2. Batch Mixer Types
Stirrer/Agitators/Gate or 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/Shearing Disc
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
Static Mixer
Typical Uses
Inline blending of like
viscosities fluids
Strengths
Low energy flow
Price
Weaknesses
Low shear
Requires feed pump
No particle disintegration
4
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
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
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
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 of Stator & 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
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 & MS Models
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 - Single 515H 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
25. Batch Mixer/Vessel Positioning Guide
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 Positioning Guide
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 a High 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
30. Emulsifying
Whyuse a High 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
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
Introduction Name, title, company
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.
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.
Static Inline sectional view with flow paths. Usually used for blending using different baffles inside of mixer.
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
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.
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.
Talk about fluid acceleration, direction changes, particle collision, milling, acceleration, deceleration
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.
Introduction Name, title, company
Silverson Models
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.
Basic configuration and the options
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)
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.
Standard Batch Mixer Guide. Sizing is also depending on type of stator used.
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
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
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
Special Cartridge seals option
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
Flow rate depends on viscosity, type of head used.
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
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.
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
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.
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
Emulsion – Rotor stator must be used to create emulsion or preemulsion (oil in water or water in oil)
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.
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.
Questions: Lit reprints, a few up front, get names & addresses to forward lit references cited
