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Static Mixer

Static mixers, or motionless mixers, are widely used in process industries for inline mixing, offering high homogeneity and lower costs compared to traditional agitators. They consist of motionless elements that redistribute fluid flow, making them efficient for various applications including liquid-liquid and gas-liquid systems. Advantages include low maintenance and energy consumption, while limitations include potential clogging and higher pressure loss.

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10 views4 pages

Static Mixer

Static mixers, or motionless mixers, are widely used in process industries for inline mixing, offering high homogeneity and lower costs compared to traditional agitators. They consist of motionless elements that redistribute fluid flow, making them efficient for various applications including liquid-liquid and gas-liquid systems. Advantages include low maintenance and energy consumption, while limitations include potential clogging and higher pressure loss.

Uploaded by

duchunshan0
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Static Mixer

What is a Static Mixer

Static mixers, also known as motionless mixers, have become standard


equipment in the process industries. Static mixers are employed inline in a
once-through process or in a recycle loop where they supplement or even
replace a conventional agitator.

Static mixers make a high degree of homogeneity in a very short length of


pipe.Static mixer is a continuous radial mixing device, characterized by an
effective degree of plug flow, depending on the specific design and application.
It ranges in size from a few millimetres in diameter to units with equivalent
diameters exceeding 3 m and volumes exceeding 100 m3.Their use in
continuous processes is an attractive alternative to conventional agitation
since similar and sometimes better performance can be achieved at lower
cost.

Motionless mixers typically have lower energy consumptions and reduced


maintenance requirements because they have no moving parts. They offer a
more controlled and scalable rate of dilution in fed batch systems and can
provide homogenization of feed streams with a minimum residence time. They
are available in most materials of construction.

Design of Static Mixer

The prototypical design of a static mixer is a series of identical, motionless inserts that are called elements and that
can be installed in pipes, columns or reactors. The purpose of the elements is to redistribute fluid in the directions
transverse to the main flow, i.e. in the radial and tangential directions. The effectiveness of this redistribution is a
function of the specific design and number of elements. Commercial static mixers have a wide variety of basic
geometries and many adjustable parameters that can be optimized for specific applications. The number of elements
in series is routinely adjusted. Another important parameter is the aspect ratio, defined as the ratio of length to
diameter of a single element. Commercial designs typically use standard values for the various parameters that
provide generally good performance throughout the range of applications and for which experimental data are
available. Ordinarily, the use of standard designs is recommended. As a group, motionless mixers exhibit far higher
efficiencies than rudimentary mixing devices such as elbows or tees and their performance is better characterized.

Applications of Static Mixer


Static mixer operations are essential in the process industries. They include
the classical mixing of miscible fluids in single phase flow as well as heat
transfer enhancement, dispersion of gas into a liquid continuous liquid phase,
dispersion of an immiscible organic phase as drops in a continuous aqueous
phase, three-phase contacting and mixing of solids. Static mixers have been
applied to all these applications, including liquid–liquid systems (e.g.
liquid–liquid extraction), gas–liquid systems (e.g. absorption), solid–liquid
systems (e.g. pulp slurries) and solid–solid systems (e.g. solids blending).

Numerous static mixers are extensively used in various homogenization


processes in industrial operations like polymer blending, chemical reactions,
food processing, heat transfer, and in cosmetics and pharmaceutics, also in
waste-water treatment. They are moreover frequently applied in disposable
applications, like in in situ mixing of two-component, epoxy adhesives and
sealants. The small space requirement, low equipment operation and
maintenance costs, sharp residence time distribution, improved selectivity
through intensified mixing and isothermal operation, byproduct reduction, and
enhanced safety are the main features that have promoted the use of these
devices
Advantages:

1. Maintenance free

2. Static Mixers are a low-cost alternative to traditional tank mixers both at purchase and during the mixer's lifetime. There are no
running costs associated with operating a Static Mixer on top of running your existing pipeline.

3. Because static mixers are motionless by design, all the energy required to provide a perfect blend is provided by the energy of the
flow stream

4. No moving parts hence extended product life


Limitations:

1. Restriction and clogging may accrue

2. Higher pressure loss

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