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Mixing art
The document discusses various types of batch and inline mixers used for mixing liquids. It describes stirrer/agitator mixers, Cowles/shearing disc mixers, static mixers, media/colloid mills, high pressure homogenizers, rotor/stator mixers, and provides details on their typical uses, strengths, and weaknesses. It also provides sizing guides and positioning recommendations for batch and inline mixers.
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Mixing art
- 1. Match to Mix “TheArt of Mixing”
- 2. Batch Mixer Types Stirrer/Agitators/Gateor Anchor Mixers Typical Uses Liquid/liquid mixing Agitator/Pumping efficiency Uniform blending/distribution & stirring Temperature/Heat transfer Strengths High flow/volume Wide viscosity range (1 to 100,000cps) Price Weaknesses Low shear No significant particle size reduction 2
- 3. Batch Mixer Types Cowles/Saw-tooth/ShearingDisc Typical Uses Dispersing pigments into paints/ink/paste/coatings Strengths High tip speed High viscosity range fluids up to 200,000 cps Price Weaknesses Limited range of sizes Low viscosity fluids/materials 3
- 4. Inline Mixer Types StaticMixer Typical Uses Inline blending of like viscosities fluids Strengths Low energy flow Price Weaknesses Low shear Requires feed pump No particle disintegration 4
- 5. Inline Mixer Types Media/ColloidMills Typical Uses Viscous emulsion Fine de- agglomeration Strengths High shear – varying shear rates Weaknesses Requires feed pump Low flow rates Price 5
- 6. Inline Mixer Type High Pressure Homogeniser Typical Uses Submicron emulsion (Dairy) Fine De-agglomeration Strengths Extremely high shear Weaknesses High cost of operation and maintenance Price 6
- 7. Batch & InlineType Rotor/Stator Mixers Typical Uses Dissolving Powder to liquid dispersing Particle size disintegration Emulsifying Strengths Dynamic & rapid mixing High shear dispersing Particle disintegration Weaknesses Low flow output Viscosity range limits (batch type) 7
- 8. R/S Mixer Basics The Silverson Advantage Radial vs. Axial Flow Mixing Elements Rotor N Stator Close fit to rotor Variety of configurations to customize performance 8
- 9.
- 10. R/S Advantage Liquidfeed into rotor Flow direction changes Fluid velocity changes Forces Involved Hydraulic Shear Cavitation Turbulence Mechanical: Milling / Grinding Impact 10
- 11. Laborator y &Batch
- 12. High Shear Mixers Laboratory Models 5ml to 12 litres Batch Models 10 to 30,000 litres Inline - Single & Multi-stage 10 to 3000 litres per min Flashblend Systems up to 15,000 kg/hr BE Bottom Entry Mixers 50 to 3000 litres Disintegrator D2500 Systems 5 tons to 30 tons 12
- 13. Laboratory Mixer Square hole Emulsor Screen Vertical Slotted High shear SL2T L4R 5/8” Micro Duplex 1” Tubular Disintegrator 13
- 14. Batch Mixer/Emulsifier Basic construction& Options Machine mounting Motor – TEFC/IP55, BX to GX10 - Suspension mounting painted frame Air driven motors GX20 -700X & larger – ( Max 4 hp) Rectangular flange for Flame proof motor channel bearer to BASEEFA, ExD Round flange Groups 2A, 2B, T1-T4 Non-sparking Mixer Frame - BASEEFA ExN T3 Stainless steel grade Stainless steel 316L frame Mild steel Special metal eg. Rotor/Shaft – Hastelloy Downthrust/Upthrust propellors Hard tip rotor Stator – Surface hardened on GPDH journal area SQHS PTFE/Bronze bush SLDH STEH & EMSC 14
- 15. Batch Mixer/Emulsifier Choice ofStator & Accessories General Purpose Disintegrating Head Square Hole High Shear Screen Downthrust Propellor Standard Emulsor Head and Emulsor Screen 15
- 16. Batch Mixer/Emulsifier Mounting &Shaft sealing Options V-ring Shaft Seal Hydraulic/ Air Lift Mobile Stand Double Mechanical Shaft Seal Single Mechanical Shaft Seal (Quench Cup) Rectangular & Round Flange 16
- 17. Production Batch Mixers SizingGuide 17
- 18. Inline Mixers Models Available LS - Standard Inline Mixer. UHLS - Ultra Hygienic Inline Mixer. MS - Twin Stator Inline Mixer. MultiShear - Three or Four stage Inline Mixer Jacketed - LS or MS Mixers with Heating/Cooling Jacket. Jacketed Inline Mixers for Asphalt/Polymer mixing. 18
- 19. LS & MSModels Standard unit conforms to 3A standards.. Available in a wide range of models/sizes with motors from 3 HP to 150 HP. Available with sanitary (Tri-clamp/SMS) or API Flanged connections. 19
- 20. LS/MS Mixers -Construction Wetted parts 316L Stainless Steel. O Rings - Viton as standard. Options of other elastomers (PTFE) Single or Double Type 2 Mechanical Seal arrangement with Carbon rotating seat, Ceramic stationary seat. Option of Tungsten Carbide/Silicon Carbide etc LS - 4 bladed rotor. Option 8 bladed. MS - 4 bladed inner, 12 bladed outer. 20
- 21. UHLS - Construction All wetted parts 316L Stainless. Electro polished. Neck section 304 Stainless. Ultra Hygienic 515H single seal or “special” seals (FTL) EPDM square section joint rings, Silicon rubber seal ring behind seal. Option of other elastomers. Tangential outlet - self draining. Completely crevice free. Option of Stainless Steel motor in USA. 21
- 22. UHLS - Single515H seal Ultra Hygienic design and construction. FDA approved materials. Available as Silicon Carbide/Carbon Ceramic or Silicon Carbide/Silicon Carbide. Formed metal bellows spring - crevice free. No grub screws, pins or other exposed shaft fixings in contact with product. 22
- 23. Inline Stators Square hole Emulsor Screen high shear Slotted Disintegrating Head General Purpose Emulsor Screen Disintegrating 23 ULHS
- 24. Silverson Inline Sizing Guide 24
- 25. Batch Mixer/Vessel PositioningGuide Dimension A = Mixer Frame Length Dimension B = Optimum Distance of Workhead from bottom of vessel Dimension C = Max. Vessel Depth including mounting MODEL A B C AX 450 75 525 BX 610 125 735 DX 690 150 840 EX 790 175 965 FX 1042 200 1242 GX10 1220 220 1440 GX20 1220 220 1440 700X 1525 250 1775 25
- 26. Inline Mixer PositioningGuide SINGLE PASS METHOD . Continuous Blending Feed and dosing of ingredients into mixer or manifold prior to inlet port Series Processing Using Multiple machines in series Pre-mix Method The ingredients are coarsely pre- mixed in a holding vessel with a Silverson batch mixer or a simple agitator. A single pass through the Inline mixer will then ensure an agglomerate free homogeneous product. All the product must pass through the Inline mixer's rotor/stator workhead as by-passing is impossible. RECIRCULATION METHOD 26
- 27. Dissolving Whyuse aHigh Shear Mixer to dissolve? Speed Uniformity Energy Input Efficiency Capital Outlay 27
- 28. Dissolving Examples of Dissolving Rubbers & Polymers into solvents or oil Sugar solutions Brine solutions Resin into Solvents Hard Candy reclamation 28
- 29. Blending Examples of Blending Viscous materials into thin liquids Hair Gels Shampoos Lubricant Blending Antifoam slurry concentrate Additive blending PMB (Polymer modified bitumen) 29
- 30. Emulsifying Whyuse aHigh Shear Mixer to Emulsify? High Shear is required to create an emulsion Use an Inline to create a “pre-emulsion” prior to a High Pressure Homogenizer Speed Low Capital Cost 30
- 31. Emulsifying Examples of Emulsions Creams and Lotions Salad Dressings Vaccines Ointments Flavor Emulsions 31
- 32. Dispersing and Re-Hydration Why use a High Shear Mixer to disperse? Speed Efficiency Capital Outlay Examples of Dispersing and Re- Hydration Milk Powder into water or milk Pigment suspensions TiO2 Slurries Clays - Bentonite, Kaolin, etc Pharmaceuticals - actives into liquid 32
- 33. Gums and Thickeners Why use a High Shear Mixer to disperse Gums and Thickeners? Speed Efficiency Most require shear to remove agglomerates Maximize Yield Capital Outlay 33
- 34. Gums and Thickeners Examples of using High Shear Mixers for Gums and Thickeners Pet Food Gravy - Xanthan, Guar, Starch Hair Gel - Carbopol Flavor Emulsions - Acacia Gum Yoghurt - Starch, Gelatin, alginate, pectin Jams & Jellies - pectin 34
- 35. Particle Size Reduction Why use a High Shear Mixer to reduce Particle Size? Speed Efficiency Capital Outlay Examples of Particle Size Reduction Pigment dispersions and milling TiO2 slurries Agrochemicals - milling actives Pharmaceuticals - milling antibiotics 35
- 36. ??? Questions ??? Qui e’? 不是很清楚 ?? 什 么 ?? Qu’est ce que c’est? Porque este? How? Pourquoi? Wat it dat? Why? Warum? APA ? What? send me Was is das? Hunh email Cosa Que es? ? e’ ? 36
Editor's Notes
- #2 Introduction Name, title, company
- #3 All agitator uses Propellors having Blades in various shapes and sizes. Main function is to create flow or fluid motion in the vessel. Maintain uniform contents in the tank Temperature/heat transfer across the vessel Because they create flow effectively, AGITATORs have the broadest range of capacities (VOLUME MOVEMENT) among all mixers If viscosity is below 1 cps (water) it can handle batches up to several hundred thousands of litres. TURBINE type agitators can operate fluid up to 75,000 CPS. The Gate & Anchor type blenders is a useful blender for cream and paste like product.
- #4 Low cost due to its plate like construction. Commonly used in Inks & paints because of its elastic material base. The shearing disc pulls along the materials as it revolves and subject it is counter driectional forces.
- #5 Static Inline sectional view with flow paths. Usually used for blending using different baffles inside of mixer.
- #6 Sometimes also known as “Stone Mill” These are Rotor Stator type mixers except that more fluid is retained in the working zone and more energy/shear is imparted to the fluid. Mechanism to allow varying the Clearance of Rotor/Stator Materials are pump fed to the Mill. Limitation is low flow capacity Application: Table sauces – Mayonaise, toothpaste
- #7 High Pressure Homogenisers Provides highest shear/energy per fluid volume of all mixers This units consists of high pressure pump capable of pressures up to 1500 bars or more plus an orifice mechanism across which the pressure created in the pump is reduced Variable pump pressure(shear rates) and Orifices or Valves determines the globule size. The INTENSE CAVITATION and TURBULENCE provides the high shear and particle size reduction. Limitations - Low vicosity, usually below 500 cps. Commonly used in Dairy Industries for Milk and beverages, dairy products.
- #9 Rotor - Stator - stationary ring around perimeter Rotor movement at high speed creates centrifugal force to pull in materials to workhead. Silverson design different from cage type r/s etc. End plate impedes/redirects flow, causes mechanical shear. Close tolerances of different rotor/stator produces better mixing.
- #10 Talk about fluid acceleration, direction changes, particle collision, milling, acceleration, deceleration
- #11 Shear Forces Hydraulic shear: Cavitation Turbulence Mechanical : Milling/grinding Impact Rotor-stator mixing operate at high shaft speeds. Considerable hydraulic shear is created both by the High TIP Speed of the rotor and by the velocity of the materials as it is Pumped through the STATOR Intank/Batch Capacity range - up to 30 - 40 Tons Viscosity: up to 20,000 CPS or higher depending on the Rheological properties of the fluid. InLine Mixer Not a pump but it can self pump it contents at viscosities below 5000 CPS. Flowrate up to 80,000 litres per hour.
- #12 Introduction Name, title, company
- #13 Silverson Models
- #14 Models of Laboratory – SL2 no motor for up/down. Models with “T” has tacho. Stator – Micro attachment Sealed units with mixer assembly for aseptic mixing. Closed vessel for vacuum condition.
- #15 Basic configuration and the options
- #16 Types of stator and application. Size of perforations of Standard EMSC & Fine EMSC Perforations of SQHS – 3/32” (2.38mm) Std EMSC – 1/16” (1.587mm) Fine EMSC – 1/32” (0.792mm)
- #17 Choice suspended mounting – Air or Hydraulic; flange etc. For Intank batch mixer to operate under atmospheric, pressure or vacuum. Shaft seals Option V-ring simple form of sealing for preventing ingress of material from outside vessel, vapour loss, liquid splashing Single mechanical shaft seal – also known as Quench seal. Using compatible liquid to fill cup to cool and lubricate the seal and maintain under atmospheric pressure or under vacuum Double seal if vessel is under pressure or vacuum. Seal is continuously flushed by compatible fluid at 1 atmosphere (15 psi) above the pressure in the vessel.
- #18 Standard Batch Mixer Guide. Sizing is also depending on type of stator used.
- #20 Used for general “Sanitary” mixing i.e. food and dairy, cosmetics and general processing industries Motors – TEFC standard, Flameproof option and Stainless steel type option
- #21 Depending on the type of materials used, special mechanical seals are used for specific purpose. Eg: Double seals for viscous products to prevent leakage. Tungsten carbide seals used for abrasive material. Rotor with different blade combinations for better tip speeds to ensure high efficient mixing
- #22 Ultra Hygienic construction meets “3A” FDA requirement for pharmacuetical and food preparations. Special profile body to reduce liquid volume – ensure no dead areas. Coupling shaft runs on it own bearings
- #23 Special Cartridge seals option
- #24 Stators of standard different from ULHS.. ULHS stators are one piece construction. Screens are vacuum brazed on to the Inlet plates Emulsor screen from solid ring and drilled holes
- #25 Flow rate depends on viscosity, type of head used.
- #26 Mixer mounted slightly off-centre. Type/shape of vessel importance to sizing of machine. Non-baffle in tank, Odd shape tanks & Baffle impedes and disturb liquid flow path. Stress easy to clean & maintain. Note depth of workhead and clearance from bottom
- #27 Continuous Blending The ingredients are metered into the mixer or a manifold just prior to the rotor/stator workhead. This will ensure that products that react together are mixed immediately upon contact. This method is ideal for continuous liquid/liquid blending and for products where aeration must be avoided e.g. detergents Series Processing In certain cases where a higher degree of homogenisation or comminution is required than can be obtained in a single pass, it is possible to achieve the required results using two or more mixers. Pre-mix Method The ingredients are coarsely pre-mixed in a holding vessel with a Silverson batch mixer or a simple agitator. A single pass through the Inline mixer will then ensure an agglomerate free homogeneous product. All the product must pass through the Inline mixer's rotor/stator workhead as by-passing is impossible. Series Processing In certain cases where a higher degree of homogenisation or comminution is required than can be obtained in a single pass, it is possible to achieve the required results using two or more mixers. Pre-mix Method The ingredients are coarsely pre-mixed in a holding vessel with a Silverson batch mixer or a simple agitator. A single pass through the Inline mixer will then ensure an agglomerate free homogeneous product. All the product must pass through the Inline mixer's rotor/stator workhead as by-passing is impossible.
- #28 SPEED – Being a dynamic type mixer all material pass thru the working head many times are subject to shear at high tip speed. Dissolving times is thus reduced compare to conventional mixers Uniformity – High speed liquid motion ensures uniformity Energy Input
- #29 Duplex disintegrator dissolvers – the upper cutting head breaks up large polymer into bits before finally dissolve in the lower head. Large pieces of sweets are broken down and dissolve in the lower head.
- #30 Hair gels – using high shear to ensure the contents are homogenuous mix before gelling agent is form. Shampoos – Usually formulation uses concentrate SLES of >65% and diluted. Stirrer or agitator will take many hours to dilute this where the Silverson will do this hundred times faster. Lubricant blending – Most lubricatn plant uses AIR-SPARGING to create air turbulence. Disadvantage – Aeration of product, high residue due poor blending action. Silverson Advantage – Faster mixing times and in some formulation it is impossible to mix antifoam and slurry additive. Polymers added are broken down faster and at lower temperature
- #31 Emulsion – Rotor stator must be used to create emulsion or preemulsion (oil in water or water in oil)
- #32 Square hole high shear and Standard emulsor head are used to achieve the emulsion size and homogenuos dispersion and hydration of stabilizers to form the stable emulsion.
- #34 General purpose head is commonly used to dispersre large volume of powders in liquid with diwnthrust propellor to increase flow brings light powder from rafting on surface.
- #37 Questions: Lit reprints, a few up front, get names & addresses to forward lit references cited