ProMixUSA Shell and Tube Static Mixers
ProMixUSA Static Mixer technology, exclusively featured in ProMixUSA Shell and Tube Static Mixers, delivers superior heat transfer coefficients for rapid and uniform thermal exchange. These Shell and Tube Static Mixers operate reliably across a broad spectrum of process applications. Moreover, such as those found in the polymer, plastic, and food and beverage industries. Unlike conventional designs, ProMixUSA Shell and Tube Static Mixers are more space efficient. The designs are also energy-efficient and require less residence time.
Static Mixing Technology
Each ProMixUSA Heat Exchanger incorporates a continuous series of static mixer elements within each tube. These elements direct fluid flow radially toward the pipe walls and back, regardless of velocity. Additionally, momentum reversal and flow division further enhance mixing efficiency. This continuous and complete intermixing of processed material eliminates radial gradients in temperature, velocity, and material composition. Consequently, ProMixUSA Heat Exchangers ensure predictable, controlled mixing, achieving the highest efficiency in thermal transfer available today.
Efficient Heat Exchanger Design
The use of ProMixUSA Static Mixer elements in each tube significantly reduces the film build-up typical of laminar flow in empty tubes. The process fluid is continually moved from the center of each tube to the wall and back, eradicating thermal gradients and improving the inside film coefficient.
ProMixUSA Static Mixer elements facilitate a more uniform and consistent transfer process, achieving heat transfer rates three to seven times greater than empty tubes alone. Key features include:
- Self-cleaning wiping action by mixer elements
- Plug flow characteristics that ensure uniform heat history
- Blending out of temperature gradients
- Minimal fouling
- Surface renewal at the tube wall, reducing the risk of thermal degradation
- Capability to cool viscous materials to near freezing temperatures
The Shell and Tube Static Mixers are furnace brazed to the pipe walls, enhancing surface area and creating an internal fin effect that significantly boosts transfer rates. Removable elements are also available for applications requiring periodic cleaning during product changeovers.
Advanced Design and Fabrication
ProMixUSA custom designs Shell and Tube Static Mixers to meet specific customer requirements. We provide units designed to comply with ASME code and TEMA standards, utilizing state-of-the-art tools for both engineering design and manufacturing. Recognizing that our heat exchanger units are often critical components in our customers’ processes, we prioritize superior design and quality. Our experienced and certified welders take great pride in crafting these products. Our designs can accommodate pressure ranges from low to over 5,000 psi, validated by over 40 years of successful installations.
Expanded Insight into ProMixUSA Shell and Tube Static Mixers
ProMixUSA Shell and Tube Static Mixers stand out due to their innovative static mixing technology, which revolutionizes how heat is transferred within industrial processes. Also, by disrupting the laminar flow that typically hinders thermal efficiency, ProMixUSA S&T Elements ensure that the process fluid is constantly mixed. Futhermore, this enhances heat transfer and ensuring a more uniform product output. This technology is particularly beneficial in industries where precise temperature control and uniformity are crucial, such as in the production of sensitive polymers or food processing where maintaining specific temperature profiles is essential for product quality.
The static mixer elements not only improve heat transfer efficiency but also contribute to the longevity and reliability of the heat exchanger. The self-cleaning action minimizes fouling, which is a common issue in conventional heat exchangers that can lead to decreased efficiency and increased maintenance costs. Continuously renewing the surface at the tube wall significantly reduces the risk of thermal degradation and ensures that we can process even high-viscosity materials effectively.
Custom-Built
Moreover, the custom-built nature of ProMixUSA Shell and Tube Static Mixers allows for a high degree of flexibility. Moreover, this flexibility is in design and application. The Shell and Tube Static Mixers can meet challenges such as dealing with highly corrosive fluids, high-pressure requirements, or specific thermal duties by being tailored accordingly. This customization extends to the choice of materials, dimensions, and even the inclusion of removable elements. This is for applications where frequent cleaning or maintenance is necessary.
ProMixUSA commitment to quality and innovation is evident in their rigorous manufacturing process. By adhering to ASME and TEMA standards, they ensure that each heat exchanger not only meets but exceeds industry requirements. The expertise of their design and manufacturing teams, combined with the use of advanced tools and techniques. In addition, guarantees that each unit is capable of performing reliably under the most demanding conditions.
In conclusion, ProMixUSA Shell and Tube Static Mixers represent a significant advancement in heat transfer technology. Their unique static mixing elements provide superior thermal efficiency, reduced energy consumption, and improved process uniformity. Customizable to meet specific industry needs and backed by decades of proven performance. Furthermore, ProMixUSA exchanger elements are an invaluable asset in any process requiring precise and efficient thermal management.
Specifications
Operating Parameters:
- Flows to 565 m³/h (2500 gpm)
- Heads to 110 m (350 ft)
- Pressures to 17 bar (250 psi)
- Temperatures from -30°C (-20°F) to 90°C (200°F)
Shaft Metallurgy Options:
- 304 SS
- 316 SS
- Alloy 20
- Hastelloy
- Titanium
Features:
- Full basket strainer
- NEMA in-line motor
- Fiberglass mounting plate
- Tapered “Polygon” impeller drive
- “Pull-out” bearing retainers
- Level controls
Options:
- Simplex and duplex pit covers
- Float switches
- Particulate separators
- Non-metallic lubrication lines
- Tailpipe
The engineered polymer composite construction offers a cost-effective solution with excellent corrosion resistance. It is lightweight, non-galling, non-sparking, and non-conductive. The unitized casing features integrally molded flanges at both the suction and discharge nozzles, fully gusseted for enhanced structural integrity.
The externally adjustable, semi-open impeller ensures consistently high efficiency while reducing maintenance needs. The shaft and bearing system operates below the first critical speed, reducing shaft whip and extending bearing life. Bearings can be lubricated via external flushing or self-lubricated using the pump fluid.
The single-piece column, made from lightweight, filament-wound reinforced fiberglass composite, provides exceptional strength and rigidity.
Installation
Preparation
Review Documentation:
Carefully read and understand the installation manual and any technical documents provided by the manufacturer.
Verify that all necessary parts and tools are available before beginning the installation.
Inspect Components:
Inspect all static mixer elements and heat exchanger tubes for any signs of damage or defects.
Ensure that the tubes and mixer elements are clean and free from debris.
Safety Precautions:
Wear appropriate personal protective equipment (PPE) such as gloves, safety goggles, and protective clothing.
Ensure the work area is clean, well-lit, and free of any hazards.
Installation Steps
Position the Heat Exchanger:
Securely position the heat exchanger on a stable, level surface.
Use appropriate lifting equipment to position the heat exchanger if it is large or heavy.
Prepare the Tubes:
Ensure the heat exchanger tubes are clean and dry.
If necessary, use a cleaning brush or appropriate cleaning solution to remove any contaminants from the tube surfaces.
Install Static Mixer Elements:
Carefully insert the static mixer elements into each heat exchanger tube.
Ensure that each element is properly aligned and seated within the tube.
For elements that require furnace brazing, ensure that they are securely brazed to the pipe walls as per manufacturer specifications.
Secure the Elements:
If the static mixer elements are of the removable type, ensure they are securely fixed in place using the provided fasteners or clamps.
Check for proper alignment and fit to ensure there are no gaps or misalignments.
Connect the Exchanger:
Connect the heat exchanger to the process piping system as per the design specifications.
Ensure all connections are tight and leak-free.
Use appropriate gaskets and sealants as recommended by the manufacturer.
Pressure Testing:
Conduct a pressure test to ensure there are no leaks in the system.
Follow the manufacturer’s guidelines for the pressure testing procedure, including the required test pressure and duration.
Inspect all connections and joints for any signs of leakage during the test.
Final Checks
Inspect Installation:
Perform a thorough inspection of the entire installation to ensure everything is correctly installed and secure.
Check that all mixer elements are correctly positioned and there are no obstructions in the tubes.
System Calibration:
If required, calibrate the system controls and instrumentation to ensure accurate monitoring and operation of the heat exchanger.
Verify that all sensors and control devices are functioning properly.
Operational Test:
Gradually bring the system online and monitor for any irregularities.
Check for proper flow rates, temperature gradients, and mixing efficiency.
Make any necessary adjustments to optimize performance.
Documentation:
Record all installation details, test results, and any adjustments made.
Maintain a log of any issues encountered and how they were resolved.
Maintenance and Monitoring
Regular Inspections:
Schedule regular inspections to ensure the static mixer elements and heat exchanger tubes remain clean and in good condition.
Look for signs of wear, fouling, or damage.
Cleaning Procedures:
Follow the manufacturer’s recommended cleaning procedures for the static mixer elements and heat exchanger tubes.
For removable elements, periodically remove and clean them to maintain optimal performance.
Performance Monitoring:
Continuously monitor the performance of the heat exchanger to ensure it is operating efficiently.
Record data on temperature gradients, flow rates, and mixing efficiency for ongoing analysis and optimization.
By following these detailed installation procedures, you can ensure that the static mixer in the shell and tube heat exchanger is installed correctly and operates efficiently, providing reliable performance in your process applications.
Maintenance
Regular Maintenance
Inspection
Frequency: Monthly
Procedure:
- Visually inspect the heat exchanger for any signs of external damage, corrosion, or leaks.
- Check for unusual noises or vibrations that may indicate internal issues.
- Ensure all connections and fasteners are secure.
Cleaning
Frequency: Quarterly or as needed based on process conditions
Procedure:
- Shut down the system and isolate the heat exchanger.
- Drain the heat exchanger and remove any process fluids.
- For removable static mixer elements, carefully extract them from the tubes.
- Use a suitable cleaning solution to remove any fouling or buildup on the mixer elements and tube walls.
- For non-removable elements, perform a chemical or mechanical cleaning as recommended by the manufacturer.
- Rinse thoroughly with clean water to remove any cleaning agents.
- Reassemble the heat exchanger and ensure all components are correctly reinstalled.
Pressure Testing
Frequency: Annually
Procedure:
- After cleaning and reassembly, conduct a pressure test to check for leaks.
- Follow the manufacturer’s guidelines for the test pressure and duration.
- Inspect all joints, connections, and welds for signs of leakage.
- Repair any leaks found during the test.
Preventive Maintenance
Performance Monitoring
Frequency: Continuous
Procedure:
- Monitor key performance indicators such as temperature gradients, flow rates, and pressure drops.
- Record data regularly to identify any trends or deviations from normal operation.
- Use this data to predict potential issues and schedule maintenance before problems occur.
Lubrication
Frequency: As recommended by the manufacturer
Procedure:
- Apply appropriate lubricants to any moving parts or seals as specified in the manufacturer’s maintenance manual.
- Ensure that only compatible lubricants are used to avoid damage to materials.
Corrective Maintenance
Troubleshooting
Symptoms:
- Decreased heat transfer efficiency
- Increased pressure drop
- Unusual noises or vibrations
- Leaks or visible damage
Procedure:
- Isolate the heat exchanger and shut down the system.
- Drain and disassemble the heat exchanger to inspect internal components.
- Identify and replace any damaged or worn static mixer elements or tubes.
- Check for and clear any blockages or fouling.
- Reassemble and test the system to ensure the issue is resolved.
Element Replacement
Frequency: As needed
Procedure:
- Remove the affected static mixer elements carefully to avoid damage to the tubes.
- Install new elements as per the manufacturer’s specifications.
- Ensure proper alignment and secure attachment of the new elements.
- Perform a pressure test and operational check after replacement.
Documentation
Maintenance Logs
Procedure:
- Maintain detailed records of all maintenance activities, including inspections, cleanings, pressure tests, and repairs.
- Record dates, procedures performed, and any issues identified and resolved.
- Keep logs organized and accessible for reference during future maintenance or troubleshooting.
Performance Records
Procedure:
- Continuously track and record performance data such as temperature gradients, flow rates, and pressure drops.
- Use this data to analyze trends and predict maintenance needs.
- Compare performance data before and after maintenance to assess the effectiveness of the procedures performed.
Safety Precautions
Personal Protective Equipment (PPE)
Requirement:
Wear appropriate PPE such as gloves, safety goggles, and protective clothing during all maintenance activities.
Lockout/Tagout (LOTO)
Procedure:
- Follow proper LOTO procedures to ensure the system is safely de-energized and isolated before performing maintenance.
- Verify that all energy sources are properly locked out and tagged out.
- By adhering to these maintenance procedures, you can ensure that your ProMixUSA Shell and Tube Heat Exchanger operates efficiently and reliably, minimizing downtime and extending the lifespan of the equipment.
Q&A
Q: What are ProMixUSA Shell and Tube Heat Exchangers?
A: ProMixUSA Shell and Tube Heat Exchangers utilize ProMixUSA Static Mixer technology to provide superior heat transfer efficiency through continuous and uniform mixing. They are used across various industries, including polymers, plastics, and food and beverages.
Q: What advantages do ProMixUSA Heat Exchangers offer over conventional designs?
A: They require less space, energy, and residence time while providing higher heat transfer rates, minimal fouling, and improved temperature control.
Technology
Q: How does the static mixer technology work?
A: The static mixer elements direct fluid flow radially and back towards the center, creating continuous intermixing that eliminates temperature, velocity, and composition gradients, enhancing heat transfer efficiency.
Q: What materials are ProMixUSA Heat Exchangers made from?
A: ProMixUSA Heat Exchangers can be constructed from various materials to meet specific customer requirements and process conditions, including stainless steel, exotic alloys, and other materials suitable for corrosive environments.
Installation
Q: What should be considered before installing a ProMixUSA Heat Exchanger?
A: Ensure all components are free from damage, read the installation manual thoroughly, and have all necessary tools and safety equipment ready. The heat exchanger should be positioned on a stable, level surface.
Q: How are the static mixer elements installed?
A: Static mixer elements are inserted into each heat exchanger tube, properly aligned, and seated. For removable elements, ensure they are securely fixed in place.
Maintenance
Q: How often should ProMixUSA Heat Exchangers be cleaned?
A: Cleaning should be done quarterly or as needed based on process conditions. Removable elements should be extracted and cleaned separately, while non-removable elements may require chemical or mechanical cleaning.
Q: What are the signs that a heat exchanger needs maintenance?
A: Signs include decreased heat transfer efficiency, increased pressure drops, unusual noises or vibrations, leaks, or visible damage.
Q: How is a pressure test conducted?
A: After cleaning and reassembly, conduct a pressure test following the manufacturer’s guidelines for the test pressure and duration. Inspect all joints and connections for leaks during the test.
Troubleshooting
Q: What should I do if I notice decreased heat transfer efficiency?
A: Isolate and shut down the system, inspect for fouling or blockages, and clean the static mixer elements and tubes. Check for any damaged components and replace them if necessary.
Q: How can I prevent fouling in my heat exchanger?
A: Regular maintenance, including cleaning and monitoring performance data, helps prevent fouling. The self-cleaning action of the static mixer elements also minimizes fouling.
Customization and Specifications
Q: Can ProMixUSA Heat Exchangers be customized for specific applications?
A: Yes, ProMixUSA Heat Exchangers are custom-built to meet customer specifications, including compliance with ASME code and TEMA standards, and can handle pressure ranges from low to over 5,000 psi.
Q: What are the design and fabrication standards for ProMixUSA Heat Exchangers?
A: They are designed and manufactured to comply with ASME code and TEMA standards, utilizing advanced design tools and techniques to ensure high quality and reliability.
Safety
Q: What safety precautions should be taken during maintenance?
A: Wear appropriate PPE, follow proper lockout/tagout (LOTO) procedures, and ensure the system is safely de-energized and isolated before beginning any maintenance activities.
Q: How can I ensure my heat exchanger operates safely and efficiently?
A: Adhere to regular maintenance schedules, perform thorough inspections, monitor performance data, and follow all safety guidelines and manufacturer recommendations.
Advantages / Disadvantages
Advantages
Superior Heat Transfer Efficiency:
- High Coefficients: The ProMixUSA Static Mixer technology offers high heat transfer coefficients, resulting in fast and uniform heat transfer.
- Reduced Thermal Gradients: Continuous mixing eliminates temperature gradients, ensuring consistent thermal performance.
Energy and Space Efficiency:
- Less Space Required: The design of ProMixUSA Heat Exchangers allows for more compact installations compared to conventional designs.
- Lower Energy Consumption: Enhanced mixing efficiency reduces the energy required for heat transfer processes.
Versatility:
- Wide Range of Applications: Suitable for various industries, including polymer, plastic, and food and beverage processing.
- Customizable: Can be tailored to meet specific process requirements, including material selection and design specifications.
Enhanced Reliability and Durability:
- Self-Cleaning Action: Static mixer elements create a wiping action that minimizes fouling and extends operational life.
- Robust Construction: Built to ASME code and TEMA standards with high-quality materials and craftsmanship.
Predictable and Controlled Mixing:
- Elimination of Radial Gradients: Ensures uniform temperature, velocity, and material composition, leading to consistent product quality.
- Improved Product Quality: Ensures uniform processing, which is critical for industries requiring precise thermal control.
Maintenance and Operational Benefits:
- Minimal Fouling: Self-cleaning properties reduce the frequency and extent of maintenance.
- Easy Cleaning and Maintenance: Removable elements allow for straightforward cleaning during product changeovers.
Pressure Handling:
- High-Pressure Applications: Capable of handling pressures from low to over 5,000 psi, making it suitable for demanding applications.
Disadvantages
Initial Cost:
- Higher Initial Investment: The advanced design and materials used in ProMixUSA Heat Exchangers can lead to a higher initial cost compared to conventional heat exchangers.
Complexity in Design and Installation:
- Specialized Knowledge Required: Installation and maintenance require a good understanding of static mixing technology and the specific requirements of the heat exchanger.
Maintenance of Static Mixer Elements:
- Periodic Cleaning: Despite the self-cleaning action, static mixer elements may still require periodic cleaning to maintain optimal performance, especially in heavily fouling processes.
- Replacement of Elements: Over time, static mixer elements may wear out and need replacement, adding to maintenance tasks.
Operational Limitations:
- Viscosity Limitations: While effective for many applications, extremely high-viscosity fluids might pose challenges for the mixing and heat transfer process.
- Sensitivity to Flow Conditions: Optimal performance is dependent on maintaining specific flow conditions, which may require precise control and monitoring.
Customization and Lead Time:
- Longer Lead Times: Customization to meet specific requirements can extend lead times for manufacturing and delivery.
- Design Adjustments: Custom designs might require additional adjustments and validation, leading to longer project timelines.
Potential for Pressure Drop:
- Higher Pressure Drop: The presence of static mixer elements can result in a higher pressure drop compared to empty tubes, which may necessitate more powerful pumps or adjustments in system design.
Installation Complexity:
- Detailed Installation Process: Proper installation involves careful alignment and secure attachment of static mixer elements, which can be more complex compared to traditional heat exchangers.
By weighing these advantages and disadvantages, users can determine whether ProMixUSA Shell and Tube Heat Exchangers are suitable for their specific applications and process requirements.
Applications
ProMixUSA Shell and Tube Heat Exchangers find applications across various industries due to their superior heat transfer efficiency and reliable performance. In the polymer and plastics industry, they are essential in polymerization processes where efficient heat transfer maintains optimal reaction temperatures and product consistency. They also play a critical role in cooling high-viscosity polymer melts to near-freezing temperatures, aiding further processing steps.
In the food and beverage industry, these heat exchangers are used for pasteurization and sterilization, ensuring uniform heating and cooling, which is crucial for maintaining product quality and safety. They are vital in chocolate and confectionery production for processes like tempering and cooling, as well as in beverage processing for heat recovery and maintaining desired temperatures.
The chemical processing industry benefits from ProMixUSA Heat Exchangers in exothermic and endothermic reactions, where efficient heat transfer controls reaction temperatures and improves product yield. They enhance solvent recovery processes involving evaporation and condensation and support efficient thermal management in distillation and rectification.
In the pharmaceutical industry, precise thermal control provided by these heat exchangers is essential for producing Active Pharmaceutical Ingredients (APIs), ensuring product purity and quality. They also maintain optimal temperatures in bioreactors and fermenters, critical for microbial growth and product formation.
In the petrochemical and refining sector, ProMixUSA Heat Exchangers are used in crude oil heating and cooling at various refining stages to control temperatures and improve process efficiency. They also facilitate efficient heat transfer in gas processing applications like gas dehydration and sweetening.
The pulp and paper industry uses these heat exchangers in black liquor processing, efficiently transferring heat during the concentration and recovery of black liquor in the pulping process. They also provide uniform heating in paper coating processes, ensuring consistent product quality.
Environmental applications include waste heat recovery, where ProMixUSA Heat Exchangers recover heat from industrial processes to improve energy efficiency and reduce operational costs. They are also used in water and wastewater treatment processes requiring precise thermal control, such as sludge treatment and anaerobic digestion.
In HVAC and refrigeration, ProMixUSA Heat Exchangers enhance energy efficiency in heat recovery systems by recovering and reusing waste heat. They also provide efficient heat exchange in refrigeration cycles, improving system performance.
In mining and metallurgy, these heat exchangers ensure uniform heating in leaching processes, enhancing metal recovery rates, and efficiently cooling molten metals and other high-temperature products.
The renewable energy sector benefits from ProMixUSA Heat Exchangers in bioenergy and bioprocessing, supporting thermal management in biofuel production and other bioprocesses. They also enhance heat transfer in geothermal heating and cooling systems.
Finally, in the textile industry, these heat exchangers provide precise temperature control in dyeing and finishing processes, ensuring uniform product quality. Their adaptability and customization to meet specific requirements make ProMixUSA Shell and Tube Heat Exchangers a valuable asset in any process requiring efficient and reliable thermal management.
- Leaching Acid
- Chemical and Liquor
- Caustic and Chlor-Alkali
- Bleach Chemicals
- Auxiliary
- Acid Transfer
- OEM
- Water Treatment
- Water Supply and Distribution
- Wastewater Collection and Treatment
- Polymers
- Plating, Galvanizing and Other Coatings
- Pharmaceuticals
- Automotive and Aircraft
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The use of ProMixUSA Static Mixer elements in each tube significantly reduces the film build-up typical of laminar flow in empty tubes. The process fluid is continually moved from the center of each tube to the wall and back, eradicating thermal gradients and improving the inside film coefficient.
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