PU static mixers

1. Static Mixers and Mixer Heat
Exchangers for PU Foam Processes
A report presented by
Fluitec mixing + reaction solutions AG,
Alain Georg, Dipl. Ing. HTL, Research and Development
CH-8413 Neftenbach

2. Overview of Topics
• Topic
• State of the Art
• Fluitec Polyol Mixer Functionality
• Mixer Heat Exchanger Functionality
• A New Approach
• New PU Concept
• New Mixer Heat Exchanger
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 2

3. Topic
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 3
Systems engineering
Formulation Dosing technique
Mixing technique
Foaming agent
Temperature control

4. Topic
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 4
Systems engineering
Formulation Dosing technique
Mixing technique
Foaming agent
Temperature control

5. State of the Art
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Typical applications since 1992
Catalyst
Activator
Flame proofing agent
High pressure
pump
CSE-XR Mixer-
Heat Exchanger
Polyol mixer
blowing agent
Pentane / R1416 / R134a ....
Isocyanate
Mixing head
CSE-XR Mixer-
Heat Exchanger
Polyol
High pressure
pump

6. State of the Art
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Fluitec CSE-XR Mixer Heat Exchanger

7. State of the Art
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 7
Fluitec CSE-XR Mixer Heat Exchanger
Fluitec CSE-XR Mixer Heat Exchanger type “A2-LQ” PN250
Water in Patented System
Product out Product in
DN1 DN1
L1 = _____
DN
Water out
DN2
DN2
L = ____
X
H

8. State of the Art
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 8
Fluitec CSE-XR Mixer Heat Exchanger
P
I P P P
P
O
P P 1
I S
I S
P
P
O P
I I
O P P
I I

9. State of the Art
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Heating and cooling systems

10. State of the Art
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Fluitec polyol mixer

11. State of the Art
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 11
Fluitec polyol mixer
for mixing air into polyol

12. State of the Art
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 12
High pressure air injection
Unit for testing available

13. State of the Art
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Loop 1995

14. State of the Art
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Loop 2005

15. Fluitec Polyol Mixer Functionality
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Characteristics of static mixing
• No moving parts
• Mixing effect only by pumping energy
• ’’Exclusively’’ radial mixing effect
Mixture
A
B
CSE-X polyol mixer
Objective: - increases the potential of diffusive mixing
- with pulsation free dosing of additives

16. Fluitec Polyol Mixer Functionality
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Soluble mixing application

17. Mixer Heat Exchanger Functionality
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18. Mixer Heat Exchanger Functionality
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19. A New Approach
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0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 5 10 15 20 25 30 35 40
Vapor
pressure
ps
(bar)
Solubility
in
a
polyurethane
foam
system
(%)
Temperature (°C)
Solubility in a PU foam with partial pressure Ps

20. A New Approach
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 20
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 5 10 15 20 25 30 35 40
Vapor
Pressure
ps
(bar)
Solubility
in
a
polyurethane
foam
system
(%)
Temperature (°C)
Solubility in a PU foam with partial pressure Ps
Solubility of n-pentane approx. 5.5% by weight for aromatic
ester polyol under pressure. (Source: Evonik)

21. A New Approach
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With most PU applications we have:
• A miscibility gap (normally more than 8% pentane)
-> Ensures a 2-phase flow
-> Means segregation effects if the dispersion is
not stable (droplet size dt > 10 µm)
• outgassing during the cooling process
-> solubility change due to cooling

22. A New Approach
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The following conditions are therefore
of major importance:
• The pentane must be dispersed as a stable
emulsion.
• During the cooling process, the mixture should be
constantly mixed or dispersed.
• The pipe system after mixing must not have any
dead zones.

23. New PU Concept
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 23
Continuous sandwich panel lines
Continuous production of metal composite elements
Activator
Catalyst
Flame resistant
High pressure pump
(closed system) NEW CSE-XR heat exchanger
Blowing agent
n-pentane iso-pentane ...
Mixing head
Polyol
Isocyanate
NEW CSE-XR heat exchanger
High pressure pump
(closed system)
Low pressure pump
(closed system)
NEW CSE-XR heat exchanger

24. New PU Concept
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 24
Loop 2014

25. New PU Concept
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No soluble mixing application

26. New PU Concept
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1.0E-02!
1.0E-01!
1.0E+00!
1.0E+01!
1.0E+02!
1.0E+03!
1.0E-07! 1.0E-06! 1.0E-05! 1.0E-04! 1.0E-03! 1.0E-02! 1.0E-01! 1.0E+00! 1.0E+01! 1.0E+02!
Critical
capillary
number
Ca
krit
(-)
!
Viscosity ratio λ
Critical Capillary Number Ca
simple shear flow (a = 0, Grace , 1982)!
planar elongational flow (a = 1, Grace , 1982)!
planar elongational flow (a=1, Bentley und Leal, 1986)!
measuring points CSE-X mikromakro Technologie!

27. New PU Concept
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 27
1.0E-02!
1.0E-01!
1.0E+00!
1.0E+01!
1.0E+02!
1.0E+03!
1.0E-07! 1.0E-06! 1.0E-05! 1.0E-04! 1.0E-03! 1.0E-02! 1.0E-01! 1.0E+00! 1.0E+01! 1.0E+02!
Critical
capillary
number
Ca
krit
(-)
!
Viscosity ratio λ
Critical Capillary Number Ca
simple shear flow (a = 0, Grace , 1982)!
planar elongational flow (a = 1, Grace , 1982)!
planar elongational flow (a=1, Bentley und Leal, 1986)!
measuring points CSE-X mikromakro Technologie!

28. New PU Concept
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 29
µ

29. New Mixer Heat Exchanger
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 30
Fluitec CSE-XR Mixer Heat Exchanger type “A2-LQ” PN250
Water in Patented System
Product out Product in
DN1 DN1
L1 = _____
DN
Water out
DN2
DN2
L = ____
X
H

30. New Mixer Heat Exchanger
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 31

31. New Mixer Heat Exchanger
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 32
Fluitec CSE-XR Mixer Heat Exchanger
with no dead zones, less volume and higher mixing performance

32. Evaluation
Advantages
• Additives savings
• No emulsifier needed
• No dead zones
• Stable emulsion
• Less soil disturbance
• Less waste
• Low cost dosing units
• Less wear of pump
technology
• Pulsations are
compensated
Disadvantages
• Closed high pressure
pumps are needed
• Air must be injected at
high-pressure if bigger
droplets are needed
Seite 33
28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach