ProMixUSA offers a range of threaded PFA Static Mixers that are chemical resistant and readily available for immediate shipping. Our inventory features static mixers with diameters ranging from 1/2″ to 1″ and is meticulously constructed using Schedule 80 PFA. We design each mixer with robust PFA mixing elements that we securely weld to the interior surface of the pipe. Finally, this construction ensures optimal performance in various demanding applications.
Our threaded PFA static mixers stand out as the most versatile option among our in-stock products. We specifically engineer them to handle aggressive chemical mixing processes, making them ideal for scenarios involving highly reactive or corrosive substances. Additionally, we design these mixers to resist elevated temperatures, ensuring reliable operation even under harsh conditions.
The Schedule 80 PFA Static Mixers construction provides exceptional chemical resistance, making them an excellent choice for industries where exposure to aggressive chemicals is a constant challenge. Furthermore, our PFA Static Mixers’ material is renowned for its durability and resistance to a broad range of chemicals, including acids, bases, and solvents. In addition, this makes our mixers particularly valuable in industries such as chemical processing, pharmaceuticals, and petrochemicals, where maintaining the integrity of the mixing process is crucial.
Solid PFA Elements
One of the key features of our static mixers is the integration of solid PFA Static Mixers elements. We precisely engineer these elements to enhance mixing efficiency and ensure thorough blending of the chemicals passing through the mixer. Furthermore, the welding of these elements to the pipe wall guarantees that there is no leakage or detachment during operation. Furthermore, which could otherwise compromise the mixing process or lead to contamination.
The design of our threaded PFA static mixers allows for easy installation and maintenance. The threaded connections enable quick and secure attachment to existing piping systems, reducing downtime and simplifying the integration process. In addition, our user-friendly design makes it easy to replace and service our mixers without causing significant disruption to ongoing operations.
Chemical Resistance
In addition to offering robust chemical resistance and temperature tolerance, we design our static mixers with versatility in mind. You can also utilize them in a wide range of applications beyond chemical mixing, including processes that require consistent blending of different fluids or materials. Furthermore, this flexibility makes them a valuable asset in many industrial settings where mixing precision and reliability are paramount.
Furthermore, our commitment to quality extends beyond the materials used in our mixers. Moreover, each static mixer undergoes rigorous quality control testing to ensure that it meets the highest standards of performance and reliability. In addition, this attention to detail guarantees that our products consistently deliver the performance required for even the most demanding applications.
Reliability
At ProMixUSA, we understand the importance of having reliable, high-performance equipment readily available. In addition, that’s why we maintain a comprehensive inventory of our threaded PFA chemical-resistant static mixers. This ensures that you can quickly access the products you need to keep your operations running smoothly. Whether you handle aggressive chemicals, high temperatures, or other challenging conditions, we design our static mixers to meet your needs effectively.
In summary, ProMixUSA’s in-stock threaded PFA Static Mixers that are chemical-resistant static mixers offer a robust, versatile solution. A solution for a wide range of industrial mixing applications. Also, constructed from Schedule 80 PFA and featuring solid PFA mixing elements welded to the pipe wall. Furthermore, these mixers provide superior chemical resistance and mixing efficiency. Finally, their design facilitates easy installation and maintenance, making them an ideal choice. This ideal choice is for industries where reliable, high-performance mixing equipment is essential.
Other Mixer Types:
Metal Alloy Static Mixers
Sanitary Mixers
CPVC / PVC Mixers
Specifications
Material: Schedule 80 PFA (Perfluoroalkoxy)
Diameter Range: Available from 1/2″ to 1″
Construction: Solid PFA mixing elements welded to the interior pipe wall
Chemical Resistance: Excellent resistance to acids, bases, solvents, and other aggressive chemicals
Temperature Tolerance: Capable of handling high temperatures without degradation
Pressure Rating: Designed to withstand high pressures (specific ratings may vary)
Design: Threaded connections for easy installation and maintenance
Mixing Efficiency: Enhanced mixing performance through precisely engineered PFA elements
Application: Suitable for chemical processing, pharmaceuticals, petrochemicals, water treatment, food and beverage, cosmetics, and research
Quality Control: Rigorous testing for performance, durability, and material integrity
Versatility: Can be used for various fluids and materials beyond chemical applications
Table
PFA Static Mixer Technical Specifications
| Model | Pipe Dia. MNPT Ends | Flow GPM | Max PSIG @ 85 F | Number of Elements | psig Drop | Removable Element | Length | Weight |
| 0.5-PFA-80-6-MNPT | 1/2" | 0.61-5.4 | 245 | 6 | 0.22-9.7 | No | 6" | 0.16 |
| 0.5-PFA-80-12-MNPT | 1/2" | 0.61-5.4 | 245 | 12 | 0.46-19.8 | No | 10" | 0.32 |
| 0.75-PFA-80-6-MNPT | 3/4" | 1.21-13.8 | 220 | 6 | 0.22-9.7 | No | 7" | 0.24 |
| 0.75-PFA-80-12-MNPT | 3/4" | 1.21-13.8 | 220 | 12 | 0.45-19.2 | No | 13" | 0.44 |
| 1.0-PFA-80-6-MNPT | 1" | 2.2-17.8 | 194 | 6 | 0.27-11.25 | No | 9" | 0.46 |
| 1.0-PFA-80-12-MNPT | 1" | 2.2-17.8 | 194 | 12 | 0.55-22.1 | No | 16" | 0.82 |
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
Q: What are the key benefits of using threaded PFA chemical-resistant static mixers?
A: The key benefits include exceptional chemical resistance, making them suitable for aggressive chemicals; high temperature tolerance, which allows them to perform reliably in heated processes; and durability due to their Schedule 80 PFA construction. They also offer efficient mixing through solid PFA elements and are designed for easy installation and maintenance.
Q: In which industries are threaded PFA static mixers typically used?
A: These static mixers are commonly used in chemical processing, pharmaceutical manufacturing, petrochemical production, water and wastewater treatment, food and beverage processing, cosmetics manufacturing, environmental cleaning, and research and development. They are ideal for applications involving corrosive substances, high temperatures, and precise mixing needs.
Q: How do threaded PFA static mixers handle high temperatures?
A: Threaded PFA static mixers are constructed from PFA material, which is known for its excellent heat resistance. This allows them to operate effectively in high-temperature environments without degrading or losing performance, making them suitable for processes that involve elevated temperatures.
Q: Are there any size limitations for the threaded PFA static mixers?
A: Yes, the in-stock threaded PFA static mixers are available in diameters ranging from 1/2″ to 1″. If your application requires a different size or custom dimensions, you may need to consult with the manufacturer or explore alternative solutions.
Q: Can these static mixers be used in applications with non-chemical fluids?
A: Yes, the versatility of the threaded PFA static mixers allows them to be used in applications beyond chemical mixing. They can handle various fluids and materials where consistent blending and mixing are required, including food and beverage ingredients, and other industrial processes.
Q: How easy is it to install and maintain the threaded PFA static mixers?
A: The threaded design of these mixers facilitates easy installation by allowing quick and secure attachment to existing piping systems. Maintenance is also straightforward, as the design enables easy replacement or servicing without significant disruption to operations.
Q: What kind of quality control measures are in place for these mixers?
A: ProMixUSA implements rigorous quality control testing to ensure that each threaded PFA static mixer meets high standards of performance and durability. This includes checks for construction quality, material integrity, and operational reliability to ensure consistent product performance.
Q: Are there any potential disadvantages to using these mixers?
A: Potential disadvantages include the higher cost of PFA material compared to other options, which may impact budget considerations. Additionally, the available size range might not suit all applications, and the threaded design may require additional fittings for certain piping systems. Despite these factors, their benefits often outweigh the drawbacks for specific applications.
Advantages / Disadvantages
Advantages
Chemical Resistance: The PFA material used in these static mixers offers excellent resistance to a wide range of aggressive chemicals, including acids, bases, and solvents. This makes them highly suitable for industries dealing with corrosive substances.
Temperature Tolerance: PFA static mixers can handle high temperatures without degrading, making them ideal for applications where heat resistance is crucial.
Durability: The Schedule 80 PFA construction ensures a robust and long-lasting product that can withstand harsh conditions and extensive use.
Efficient Mixing: Solid PFA mixing elements welded to the interior pipe wall enhance mixing efficiency by promoting thorough blending of fluids, leading to improved process outcomes.
Easy Installation and Maintenance: The threaded design allows for straightforward installation and quick replacement or servicing, minimizing downtime and facilitating seamless integration into existing systems.
Versatility: These mixers are versatile and can be used in various applications beyond chemical processing, including blending different fluids or materials.
Disadvantages
Cost: PFA is a high-performance material and can be more expensive than other options, which might be a concern for budget-conscious projects.
Limited Size Range: The available diameters (1/2″ to 1″) might not suit all applications, particularly those requiring larger or custom-sized mixers.
Specialized Applications: While highly resistant to chemicals and heat, these mixers may not be necessary for less demanding applications, where more cost-effective options could suffice.
Potential for Wear: Despite their durability, constant exposure to extremely harsh chemicals or high temperatures could eventually lead to wear and degradation over time.
Installation Constraints: The threaded design might not be compatible with all piping systems, potentially requiring additional fittings or modifications for proper integration.
Applications
The threaded PFA chemical-resistant static mixers from ProMixUSA are highly versatile and can be utilized in a range of applications across various industries. Here are some key applications:
Chemical Processing
Acid and Base Neutralization: These mixers are ideal for applications involving the neutralization of strong acids and bases, ensuring thorough mixing and effective reaction.
Corrosive Chemical Handling: They handle aggressive chemicals such as chlorine, sulfuric acid, and nitric acid, providing a reliable solution for mixing and blending in chemical plants.
Pharmaceutical Manufacturing
Active Ingredient Mixing: In pharmaceutical production, the static mixers ensure consistent blending of active ingredients and excipients, which is crucial for maintaining product quality and efficacy.
Sterilization Processes: The mixers can be used in processes that involve high temperatures and require chemical resistance to maintain sterile conditions.
Petrochemical Industry
Hydrocarbon Blending: The mixers are well-suited for blending various hydrocarbons and additives, essential for producing consistent fuel and lubricant products.
Polymer Production: In polymer synthesis, these mixers ensure uniform mixing of monomers and catalysts under high-temperature conditions.
Water and Wastewater Treatment
Chemical Dosing: They can be used for mixing chemicals added to water and wastewater treatments, such as flocculants and coagulants, ensuring effective treatment and purification.
pH Adjustment: Static mixers assist in the uniform distribution of pH adjusters in treatment processes, improving overall water quality.
Food and Beverage Processing
Ingredient Blending: In food and beverage production, these mixers can blend ingredients such as flavorings, colorants, and preservatives, ensuring even distribution and quality control.
Heat-sensitive Applications: They are suitable for applications where high temperatures are involved, such as pasteurization processes.
Cosmetics Manufacturing
Ingredient Mixing: Static mixers are used to combine cosmetic ingredients like emulsifiers, colorants, and active ingredients, ensuring a consistent product texture and performance.
High-Temperature Processing: They can handle the mixing of ingredients under elevated temperatures required for certain cosmetic formulations.
Environmental and Industrial Cleaning
Chemical Cleaning Solutions: The mixers are used to blend cleaning agents and solvents for industrial cleaning applications, ensuring thorough and effective cleaning.
Research and Development
Lab-Scale Experiments: In research settings, these mixers facilitate precise mixing of chemicals and materials, supporting experimental processes and product development.
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