Custom Static Mixers

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 an intricate and specialized devices employed across industries to effectively blend fluids and gases.  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.  The number, shape, and configuration of the plates can be customized to achieve the desired turbulence and mixing intensity 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. The pitch, diameter, and orientation of the helical elements can be fine-tuned by the required mixing performance.

Customer Static Mixers Materials

Constructed from a variety of materials such as stainless steel, PVC, Teflon, and other corrosion-resistant alloys, custom static mixers are tailored to meet the needs of diverse industries and applications.  The material selection is critical to ensure compatibility with the substances being mixed and to uphold the durability and longevity of the mixer under varying operational conditions.  The applications of custom static mixers span various sectors including chemical processing and water treatment.  In addition, they are also used for food and beverage production, pharmaceutical manufacturing, petrochemicals, and environmental engineering.  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.

 

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Stock Static Mixers

Injection Quills

Weight 16 lbs
Dimensions 14 × 1 × 1 in
Size

1/2", 3/4", 1", 1-1/4", 1-1/2", 2", 2-1/2", 3", 4", 6", 8 ", 12"

Elements Qty

6, 12

Element Type

Blade, Helical, Non-Foul

Connection Ends

Threaded (MNPT), Flanged (RF Class 150), Tri-Clamp (Sanitary)

Element Material

CS, 304SS, 316SS, PTFE / PFA, PVC, Kynar PVDF, Hastelloy C276, Alloy 20, Titanium

Thickness (Sch.)

10S, STD, 80S, XH, 160, XXH

Removable Elements

No, Yes

Injection Port

No, Yes

Heating / Cooling Jackets

No, Yes

Technical Specifications

Stainless Static Mixer Technical Specifications

ModelPipe Dia.
MNPT Ends
Number of
Elements
LengthRemovable
Element
Weight
0.25-STD-304-2B-6-MNPT1/4"63"Yes0.18
0.25-STD-304-2B-12-MNPT1/4"126"Yes0.34
0.37-STD-304-2B-6-MNPT3/8"64"Yes0.24
0.25-STD-304-2B-12-MNPT3/8"128"Yes0.46
0.5-STD-304-2B-6-MNPT1/2"65"Yes0.39
0.5-STD-304-2B-12-MNPT1/2"1210"Yes0.80
0.75-STD-304-2B-6-MNPT3/4"67"Yes0.75
0.75-STD-304-2B-12-MNPT3/4"1213"Yes1.39
1.0-STD-304-2B-6-MNPT1"69"Yes1.31
1.0-STD-304-2B-12-MNPT1"1217"Yes2.55
1.25-STD-304-2B-6-MNPT1-1/4"611"Yes2.71
1.25-STD-304-2B-12-MNPT1-1/4"1222"Yes4.99
1.5-STD-304-2B-6-MNPT1-1/2"613"Yes3.41
1.5-STD-304-2B-12-MNPT1-1/2"1226"Yes6.55
2.0-STD-304-2B-6-MNPT2"617"Yes5.71
2.0-STD-304-2B-12-MNPT2"1233"Yes11.21

Clear PVC Static Mixer Technical Specifications

ModelPipe Dia. MNPT EndsFlow GPMNumber of Elementspsig DropRemovable ElementLengthWeight
0.37-CPVC-STD-6-MNPT3/8"0.31-3.460.22-11.01No7"0.12
0.37-CPVC-STD-12-MNPT3/8"0.31-3.4120.47-21.85No12"0.18
0.5-CPVC-STD-6-MNPT1/2"0.61-5.460.22-9.7No80.16
0.5-CPVC-STD-12-MNPT1/2"0.61-5.4120.46-19.8No120.24
0.75-CPVC-STD-6-MNPT3/4"1.21-13.860.22-9.7No100.28
0.75-CPVC-STD-12-MNPT3/4"1.21-13.8120.45-19.2No160.41
1.0-CPVC-STD-6-MNPT1"2.2-17.860.27-11.25No12.48
1.0-CPVC-STD-12-MNPT1"2.2-17.8120.55-22.1No20.84
1.25-CPVC-STD-6-MNPT1-1/4"3.77-34.860.23-12.7No140.81
1.25-CPVC-STD-12-MNPT1-1/4"3.77-34.8120.45-26.1No241.42
1.5-CPVC-STD-6-MNPT1-1/2"5.1-4560.21-11.77No161.18
1.5-CPVC-STD-12-MNPT1-1/2"5.1-45120.21-11.12No301.98
2.0-CPVC-STD-6-MNPT2"7.5-6660.21-8.99No201.91
2.0-CPVC-STD-12-MNPT2"7.5-66120.47-17.1No363.32

Gray PVC Static Mixer Technical Specifications

ModelPipe Dia. MNPT EndsFlow GPMMax PSIG @ 85 FNumber of Elementspsig DropRemovable ElementLengthWeight
0.37-GPVC-80-6-MNPT3/8"0.31-3.441560.22-11.01No7".19
0.37-GPVC-80-12-MNPT3/8"0.31-3.4415120.47-21.85No12".24
0.5-GPVC-80-6-MNPT1/2"0.61-5.440060.22-9.7No80.26
0.5-GPVC-80-12-MNPT1/2"0.61-5.4400120.46-19.8No120.34
0.75-GPVC-80-6-MNPT3/4"1.21-13.832060.22-9.7No10.48
0.75-GPVC-80-12-MNPT3/4"1.21-13.8320120.45-19.2No16.64
1.0-GPVC-80-6-MNPT1"2.2-17.830060.27-11.25No12.95
1.0-GPVC-80-12-MNPT1"2.2-17.8300120.55-22.1No200.48
1.25-GPVC-80-6-MNPT1-1/4"3.77-34.825060.23-12.7No14.98
1.25-GPVC-80-12-MNPT1-1/4"3.77-34.8250120.45-26.1No241.56
1.5-GPVC-80-6-MNPT1-1/2"5.1-4522060.21-11.77No161.42
1.5-GPVC-80-12-MNPT1-1/2"5.1-45220120.21-11.12No302.31
2.0-GPVC-80-6-MNPT2"7.5-6618560.21-8.99No202.05
2.0-GPVC-80-12-MNPT2"7.5-66185120.47-17.1No363.56

Kynar Static Mixer Technical Specifications

NPT Kynar / PVDF
ModelPipe Dia. MNPT EndsFlow GPMMax PSIG @ 85 FNumber of Elementspsig DropRemovable ElementLengthWeight
0.37-PVDF-80-6-MNPT3/8"0.31-3.441560.22-11.01No5"0.13
0.37-PVDF-80-12-MNPT3/8"0.31-3.4415120.47-21.85No9"0.24
0.5-PVDF-80-6-MNPT1/2"0.61-5.432660.22-9.7No6"0.16
0.5-PVDF-80-12-MNPT1/2"0.61-5.4326120.46-19.8No10"0.26
0.75-PVDF-80-6-MNPT3/4"1.21-13.824460.22-9.7No7"0.24
0.75-PVDF-80-12-MNPT3/4"1.21-13.8244120.45-19.2No13"0.44
1.0-PVDF-80-6-MNPT1"2.2-17.822860.27-11.25No9"0.46
1.0-PVDF-80-12-MNPT1"2.2-17.8228120.55-22.1No16"0.82
1.25-PVDF-80-6-MNPT1-1/4"3.77-34.820160.23-12.7No11.78
1.25-PVDF-80-12-MNPT1-1/4"3.77-34.8201120.45-26.1No221.56
1.5-PVDF-80-6-MNPT1-1/2"5.1-4517860.21-11.77No12"1.15
1.5-PVDF-80-12-MNPT1-1/2"5.1-45178120.21-11.12No24"2.14
2.0-PVDF-80-6-MNPT2"7.5-6614560.21-8.99No18"1.98
2.0-PVDF-80-12-MNPT2"7.5-66145120.47-17.1No34"3.56

PFA Static Mixer Technical Specifications

ModelPipe Dia. MNPT EndsFlow GPMMax PSIG @ 85 FNumber of Elementspsig DropRemovable ElementLengthWeight
0.5-PFA-80-6-MNPT1/2"0.61-5.424560.22-9.7No6"0.16
0.5-PFA-80-12-MNPT1/2"0.61-5.4245120.46-19.8No10"0.32
0.75-PFA-80-6-MNPT3/4"1.21-13.822060.22-9.7No7"0.24
0.75-PFA-80-12-MNPT3/4"1.21-13.8220120.45-19.2No13"0.44
1.0-PFA-80-6-MNPT1"2.2-17.819460.27-11.25No9"0.46
1.0-PFA-80-12-MNPT1"2.2-17.8194120.55-22.1No16"0.82

 

Pressure Drop

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.

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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