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Tube Static Mixer
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Tube Static Mixers

Price range: $195.00 through $310.00

Tube Static Mixers, also known as Tube Bundle Static Mixers, are inline mixing devices that use a bundle of small-diameter tubes inside a larger pipe to achieve thorough and uniform blending of fluids.

What Are Tube Static Mixers?

The process fluid is divided into many small streams as it flows through the tube bundle.
These streams are repeatedly recombined and re-divided, creating intense radial mixing without any moving parts.

They are particularly effective for moderate to high-viscosity liquids, slurries, and applications where consistent radial mixing is required in a relatively short pipe length.

Key Benefits

Excellent Radial Mixing Achieves highly uniform mixtures through multiple division and recombination stages.
Good for Viscous Fluids Performs well with moderate to high-viscosity liquids and slurries.
Compact Design Delivers effective mixing in shorter installation lengths.
No Moving Parts Maintenance-free and highly reliable.

Tube Static Mixers offer a simple, efficient, and cost-effective solution for continuous inline mixing, especially when radial homogeneity is required in viscous or multiphase flows.

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Tube Static Mixers, also known as Tube Bundle Static Mixers or Multi-Tube Static Mixers, use a bundle of small-diameter tubes inside a larger pipe to blend fluids thoroughly. Furthermore, these mixers excel with moderate to high-viscosity liquids, slurries, and multiphase flows. They create consistent radial mixing in a relatively short pipe length. In addition, the tube bundle design forces the fluid to split and recombine many times. As a result, they deliver highly uniform mixing with low pressure drop. Moreover, engineers often choose tube static mixers when space is limited but strong mixing performance is still required.

What Are Tube Static Mixers?

A Tube Static Mixer consists of a cylindrical housing that contains a tightly packed bundle of smaller tubes. Manufacturers typically build the housing from stainless steel, PVC, CPVC, or special alloys. As the process fluid enters the mixer, it splits into many individual streams that flow through the small tubes. Furthermore, these streams repeatedly recombine and divide as they travel through the bundle. As a result, the mixer creates intense radial mixing and produces a highly uniform mixture by the time the fluid exits. In addition, tube bundle mixers differ from helical static mixers. While helical mixers rotate the flow, tube bundle mixers achieve mixing mainly through division and recombination of multiple parallel paths. Consequently, they perform especially well with viscous fluids. Moreover, engineers can customize this design for specific pressure drop and mixing requirements.

How Tube Static Mixers Work

The mixing process occurs in three main stages:

  1. Division: The incoming fluid is split into dozens or hundreds of small streams as it enters the tube bundle.
  2. Recombination & Re-division: At the end of each tube section, the streams exit and immediately recombine with neighboring streams before entering the next set of tubes, creating strong radial exchange.
  3. Uniform Mixing: After several stages of division and recombination, the fluid exits with a highly homogeneous composition and uniform velocity profile.

This method is especially effective for applications where thorough radial mixing is needed without excessive turbulence or very high pressure drop.

Key Benefits

Excellent Radial Mixing Creates highly uniform mixtures through multiple division and recombination stages.
Effective with Viscous Fluids Performs well with moderate to high-viscosity liquids and slurries.
Compact Installation Length Achieves good mixing in shorter lengths compared to some other static mixer designs.
No Moving Parts Zero maintenance related to mechanical wear.
Wide Material Compatibility Available in stainless steel, PVC, CPVC, Hastelloy, and other alloys.
Customizable Performance Number of tubes, tube diameter, and bundle length can be engineered for specific mixing and pressure-drop requirements.

Common Applications

  • Chemical dosing and pH adjustment in water treatment
  • Polymer dilution and blending in wastewater and industrial processes
  • Oil & gas additive injection and fuel oil blending
  • Slurry mixing and homogeneous distribution of solids
  • Food and beverage processing (non-sanitary lines)
  • Petrochemical and refining applications
  • Any process requiring thorough radial mixing in a short pipe section

Tube Static Mixers offer a simple, reliable, and cost-effective solution for continuous inline mixing. Their tube-bundle design provides excellent radial mixing performance while maintaining a relatively compact installation length, making them a popular choice in many industrial fluid handling systems.

Weight 1 lbs
Dimensions 12 × 0.5 × 0.5 in
Size

3/16", 1/4", 3/8", 1/2"
Element Type

Helical, Blade
Connection Ends

Plain Ends, Compression
Element Qty

15, 17, 21, 27, 32, 34
Material

316SS, 316LSS
Removable Elements

Included (Default)

Specifications

Tube Static Mixers (also known as Tube Bundle Static Mixers) are inline mixing devices that utilize a bundle of small-diameter tubes inside a larger housing to achieve thorough radial mixing through repeated division and recombination of the process fluid.

Detailed Specifications – Tube Static Mixers

Parameter Specification Notes
Mixer Type Tube Bundle / Multi-Tube Static Mixer Radial mixing through division and recombination
Housing / Pipe Sizes ½” to 24″ (DN15 to DN600) Larger custom sizes available
Tube Bundle Configuration Multiple small-diameter tubes (typically ¼” to 1″ OD) packed inside the main housing Number and diameter of tubes optimized for flow rate and mixing intensity
Materials of Construction 316L Stainless Steel (standard), 304 Stainless Steel, PVC, CPVC, Hastelloy, Duplex, Titanium Selected based on chemical compatibility and pressure requirements
Connection Types Flanged (ANSI/DIN), Wafer Style, Butt Weld, Threaded (smaller sizes) Raised face or flat face flanges standard
Pressure Rating Up to 600 PSI (41 bar) for metallic units
Up to 150 PSI (10 bar) for PVC/CPVC units		 Higher ratings available on request
Temperature Rating -20°F to 300°F (-29°C to 149°C) for PVC/CPVC
Up to 1200°F (649°C) for stainless steel		 Limited by gasket and material selection
Mixing Performance High radial mixing efficiency through multiple division/recombination stages Typically achieves CoV < 0.05 after 6–12 tube lengths
Pressure Drop Moderate to high (typically 2–10 psi at design flow) Depends on viscosity, flow rate, and number of tubes
Viscosity Range 1 cP to 50,000+ cP Particularly effective with moderate to high viscosity fluids
Applications Chemical dosing, polymer dilution, slurry mixing, pH adjustment, oil blending, water treatment, food processing (non-sanitary) Best for applications needing strong radial mixing
Standards Compliance ASME B31.3, ASTM, PED/CE, FDA-compliant materials available Full material certification packages available

Tube Static Mixers are custom-engineered based on flow rate, viscosity, required mixing uniformity (CoV), and allowable pressure drop.
The number, diameter, and arrangement of the internal tubes are optimized during the design phase to deliver the best balance between mixing performance and energy efficiency.

They offer a robust, maintenance-free solution for continuous inline mixing, especially when radial homogeneity is critical in viscous or multiphase flows.

Pressure Drop

Pressure Drop vs. Flow Rate

Tube Static Mixer – 4″ Nominal Size
Fluid: Water (1 cP viscosity) at 68°F (20°C)

Typical Pressure Drop Curve – Tube Static Mixer

Flow Rate (GPM)   |   Pressure Drop (psi)
─────────────────────────────────────────────
50            |    3.2
100            |    9.8
150            |   18.5
200            |   30.0  ← Typical Design Point
250            |   44.5
300            |   61.0
350            |   80.0
400            |   101.5

Tube Static Mixers produce the highest pressure drop among common static mixer types due to multiple small tubes and radial flow divisions.
Recommended design range: 15 – 60 psi for intensive mixing performance.

Key Notes on Pressure Drop for Tube Static Mixers

  • Tube Static Mixers generate the highest pressure drop of common static mixer designs because the flow is divided into many small tubes and recombined radially.
  • They excel at mixing viscous fluids, slurries, immiscible liquids, and applications requiring very high mixing intensity.
  • Pressure drop increases with the square of the flow rate and rises dramatically with higher viscosity or non-Newtonian fluids.
  • The more tubes and smaller tube diameters used, the better the mixing — but the higher the pressure drop.
  • Typical design target is 15 – 60 psi, depending on required mixing uniformity and fluid properties.
  • Best suited for applications where superior mixing performance justifies the higher energy cost.

Tube Static Mixers are chosen when maximum mixing performance is needed, especially with challenging fluids such as high-viscosity liquids, pastes, or multiphase systems.
The higher pressure drop is the trade-off for their excellent radial mixing capability.

For accurate pressure drop calculations based on your exact flow rate, viscosity, density, and tube configuration, consult the manufacturer for a custom performance curve.

Installation

Proper installation of Tube Static Mixers is essential for achieving optimal mixing performance, maintaining the designed pressure drop, and ensuring long-term reliability.
Incorrect orientation or alignment can significantly reduce mixing efficiency.

Installation Procedures for Tube Static Mixers

Step Installation Procedure Tools / Materials Required Safety & Important Notes
1 Verify the flow direction arrow on the mixer body matches the actual process flow direction. Tube bundle mixers are directional and performance will be severely reduced if installed backwards. None Incorrect flow direction is one of the most common installation errors and greatly reduces mixing efficiency.
2 Ensure sufficient straight pipe upstream and downstream. Recommended minimum is 5–10 pipe diameters upstream and 3–5 diameters downstream for best performance. Measuring tape Avoid installing immediately after elbows, valves, or pumps without adequate straight run.
3 Clean all flange faces thoroughly. Use new, compatible gaskets rated for the process fluid, pressure, and temperature. Lint-free cloths, approved gaskets Old or damaged gaskets are a common cause of leaks.
4 Align the mixer between the flanges. Install bolts and hand-tighten in a criss-cross pattern, then torque gradually and evenly to the manufacturer’s specified values. Calibrated torque wrench, bolt lubricant Uneven torque can distort the housing or cause leaks.
5 For flanged models, ensure proper gasket compression. For butt-weld models, use qualified welding procedures and perform post-weld inspection if required by code. Welding equipment (for butt-weld) Follow applicable piping codes (ASME B31.3, etc.).
6 Perform a pressure test and leak check on all connections after installation. Monitor for any signs of leakage during initial startup. Pressure testing equipment Test at 1.5× operating pressure or per site requirements.
7 Slowly bring the system to operating flow rate. Monitor pressure drop across the mixer and verify mixing performance visually or through sampling if possible. Pressure gauges, sampling points Compare actual pressure drop with the manufacturer’s predicted value.
8 Document the installation, including orientation, torque values, gasket type, pressure test results, and baseline pressure drop in the equipment log. Include photos of the installed mixer. Installation checklist, camera Record serial number and installation date for future reference.

Important Notes:

• Always install the mixer in the correct flow direction (arrow on the body).
• Ensure the upstream piping provides a reasonably developed flow for best performance.
• Tube Static Mixers can have higher pressure drop than helical mixers — confirm the system can accommodate the designed pressure loss.
• For PVC/CPVC units, avoid overtightening flanges to prevent cracking.

Proper installation ensures the Tube Static Mixer delivers the designed mixing performance with the expected pressure drop.

Maintenance

Tube Static Mixers have no moving parts, making them inherently reliable and low-maintenance. However, periodic inspection and cleaning are essential to prevent fouling, scaling, or buildup inside the tube bundle, which can increase pressure drop and reduce mixing efficiency over time.

Maintenance Procedures for Tube Static Mixers

Maintenance Task Procedure & Frequency
Daily / Visual Inspection • Check for external leaks at flanges or welds
• Monitor and record pressure drop across the mixer
• Listen for any unusual noise or vibration
Weekly Inspection • Record trending pressure drop data
• Visually inspect accessible flanges and connections
• Check for any signs of external corrosion
Monthly Cleaning • Flush the mixer with clean water or a compatible solvent
• If pressure drop has increased, perform a chemical cleaning cycle
• Wipe external surfaces to remove residue
Quarterly / Semi-Annual Deep Cleaning • Isolate the mixer and perform thorough internal flushing or hydrojetting
• Inspect tube bundle for scaling, polymer buildup, or particulate accumulation
• Check flange bolts for proper torque
Annual / Major Maintenance • Remove the mixer if design allows (flanged/removable models)
• Mechanically clean or chemically soak the tube bundle
• Inspect tubes for erosion, corrosion, or blockage
• Replace gaskets and seals during reassembly
• Pressure test after reinstallation
After Process Changes or Long Shutdown • Thoroughly flush the mixer before and after extended shutdowns
• Inspect for hardened deposits or corrosion from stagnant fluid
• Re-establish baseline pressure drop values after restart

Important Notes:

• Tube Static Mixers are prone to fouling when handling sticky, polymerizing, or high-solids fluids. Monitor pressure drop trends closely — a gradual increase is the best early warning sign of buildup.
• Cleaning frequency depends heavily on the process fluid. Viscous polymers or slurries may require monthly deep cleaning, while clean water-like fluids may only need annual attention.
• For PVC/CPVC units, use only mild, compatible cleaning agents and avoid high temperatures or aggressive solvents that can damage the material.
• Always isolate the mixer and follow lockout/tagout procedures before any maintenance. Use proper PPE and chemical handling protocols.

Keeping accurate records of pressure drop and cleaning activities will help predict maintenance needs and extend the service life of your Tube Static Mixer.

Q&A

Question Answer
What is a Tube Static Mixer? A Tube Static Mixer (also called a Tube Bundle Static Mixer) is an inline mixing device that uses a bundle of small-diameter tubes inside a larger pipe housing. The fluid is divided into many small streams, recombined, and re-divided multiple times to achieve thorough radial mixing without any moving parts.
How does a Tube Static Mixer work? The incoming fluid is forced through hundreds of small tubes. As the streams exit each tube section, they mix with neighboring streams before entering the next set of tubes. This repeated division and recombination creates strong radial exchange, resulting in a highly uniform mixture by the outlet.
What are the main advantages of Tube Static Mixers? They provide excellent radial mixing, perform well with moderate to high-viscosity fluids, have no moving parts, and can achieve good mixing in relatively short lengths. They are also simple, reliable, and cost-effective.
What types of fluids are Tube Static Mixers best suited for? They excel with moderate to high-viscosity liquids, slurries, polymer solutions, emulsions, and multiphase flows. They are particularly effective when strong radial mixing is needed rather than high shear.
How do Tube Static Mixers compare to Helical Static Mixers? Tube bundle mixers generally provide better radial mixing and perform better with viscous fluids, while helical (twisted ribbon) mixers are often better for low-viscosity fluids and create more turbulence. Tube mixers can have higher pressure drop but shorter required length in some cases.
What materials are Tube Static Mixers available in? Common materials include 316L Stainless Steel, 304 Stainless Steel, PVC, CPVC, Hastelloy, Duplex, and Titanium. The choice depends on chemical compatibility, pressure, and temperature requirements.
What is the typical pressure drop across a Tube Static Mixer? Pressure drop is moderate to high and depends on flow rate, viscosity, and the number/diameter of tubes. It is typically higher than helical static mixers but can be optimized during design.
How long should a Tube Static Mixer be? Length is custom-engineered based on required mixing uniformity (CoV), flow rate, and viscosity. Most applications use 6 to 24 tube lengths (equivalent to 3–12 times the pipe diameter).
Are Tube Static Mixers suitable for sanitary applications? Standard tube bundle mixers are not typically sanitary. However, specially designed versions with polished stainless steel, removable tube bundles, and Tri-Clamp connections can be made for food, beverage, or pharmaceutical use.
How do you maintain a Tube Static Mixer? Maintenance is minimal because there are no moving parts. The main tasks are periodic flushing or chemical cleaning to prevent buildup inside the tubes, checking flanges for leaks, and monitoring pressure drop trends. Severe fouling may require removal and mechanical cleaning or hydrojetting.

Note: Tube Static Mixers are a robust, maintenance-free solution for continuous inline mixing, especially when strong radial mixing is needed in viscous or multiphase flows.
Proper sizing, correct flow direction, and periodic cleaning (based on pressure drop trends) are key to long-term performance.

Advantages / Disadvantages

Advantages Disadvantages
  • Excellent radial mixing through repeated division and recombination of flow streams
  • Particularly effective with moderate to high-viscosity fluids and slurries
  • No moving parts — extremely reliable and virtually maintenance-free
  • Compact installation length compared to some other static mixer designs
  • Wide range of material options (stainless steel, PVC, CPVC, Hastelloy, etc.)
  • Simple, robust construction with low risk of mechanical failure
  • Customizable tube bundle design for specific mixing and pressure drop requirements
  • Cost-effective solution for continuous inline mixing applications
  • Higher pressure drop than helical (twisted ribbon) static mixers
  • Can foul or plug more easily when handling fluids with high solids content or polymerizing materials
  • More difficult to clean internally compared to removable-element helical mixers
  • Limited effectiveness with very low-viscosity fluids where helical mixers may perform better
  • Requires precise flow direction — performance drops significantly if installed backwards
  • Heavier and bulkier than simple helical mixers of the same diameter
  • Tube bundle design can be more expensive to fabricate in very large diameters

Note: Tube Static Mixers are an excellent choice when strong radial mixing is needed, especially with viscous or multiphase fluids.
While they may have a higher pressure drop than helical designs, their robust performance and reliability make them a preferred solution in many industrial applications.
Proper fluid characterization during sizing helps balance mixing quality with acceptable pressure loss.

Applications

Tube Static Mixers excel in applications where strong radial mixing is required, especially with moderate to high-viscosity fluids, slurries, or multiphase flows.
Their tube-bundle design provides consistent, uniform blending through repeated division and recombination of the process fluid in a relatively compact length.

Applications of Tube Static Mixers

Industry / Application Typical Use Cases Purpose & Benefits
Water & Wastewater Treatment Polymer dilution and activation, coagulant/flocculant mixing, pH adjustment, chemical dosing, sludge blending Provides excellent radial mixing for viscous polymer solutions and ensures uniform distribution of treatment chemicals with minimal pressure drop.
Chemical Processing Acid/base dilution, catalyst dispersion, solvent blending, viscous liquid mixing, neutralization processes Delivers consistent mixing of moderate to high-viscosity fluids while maintaining controlled pressure drop in continuous processes.
Oil & Gas / Petrochemical Fuel oil blending, additive injection, demulsifier mixing, heavy hydrocarbon treatment, produced water conditioning Handles viscous oils and multiphase flows effectively, ensuring homogeneous mixtures without excessive turbulence.
Polymer & Plastics Manufacturing Polymer dilution, resin blending, additive dispersion, viscous melt processing Excellent for mixing high-viscosity polymers where uniform distribution of additives is critical.
Food & Beverage (Non-Sanitary Lines) Syrup blending, sauce thickening, starch slurry mixing, flavor emulsion preparation Achieves consistent texture and ingredient distribution in viscous food products.
Pulp & Paper Stock preparation, coating color mixing, filler slurry dispersion, chemical additive injection Provides uniform mixing of fibrous slurries and viscous chemical additives.
Mining & Mineral Processing Slurry conditioning, reagent mixing, tailings treatment, flotation feed preparation Ensures even distribution of reagents in abrasive slurries with good resistance to wear.
General Industrial Processes Adhesive blending, paint and coating mixing, emulsion production, fertilizer solution preparation Offers reliable radial mixing for a wide variety of viscous and multiphase industrial fluids.

Tube Static Mixers are particularly valuable when the process fluid has moderate to high viscosity or contains solids, and when a strong radial mixing action is needed to achieve homogeneity.
Their robust, maintenance-free design makes them a dependable choice in continuous production environments across chemical, water treatment, oil & gas, polymer, and mineral processing industries.

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