-term functionality of the mixer.
Q: How can a custom static mixer address unique challenges in specific applications?
A: Custom static mixers are designed to meet the unique demands of various industries and applications, such as chemical processing, food production, pharmaceuticals, and wastewater treatment. By tailoring the mixer’s design and features, it can effectively address specific challenges and optimize mixing performance for the application at hand.
Advantages / Disadvantages
Advantages of a Custom Static Mixer
Optimized Mixing Performance: A custom static mixer can be designed to meet specific mixing requirements, ensuring optimal blending, dispersion, and reaction of fluids tailored to the application.
Enhanced Efficiency: Tailoring the mixer’s geometry, elements, and features can lead to improved mixing efficiency, reduced energy consumption, and minimized waste in the process.
Application Specificity: Custom static mixers are designed to accommodate unique process conditions, fluid properties, flow rates, and other specific factors of the application, leading to better results.
Longevity and Durability: Utilizing high-quality materials such as stainless steel ensures longevity and corrosion resistance, resulting in a durable mixing solution that withstands harsh operating environments.
Disadvantages of a Custom Static Mixer
Higher Cost: Custom static mixers can be more expensive to design, manufacture, and install compared to off-the-shelf options due to the specialized engineering and customization involved.
Complex Design Process: Developing a custom static mixer requires expertise, time, and resources to ensure the design meets the application’s unique requirements, potentially leading to longer lead times.
Maintenance Challenges: Custom mixers may have unique maintenance requirements, such as specific cleaning procedures or periodic adjustments, which could pose challenges if not properly addressed.
Limited Compatibility: If the custom design is not well-matched to the evolving needs of the process or if modifications are required, it may be challenging to adapt the mixer without significant redesign or replacement.
While custom static mixers offer tailored solutions for specific applications, it’s essential to weigh the advantages of enhanced performance and application fit against the potential drawbacks of cost, complexity, maintenance, and compatibility challenges that may arise with customized mixing solutions.
Applications
Static Mixers are used for a wide variety of applications including:
Thermal homogenization extrusion and injection molding
Color blending extrusion and injection molding
Wastewater neutralization
PH control
Starch cooker
Heat exchanger
Food mixing and blending
Reactive mixes such as epoxies and urethanes
Plastic pellets
Gas-liquid dispersions
Delustring of polymer dope
Liquid-liquid dispersions
Fuel oil blending
Solvent dilution
Pipeline reactions
The blending of fruits in yogurt
Catalyst additions
Dye blending
Dispersion of solids into liquid streams
Two-part epoxy adhesives
Emulsions
Biodiesel production
Asphalt dilution
Epoxy coatings
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