Engineers design Kynar PVDF static mixers as specialized devices for blending, dispersing, and mixing fluids in various industrial processes. In addition, these mixers are constructed from Kynar PVDF (Polyvinylidene Fluoride), a high-performance thermoplastic known for its excellent chemical resistance, thermal stability, and mechanical strength. Furthermore, the use of Kynar PVDF makes these static mixers particularly suitable for applications involving aggressive chemicals, high temperatures, and stringent purity requirements.
Properties and Benefits of Kynar PVDF Static Mixers
Kynar PVDF Static Mixers are renowned for their exceptional chemical resistance. This effectively withstanding a broad spectrum of acids, bases, solvents, and other corrosive substances. This makes it an ideal material for static mixers used in chemical processing, pharmaceutical manufacturing, water treatment, and other industries where chemical exposure is prevalent. Finally, unlike many metals and other plastics, Kynar PVDF does not corrode or degrade when exposed to harsh chemicals, ensuring long-term durability and reliability.
In addition to chemical resistance, they offer excellent thermal stability. It can operate at temperatures ranging from -40°C to 150°C, making it suitable for both high-temperature and cryogenic applications. Furthermore, this thermal stability ensures that the static mixers can maintain their structural integrity and performance under varying temperature conditions, which is critical in processes involving temperature-sensitive reactions or products.
Another significant advantage of them is its mechanical strength. It has a high tensile strength and impact resistance, which allows the mixers to withstand physical stresses and pressure fluctuations in the process flow. This robustness ensures that the mixers can handle high-pressure applications without cracking or breaking, providing reliable and consistent mixing performance.
Design and Functionality
Kynar PVDF static mixers typically consist of a series of fixed mixing elements arranged within a tubular housing. Engineers design these elements to create turbulence by inducing mixing through the division and recombination of fluid streams as they pass through the mixer. In addition, the design can include various configurations, such as helical, flat blade, or baffle elements. All this depends on the specific mixing requirements. The choice of element design and arrangement depends on factors such as the fluid properties (viscosity, density, etc.). It also depends on flow rate, and the degree of mixing required.
The internal surface of the mixer is smooth, minimizing the risk of fouling and making it easier to clean. In addition, this is particularly important in applications where cross-contamination must be avoided. Cross contamination such as in the pharmaceutical and food industries. Finally, the smooth surface also reduces pressure drop across the mixer, contributing to energy efficiency and lower operational costs.
Conclusion
Kynar PVDF static mixers represent a highly effective solution for mixing applications. This is specific in industries that demand superior chemical resistance, thermal stability, and purity. Their robust construction and versatile design make them suitable for a wide range of processes. This includes processes from chemical manufacturing to food processing. While they may come with a higher initial cost compared to other materials, the long-term benefits of durability, low maintenance, and reliability often outweigh the initial investment. Finally, for applications where purity and chemical resistance are critical, they offer unmatched performance and peace of mind.
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Specifications
- Housing: Schedule 80 Kynar® PVDF
- Elements: Blade / Helical with Solid Kynar® PVDF
- End Connections: Machined Male NPT (Threaded Ends)
*Note that 3/8″ Kynar® PVDF mixers use helical design mixing elements
- Kynar® PVDF design offers superior corrosion resistance
- Lightweight and easy to install with male NPT threaded ends
Kynar Static Mixer Technical Specifications
NPT Kynar / PVDF
| Model | Pipe Dia. MNPT Ends | Flow GPM | Max PSIG @ 85 F | Number of Elements | psig Drop | Removable Element | Length | Weight |
| 0.37-PVDF-80-6-MNPT | 3/8" | 0.31-3.4 | 415 | 6 | 0.22-11.01 | No | 5" | 0.13 |
| 0.37-PVDF-80-12-MNPT | 3/8" | 0.31-3.4 | 415 | 12 | 0.47-21.85 | No | 9" | 0.24 |
| 0.5-PVDF-80-6-MNPT | 1/2" | 0.61-5.4 | 326 | 6 | 0.22-9.7 | No | 6" | 0.16 |
| 0.5-PVDF-80-12-MNPT | 1/2" | 0.61-5.4 | 326 | 12 | 0.46-19.8 | No | 10" | 0.26 |
| 0.75-PVDF-80-6-MNPT | 3/4" | 1.21-13.8 | 244 | 6 | 0.22-9.7 | No | 7" | 0.24 |
| 0.75-PVDF-80-12-MNPT | 3/4" | 1.21-13.8 | 244 | 12 | 0.45-19.2 | No | 13" | 0.44 |
| 1.0-PVDF-80-6-MNPT | 1" | 2.2-17.8 | 228 | 6 | 0.27-11.25 | No | 9" | 0.46 |
| 1.0-PVDF-80-12-MNPT | 1" | 2.2-17.8 | 228 | 12 | 0.55-22.1 | No | 16" | 0.82 |
| 1.25-PVDF-80-6-MNPT | 1-1/4" | 3.77-34.8 | 201 | 6 | 0.23-12.7 | No | 11 | .78 |
| 1.25-PVDF-80-12-MNPT | 1-1/4" | 3.77-34.8 | 201 | 12 | 0.45-26.1 | No | 22 | 1.56 |
| 1.5-PVDF-80-6-MNPT | 1-1/2" | 5.1-45 | 178 | 6 | 0.21-11.77 | No | 12" | 1.15 |
| 1.5-PVDF-80-12-MNPT | 1-1/2" | 5.1-45 | 178 | 12 | 0.21-11.12 | No | 24" | 2.14 |
| 2.0-PVDF-80-6-MNPT | 2" | 7.5-66 | 145 | 6 | 0.21-8.99 | No | 18" | 1.98 |
| 2.0-PVDF-80-12-MNPT | 2" | 7.5-66 | 145 | 12 | 0.47-17.1 | No | 34" | 3.56 |
Installation
Installing a static mixer requires careful planning and attention to detail to ensure optimal performance and longevity. Static mixers are devices used to mix fluids in a pipeline without moving parts, relying on the flow energy to achieve mixing. The installation process involves several key steps, including preparation, installation, and post-installation checks. Below is a detailed procedure for installing a static mixer:
Preparation
Select the Installation Location:
- Choose a suitable location in the pipeline where the static mixer can be installed. Ensure there is sufficient space for installation and future maintenance.
- Consider the flow profile and ensure there are sufficient straight pipe lengths upstream and downstream of the mixer to allow for proper mixing. Typically, a length of 5-10 pipe diameters upstream and 3-5 pipe diameters downstream is recommended.
Verify Compatibility:
- Ensure that the static mixer material is compatible with the fluids being processed to avoid corrosion or degradation.
- Check that the mixer size matches the pipeline diameter and the flow rate requirements.
Prepare the Tools and Equipment:
- Gather the necessary tools, such as wrenches, gaskets, flanges, bolts, nuts, and a torque wrench.
- Have the installation manual and technical drawings on hand for reference.
Safety Precautions:
- Ensure the pipeline is depressurized and drained of any fluids.
- Follow all relevant safety protocols, including wearing appropriate personal protective equipment (PPE).
Installation
Prepare the Pipeline:
- Cut the pipeline at the designated installation point, ensuring clean, straight cuts.
- Remove any burrs, debris, or sharp edges from the cut ends to prevent damage to the mixer and ensure a proper seal.
Install the Flanges (if not already present):
- Attach the appropriate flanges to the pipeline ends where the mixer will be installed.
- Ensure the flanges are aligned correctly and securely attached.
Insert the Static Mixer:
- Place the static mixer between the flanges, ensuring the correct orientation as specified by the manufacturer. Some mixers have a preferred flow direction, marked with an arrow.
- Insert gaskets between the flanges and the mixer to ensure a tight seal.
Secure the Mixer:
- Align the mixer and the pipeline flanges, ensuring proper alignment to avoid stress on the pipeline.
- Insert and hand-tighten the bolts and nuts evenly around the flange.
- Using a torque wrench, tighten the bolts in a crisscross pattern to the manufacturer’s specified torque values. This ensures even pressure distribution and prevents leaks.
Post-Installation Checks
Leak Test:
- Once the mixer is securely installed, conduct a leak test by slowly pressurizing the pipeline and inspecting for leaks at the flange connections.
- If any leaks are detected, depressurize the system and retighten the bolts as needed.
Flow Test:
- Gradually introduce the fluid flow to ensure the static mixer operates correctly.
- Observe the mixing performance and verify that the desired mixing level is achieved.
Final Inspection:
- Check that all components are securely installed and that there are no visible signs of damage or misalignment.
- Ensure that the area around the mixer installation is clean and free of debris.
Documentation and Maintenance
Record Keeping:
- Document the installation details, including the location, date, and personnel involved.
- Record any observations during the installation and testing phases, including torque values used for tightening the bolts.
Maintenance Schedule:
- Establish a maintenance schedule based on the manufacturer’s recommendations and the specific application requirements.
- Regularly inspect the mixer and surrounding pipeline for signs of wear, corrosion, or damage.
Operational Guidelines:
- Provide training for personnel on the operation and maintenance of the static mixer.
- Ensure that any operational changes, such as variations in flow rate or fluid composition, are communicated and assessed for their impact on the mixer’s performance.
By following these installation procedures, you can ensure the reliable operation of the static mixer and achieve consistent mixing results. Proper installation is crucial for the longevity and efficiency of the mixer, as well as for maintaining the safety and integrity of the entire process system.
Maintenance
Maintenance Procedure for Static Mixers
Purpose:
This procedure outlines the steps required to maintain static mixers in optimal working condition, ensuring efficient performance, longevity, and safety.
Preparation
Safety Precautions:
- Before starting maintenance, ensure the system is completely shut down, depressurized, and drained of any fluids.
- Lock out and tag out (LOTO) the system to prevent accidental startup.
- Wear appropriate personal protective equipment (PPE) including gloves, goggles, and protective clothing.
Tools and Materials:
- Wrenches and torque wrench
- Cleaning brushes and tools
- Appropriate cleaning solvents (compatible with the fluids used in the system)
- Replacement gaskets and seals
- Inspection tools (flashlight, mirrors, borescope, if necessary)
- Lubricants suitable for the application
Inspection
External Inspection:
- Visually inspect the static mixer and surrounding piping for any signs of leaks, corrosion, or mechanical damage.
- Check for signs of wear or misalignment in the flanges and bolts.
Internal Inspection:
- Remove the static mixer from the pipeline following proper disassembly procedures.
- Inspect the internal mixing elements for any signs of wear, corrosion, or blockage.
- Check for residue buildup on the mixing elements and inside the housing.
- Ensure that all internal surfaces, including the mixing elements and housing, maintain the specified surface finish (e.g., 20 Ra or better for sanitary applications).
Cleaning
Cleaning Process:
- Clean the mixing elements and internal housing thoroughly using appropriate solvents and cleaning tools.
- For sanitary applications, use approved food-grade or pharmaceutical-grade cleaning agents.
- Carefully remove any residue or buildup without damaging the mixing elements or the housing.
Rinse and Dry:
- Rinse all components with clean water or an appropriate solvent to remove any remaining cleaning agent residues.
- Dry all components thoroughly to prevent corrosion.
Component Replacement
Gaskets and Seals:
- Inspect all gaskets and seals for wear, cracks, or deformation.
- Replace gaskets and seals with new ones of the appropriate material and size.
Mixing Elements (if applicable):
- If mixing elements show significant wear or damage, replace them according to the manufacturer’s specifications.
Reassembly and Reinstallation
Reassembly:
- Reassemble the static mixer, ensuring all components are correctly aligned and seated.
- Use a torque wrench to evenly tighten all bolts to the manufacturer’s specified torque values in a crisscross pattern to ensure a proper seal.
Reinstallation:
- Reinstall the static mixer into the pipeline, ensuring proper alignment and orientation.
- Verify that the flow direction marked on the mixer aligns with the actual flow direction in the pipeline.
Final Checks
Leak Test:
- Gradually repressurize the system and check for leaks at all connections and seals.
- If leaks are detected, depressurize the system and retighten the bolts as necessary.
Operational Test:
- Once the system is confirmed to be leak-free, gradually introduce the fluid and check the mixing performance.
- Observe the system for any unusual noises, vibrations, or other signs of improper operation.
Documentation
Maintenance Log:
- Record all maintenance activities, including date, personnel involved, observations, and any components replaced.
- Note any issues encountered and actions taken to resolve them.
Scheduling:
- Update the maintenance schedule based on the findings from the current maintenance session.
- Schedule the next maintenance inspection according to the manufacturer’s recommendations or based on operational experience.
Training and Safety Review
Personnel Training:
- Ensure that all personnel involved in maintenance activities are adequately trained and familiar with the static mixer and safety procedures.
Safety Review:
- Review safety procedures and protocols periodically to ensure compliance and address any new hazards or changes in the system.
Continuous Improvement
Performance Monitoring:
- Monitor the performance of the static mixer continuously, looking for signs of reduced efficiency or increased wear.
- Adjust maintenance frequency and procedures based on observed performance trends.
By adhering to this maintenance procedure, you can ensure that your static mixer operates efficiently, safely, and consistently. Regular maintenance helps prevent unexpected failures, prolongs the lifespan of the equipment, and maintains the quality of the mixing process.
Q&A
Q1: What is Kynar PVDF, and why is it used in static mixers?
A1: Kynar PVDF (Polyvinylidene Fluoride) is a high-performance thermoplastic known for its exceptional chemical resistance, thermal stability, and mechanical strength. It is used in static mixers because it can withstand aggressive chemicals, high temperatures, and rigorous process conditions, making it suitable for a variety of demanding industrial applications.
Q2: What types of fluids can Kynar PVDF static mixers handle?
A2: Kynar PVDF static mixers are versatile and can handle a wide range of fluids, including both low and high-viscosity liquids, gases, and corrosive chemicals. They are particularly effective in applications where chemical resistance and purity are critical.
Q3: What are the key benefits of using Kynar PVDF static mixers?
A3: The primary benefits include excellent chemical resistance to a broad range of acids, bases, and solvents; high thermal stability, allowing operation in extreme temperatures; and superior mechanical strength. These properties ensure durability, reliability, and low maintenance needs in harsh environments.
Q4: How does the design of Kynar PVDF static mixers promote effective mixing?
A4: The design incorporates a series of fixed helical or baffle elements inside a tubular housing. These elements create turbulence and induce mixing by continuously dividing and recombining the fluid streams, leading to thorough and consistent blending.
Q5: Are Kynar PVDF static mixers suitable for sanitary applications?
A5: Yes, Kynar PVDF static mixers are ideal for sanitary applications due to their smooth internal surfaces, which minimize fouling and facilitate easy cleaning. This makes them suitable for industries like pharmaceuticals and food and beverage processing where maintaining cleanliness and avoiding contamination are crucial.
Q6: What industries commonly use Kynar PVDF static mixers?
A6: Kynar PVDF static mixers are commonly used in chemical processing, water and wastewater treatment, pharmaceuticals, food and beverage manufacturing, and oil and gas industries. Their chemical resistance and thermal stability make them suitable for various demanding environments.
Q7: Are there any disadvantages to using Kynar PVDF static mixers?
A7: Potential disadvantages include a higher initial cost compared to mixers made from less expensive materials and the need for specialized handling and installation. Additionally, Kynar PVDF can become brittle at very low temperatures, which may affect its performance in extremely cold conditions.
Q8: How do Kynar PVDF static mixers compare to mixers made from other materials?
A8: Compared to other materials, Kynar PVDF offers superior chemical resistance and thermal stability, making it more suitable for aggressive and high-temperature applications. However, it may be more expensive than alternatives like stainless steel or other plastics. The choice of material depends on the specific requirements of the application.
Q9: How are Kynar PVDF static mixers cleaned and maintained?
A9: Kynar PVDF static mixers are designed for easy cleaning, with smooth internal surfaces that reduce fouling and scaling. Cleaning typically involves standard procedures such as flushing with cleaning agents or using CIP (Clean-In-Place) systems. Regular inspections and maintenance are recommended to ensure optimal performance and longevity.
Q10: Can Kynar PVDF static mixers be customized for specific applications?
A10: Yes, Kynar PVDF static mixers can be customized to meet specific process requirements. Customizations may include varying the size and length of the mixer, the configuration of mixing elements, and connection types. This allows the mixers to be tailored to different fluid properties, flow rates, and operational conditions.
Advantages / Disadvantages
Advantages of Kynar PVDF Static Mixers
Exceptional Chemical Resistance: Kynar PVDF offers outstanding resistance to a broad spectrum of chemicals, including acids, bases, solvents, and oxidizing agents. This makes PVDF static mixers ideal for applications involving aggressive or corrosive substances, ensuring longevity and performance in harsh environments.
High Thermal Stability: Kynar PVDF can operate effectively over a wide temperature range, from -40°C to 150°C. This thermal stability allows the mixers to handle both high-temperature and low-temperature processes without compromising material integrity.
Superior Mechanical Strength: The material’s high tensile strength and impact resistance provide durability under high-pressure conditions. This robustness ensures that the static mixers can withstand physical stresses and pressure fluctuations in various industrial processes.
Non-Contaminating: Kynar PVDF is a pure material that does not leach harmful substances into the mixed fluids. This property is crucial for applications requiring stringent purity, such as pharmaceuticals and food processing.
Ease of Cleaning and Maintenance: The smooth internal surfaces of Kynar PVDF static mixers minimize fouling and scaling, making them easier to clean. This is particularly advantageous in applications where maintaining hygiene and avoiding cross-contamination are essential.
Low Maintenance Requirements: With no moving parts, Kynar PVDF static mixers require minimal maintenance. This design reduces downtime and associated maintenance costs, offering a reliable and efficient mixing solution.
Customizable Design: Kynar PVDF static mixers can be tailored to specific application needs. Customizations may include varying sizes, lengths, and configurations of mixing elements, ensuring optimal performance for different fluid properties and flow rates.
Disadvantages of Kynar PVDF Static Mixers
Higher Initial Cost: The advanced properties of Kynar PVDF result in higher material and manufacturing costs compared to mixers made from less expensive materials. This can be a significant consideration for cost-sensitive applications.
Brittleness at Low Temperatures: While Kynar PVDF is highly stable over a wide temperature range, it can become brittle at very low temperatures. This brittleness may lead to cracking or failure in extremely cold conditions.
Limited Flexibility: Kynar PVDF lacks the flexibility of some other materials, which may be a limitation in applications requiring a degree of elasticity or impact resistance beyond what the material can provide.
Specialized Handling and Installation: The handling and installation of Kynar PVDF static mixers may require specialized knowledge and equipment. This can add complexity to the installation process, particularly in high-temperature or aggressive chemical environments.
Potential for High Impact Damage: Despite its mechanical strength, Kynar PVDF can be susceptible to damage from high-impact forces or accidental drops. Proper care and handling are necessary to avoid compromising the mixer’s integrity.
Limited Impact Resistance in Some Applications: While the material is strong, it may not offer the same level of impact resistance as some metals, potentially leading to issues in applications where mechanical shocks or heavy impacts are common.
Potential Cost of Customization: Customizing Kynar PVDF static mixers to meet specific needs can increase costs. Customization may involve additional manufacturing processes or specialized design considerations, further impacting the overall expense.
In summary, Kynar PVDF static mixers offer significant advantages in terms of chemical resistance, thermal stability, and ease of maintenance, making them well-suited for demanding industrial applications. However, their higher initial cost, potential brittleness at low temperatures, and specialized handling requirements should be carefully considered when selecting a mixer for a specific application.
Applications
Kynar PVDF (Polyvinylidene Fluoride) static mixers are highly valued for their versatility and robust performance in various industrial applications. Their unique properties—such as exceptional chemical resistance, high thermal stability, and excellent mechanical strength—make them suitable for several demanding environments. Here are some key applications of Kynar PVDF static mixers:
Chemical Processing
In chemical processing, Kynar PVDF static mixers are used for blending and homogenizing chemicals, ensuring uniformity in reactions and product consistency. Their resistance to aggressive chemicals, such as strong acids and bases, makes them ideal for handling corrosive substances and maintaining process integrity.
Pharmaceutical Manufacturing
Kynar PVDF mixers are crucial in pharmaceutical manufacturing, where precision and purity are paramount. They are employed in the mixing of active pharmaceutical ingredients (APIs) and excipients, where the non-contaminating nature of Kynar PVDF ensures that no undesirable substances leach into the final product. The ease of cleaning and maintaining sanitary conditions is vital in this industry to prevent cross-contamination.
Food and Beverage Processing
In the food and beverage industry, Kynar PVDF static mixers are used for tasks such as blending ingredients, flavoring, and emulsifying. The material’s compliance with food safety regulations ensures that it does not impart any harmful substances to the food products. Additionally, the mixers’ resistance to various cleaning agents and their ability to maintain hygiene make them suitable for applications requiring frequent sanitation.
Water and Wastewater Treatment
Kynar PVDF static mixers play a critical role in water and wastewater treatment processes. They are used for mixing chemicals such as coagulants, flocculants, and disinfectants. Their resistance to chlorine and other oxidizing agents ensures durability and consistent performance in treating water and wastewater. The mixers help in achieving efficient chemical dosing and optimal treatment outcomes.
Oil and Gas Industry
In the oil and gas industry, Kynar PVDF static mixers are used for mixing additives with crude oil, natural gas, or other hydrocarbons. The material’s chemical resistance allows it to handle corrosive substances and harsh process conditions encountered in this sector. The mixers contribute to the effective blending of various additives, ensuring proper product formulation and performance.
Environmental Applications
Kynar PVDF static mixers are utilized in environmental applications, including air pollution control and soil remediation. They are used to mix reagents or neutralizing agents with contaminated air or soil. The chemical resistance of Kynar PVDF ensures that the mixers can withstand the harsh conditions associated with environmental cleanup processes.
Polymer Production
In the polymer production industry, Kynar PVDF static mixers are employed for blending polymer solutions and additives. The ability to handle high-viscosity fluids and maintain uniform mixing is crucial in producing consistent polymer products with the desired properties.
Electronics Manufacturing
In electronics manufacturing, Kynar PVDF static mixers are used in the production of electronic materials, such as adhesives and coatings. The mixers help in achieving uniform dispersion of components, which is essential for ensuring the quality and performance of electronic products.
Hydrocarbon Processing
Kynar PVDF static mixers are used in hydrocarbon processing to mix various hydrocarbon streams and additives. Their resistance to hydrocarbons and high temperatures ensures reliable performance in processes such as refining and petrochemical production.
Specialty Chemicals Production
For specialty chemicals that require precise mixing of reactive or sensitive components, Kynar PVDF static mixers offer the necessary performance and reliability. The material’s chemical resistance and thermal stability support the production of high-quality specialty chemicals with specific characteristics.
In summary, Kynar PVDF static mixers are indispensable in a wide range of industries due to their robust performance and versatility. Their ability to handle harsh chemicals, extreme temperatures, and demanding process conditions makes them a valuable asset in applications where reliability and efficiency are crucial.
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