Engineers design the Tube Static Mixers with a sequence of fixed, alternating right- and left-hand helical mixing elements to blend materials across a wide range of viscosities, from light to heavy. They construct the mixer entirely from 316L stainless steel, which offers excellent corrosion resistance and durability, ensuring high performance in various applications. Additionally, they securely fix the mixing elements in place using different methods depending on the size of the tube. For tube mixers with diameters of 1/4″, 3/8″, and 1/2″, we weld the elements using 316L stainless steel TIG welding. For the smaller 3/16″ tube mixer, we use a silver brazing technique to attach the elements.
316L stainless steel is a critical material choice for these mixers, offering several advantages, including resistance to corrosion, ease of cleaning, and the ability to withstand high pressures and temperatures. In addition, this makes these mixers ideal for applications in industries such as food processing, pharmaceuticals, chemicals, and petrochemicals, where maintaining the purity and integrity of the product is paramount.
Detailed Description and Applications
Design and Construction
The design of the Tube Static Mixers focuses on achieving efficient and homogeneous mixing through a carefully engineered series of helical elements. These elements create a complex flow pattern that induces both radial and axial mixing. In addition, the alternating right- and left-hand configuration ensures that the flow is thoroughly mixed by continuously splitting and reorienting the fluid streams. This design is particularly effective for mixing fluids with varying viscosities or those with different physical properties, such as density and flow behavior.
The construction of the mixer using 316L stainless steel offers several benefits. This material’s high resistance to corrosion makes it suitable for use with aggressive chemicals and in environments where exposure to moisture or corrosive agents is a concern. Additionally, 316L stainless steel can withstand high temperatures, making it ideal for processes that involve heating or cooling fluids. The smooth surface finish of stainless steel also minimizes the risk of product contamination, which is critical in food, beverage, and pharmaceutical applications.
Fixing Methods
The method of securing the mixing elements within the tube varies based on the mixer size. For larger tube sizes (1/4″, 3/8″, and 1/2″), TIG welding is used. This method provides a strong, durable bond that can withstand the stresses of high-pressure applications and ensures that the elements remain securely in place during operation. Furthermore, TIG welding also offers a clean finish, which is important for maintaining sanitary conditions.
For the smaller 3/16″ Tube Static Mixers, a silver brazing technique is used. Silver brazing involves using a filler metal with a lower melting point than the base materials, allowing the elements to be joined without melting the stainless steel. Finally, this method is particularly advantageous for smaller components where precision and minimal thermal distortion are essential.
Variety and Customization
We offer these Tube Static Mixers in a wide range of sizes and lengths, accommodating various process requirements. In addition, select the appropriate mixer size and length based on the viscosity of the fluids you are mixing. It also depends on whether the components have similar or dissimilar physical characteristics. For instance, mixing two liquids of similar viscosities and densities may require a different configuration than mixing a gas with a liquid or a high-viscosity fluid with a low-viscosity fluid.
The ability to customize the mixer to specific applications is a key advantage of the Tube Static Mixers. This customization includes the number and orientation of the mixing elements, Also, the length of the mixer, and the choice of connection types (flanged, threaded, or custom connections). This flexibility allows for optimization of the mixing process, ensuring efficient and consistent results.
Applications and Benefits
The Tube Static Mixers are suitable for a broad range of applications across various industries. Also, in the chemical industry, it can be used for mixing reactants in continuous processes. This ensures uniform distribution and reaction rates. In addition, in the food and beverage sector, it helps blend ingredients, maintain product consistency, and improve texture. In pharmaceuticals, the mixer ensures the uniform dispersion of active ingredients. Also, it is critical for the efficacy and safety of the final product.
One of the primary benefits of using a static mixer like the Static Tube Mixer is its lack of moving parts. This design eliminates mechanical wear and tear, reducing maintenance requirements and downtime. Additionally, static mixers are energy-efficient since they rely on the flow energy of the fluids rather than external power sources. This energy efficiency, combined with their compact design, makes them an attractive option for facilities. Especially in industries looking to optimize space and reduce operational costs.
Another significant advantage is the ease of cleaning and sterilization, particularly important in industries where hygiene is crucial. In addition, the 316L stainless steel construction allows for effective cleaning procedures. This includes CIP (Clean-In-Place) systems, which reduce the need for disassembly and minimize contamination risks.
Conclusion of Tube Static Mixers
The Tube Static Mixers represent a versatile and reliable solution for a wide range of mixing applications. Its robust construction from 316L stainless steel, coupled with the efficient design of the helical mixing elements, ensures consistency. It also ensures that you have high-quality mixing performance. In addition, whether for blending similar or dissimilar fluids or managing different viscosities. Also, it ensures if you are meeting stringent sanitary requirements, the Static Tube Mixer provides a customizable and efficient solution. Finally, its durability, low maintenance needs, and energy efficiency make it a valuable asset. It is a valuable asset in any process that requires precise and reliable mixing.
Other Mixers you might be interested in:
Sanitary Static Mixers
CPVC/PVC Static Mixers
PFA Static Mixers
Specifications
- Housing: 316 or 316/L Stainless Steel
- Elements: 316 or 316/L Stainless Steel
- End Connections: Plain or Compression Ends
- Small-scale design allows for homogeneous blending in lab-scale applications
- Helical design elements optimal performance with viscous, laminar flows such as epoxy resins
| Part No. | Tube O.D. | Tube I.D. | Length | Weight | Max. Working Pressure (PSI @ 75°F) | # of Elements |
| 3/16-17 | .187 | .132 | 4-7/8" | .02 lb | 5000 | 17 |
| 3/16-21 | .187 | .132 | 6" | .03 lb | 5000 | 21 |
| 3/16-27 | .187 | .132 | 7-1/2" | .03 lb | 5000 | 27 |
| 1/4-21 | .250 | .194 | 7" | .05 lb | 4200 | 21 |
| 1/4-27 | .250 | .194 | 9-1/4" | .06 lb | 4200 | 27 |
| 1/4-34 | .250 | .194 | 11-1/2" | .07 lb | 4200 | 34 |
| 3/8-21 | .375 | .319 | 11" | .12 lb | 2800 | 21 |
| 3/8-27 | .375 | .319 | 14" | .15 lb | 2800 | 27 |
| 3/8-32 | .375 | .319 | 17" | .18 lb | 2800 | 32 |
| 1/2-15 | .500 | .430 | 11-7/8" | .21 lb | 2100 | 15 |
| 1/2-21 | .500 | .430 | 16-3/8" | .29 lb | 2100 | 21 |
| 1/2-32 | .500 | .430 | 24-3/4" | .44 lb | 2100 | 32 |
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 materials are used in the construction of SRS Static Tube Mixers?
A1: SRS Static Tube Mixers are primarily constructed from 316L stainless steel, known for its excellent corrosion resistance, durability, and suitability for sanitary applications. The use of high-quality stainless steel ensures the mixers can withstand a variety of harsh conditions and maintain a clean, hygienic environment.
Q2: How are the mixing elements secured within the tube mixers?
A2: The method for securing the mixing elements depends on the size of the tube mixer. For tube mixers with diameters of 1/4″, 3/8″, and 1/2″, the elements are attached using 316L stainless steel TIG welding. For the smaller 3/16″ tube mixer, the elements are fixed in place using a silver brazing technique. Both methods provide robust and reliable attachment, ensuring the elements remain securely positioned during operation.
Q3: What types of fluids can SRS Static Tube Mixers handle?
A3: SRS Static Tube Mixers are designed to handle a wide range of fluids, from low-viscosity liquids to high-viscosity components. They are effective in blending fluids with similar or dissimilar physical characteristics, making them suitable for diverse applications, including mixing liquids, gases, or a combination of both.
Q4: Are SRS Static Tube Mixers suitable for sanitary applications?
A4: Yes, SRS Static Tube Mixers are ideal for sanitary applications. The 316L stainless steel construction is resistant to corrosion and easy to clean, meeting the stringent hygiene standards required in industries such as food and beverage, pharmaceuticals, and biotechnology.
Q5: What are the advantages of using SRS Static Tube Mixers?
A5: Key advantages include their durability, low maintenance due to the lack of moving parts, efficient mixing performance, and energy efficiency. The mixers can be customized in size and configuration to meet specific process requirements, and their stainless steel construction ensures long-lasting use and easy cleaning.
Q6: Can the SRS Static Tube Mixers be customized?
A6: Yes, SRS Static Tube Mixers can be customized to fit specific application needs. This includes varying the size and length of the mixers, the number and orientation of the mixing elements, and the type of connections (such as flanged or threaded) to ensure compatibility with existing systems.
Q7: What industries commonly use SRS Static Tube Mixers?
A7: These mixers are widely used in various industries, including chemical processing, water treatment, food and beverage, pharmaceuticals, and petrochemicals. They are suitable for any application that requires consistent and efficient mixing of fluids.
Q8: How quickly can SRS produce a custom static mixer?
A8: SRS can produce custom static mixers rapidly, often within 1-2 days, depending on the urgency and availability of materials. This quick turnaround is possible due to their extensive stock of raw materials and efficient manufacturing processes.
Q9: How do SRS Static Tube Mixers compare with mechanical mixers?
A9: Unlike mechanical mixers, SRS Static Tube Mixers have no moving parts, which significantly reduces maintenance requirements and potential downtime. They rely on the flow energy of the process fluid for mixing, making them more energy-efficient and less prone to wear and tear.
Q10: What are the typical maintenance requirements for SRS Static Tube Mixers?
A10: SRS Static Tube Mixers require minimal maintenance due to their simple design and lack of moving parts. Regular inspections and cleaning are recommended to ensure optimal performance, especially in applications where fouling or scaling might occur. The stainless-steel construction also facilitates easy cleaning and sterilization, especially in sanitary applications.
Advantages / Disadvantages
Advantages of SRS Tube static mixers
Durability: Constructed from 316L stainless steel, these mixers are highly resistant to corrosion and can withstand harsh environmental conditions, making them durable and long-lasting.
Versatility: Capable of handling a wide range of fluids, from low-viscosity liquids to high-viscosity components, and suitable for mixing fluids with different physical characteristics.
Efficiency: The helical design of the mixing elements ensures thorough and uniform mixing, reducing the need for additional mixing stages and saving time and energy.
Low Maintenance: With no moving parts, these mixers require minimal maintenance, reducing downtime and associated costs.
Hygienic Design: The smooth, stainless-steel construction meets high sanitary standards, making these mixers ideal for industries like food and beverage, pharmaceuticals, and biotechnology.
Customization: Available in various sizes and configurations, SRS Static Tube Mixers can be tailored to meet specific process requirements, including the choice of connection types.
Quick Production: SRS can produce custom static mixers rapidly, often within 1-2 days, catering to urgent needs and reducing lead times.
Disadvantages of SRS Tube static mixers
Cost: The use of high-quality 316L stainless steel and the customization options may make these mixers more expensive than alternatives made from less costly materials.
Weight: Stainless steel mixers can be heavier than those made from other materials, which may complicate installation and increase transportation and handling costs.
Limited Flexibility: Being rigid, metal mixers lack the flexibility of some plastic or elastomer mixers, which can be a drawback in applications requiring vibration absorption or adaptability to dynamic conditions.
Potential for Fouling: Despite their smooth surfaces, metal mixers can still be prone to fouling or scaling, particularly in certain chemical or high-temperature processes. This can affect performance and require regular cleaning.
Thermal Conductivity: While beneficial in some cases, the high thermal conductivity of metal mixers can lead to unintended heat transfer, which might not be desirable in all applications.
Complex Cleaning for Certain Applications: Although the mixers are designed to be easy to clean, in applications involving highly viscous or sticky materials, more effort may be needed to ensure thorough cleaning and prevent contamination.
Applications
Tube type static mixers are highly efficient devices used for blending, dispersing, or homogenizing fluids in a continuous flow process. Their design consists of a series of fixed, stationary mixing elements enclosed within a cylindrical tube. These elements create turbulence and mixing by dividing and recombining the fluid streams as they pass through the mixer. The following are some key applications of tube type static mixers:
Chemical Processing:
Tube type static mixers are extensively used in the chemical industry for a variety of mixing applications, such as:
- Reactant Mixing: Ensuring uniform mixing of reactants to optimize chemical reactions and improve yield.
- Dilution Processes: Mixing concentrated chemicals with diluents to achieve a desired concentration.
- Neutralization: Blending acids and bases for pH control and neutralization.
Water and Wastewater Treatment:
In water and wastewater treatment plants, tube type static mixers are used for:
- Chemical Dosing: Mixing coagulants, disinfectants (like chlorine), and other treatment chemicals with water.
- Flocculation: Promoting the formation of flocs by mixing coagulants with water to aggregate suspended particles.
- pH Adjustment: Blending acidic or basic chemicals to maintain the desired pH level in water.
Food and Beverage Industry:
The food and beverage industry utilizes tube type static mixers for:
- Flavor and Color Mixing: Ensuring consistent distribution of flavors, colors, and additives in food and beverages.
- Ingredient Blending: Mixing different ingredients, such as oils, syrups, and dairy products, to achieve uniform product quality.
- Emulsification: Creating stable emulsions for products like sauces, dressings, and dairy-based beverages.
Pharmaceutical Industry:
In pharmaceutical manufacturing, tube type static mixers are employed for:
- Active Ingredient Mixing: Ensuring homogeneous distribution of active pharmaceutical ingredients (APIs) in liquid formulations.
- Solvent Blending: Mixing solvents and diluents with APIs or other compounds.
- Sterile Mixing: Used in processes requiring sterile conditions, as the design minimizes dead zones and contamination risks.
Petroleum and Petrochemical Industry:
Tube type static mixers are used in the petroleum and petrochemical sectors for:
- Fuel Blending: Mixing different grades of fuels or additives to achieve specific fuel properties.
- Viscosity Adjustment: Blending heavy and light petroleum fractions to adjust viscosity for transportation or refining.
- Gas-Liquid Mixing: Ensuring efficient mixing of gases with liquids in refining processes.
Cosmetics and Personal Care Products:
In the production of cosmetics and personal care products, tube type static mixers are used for:
- Ingredient Homogenization: Mixing oils, water, surfactants, and other ingredients to create creams, lotions, and gels.
- Pigment Dispersion: Ensuring even distribution of pigments in products like makeup and hair dyes.
- Fragrance Blending: Homogenizing fragrances with other ingredients in perfumes and scented products.
Polymer and Plastics Industry:
Tube type static mixers are applied in the polymer and plastics industry for:
- Additive Mixing: Incorporating additives, colorants, and stabilizers into polymer melts.
- Temperature Homogenization: Ensuring uniform temperature distribution in polymer processing.
- Blending of Different Polymers: Mixing different types of polymers to create specific material properties.
HVAC and Environmental Systems:
In HVAC systems and environmental applications, tube type static mixers are used for:
- Air-Gas Mixing: Blending gases or vapors with air in ventilation and air conditioning systems.
- Humidification: Mixing water vapor with air for humidity control.
- Odor Control: Dispersing odor-neutralizing agents in air streams.
Mining and Mineral Processing:
In the mining and mineral processing industries, tube type static mixers are employed for:
- Slurry Mixing: Blending water and solids to create slurries for mineral processing.
- Chemical Additive Mixing: Adding chemicals to ores or slurries for extraction and processing.
Environmental Remediation:
Tube type static mixers are used in environmental remediation processes for:
- Chemical Injection: Injecting chemicals into contaminated water or soil for treatment.
- Groundwater Treatment: Mixing treatment agents with groundwater to neutralize contaminants.
These applications demonstrate the versatility and efficiency of tube type static mixers in various industries. Their ability to provide consistent and thorough mixing, along with their compact design and low maintenance requirements, make them an essential component in many industrial processes.
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