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Spiral static mixers are designed for continuous processes because they mix fluids and semi-solids at a constant rate without moving parts. The key differences between various static mixers are the type of mixing elements they have, the materials they are made from, and the sizes available. Here are the main types of static spiral mixers:
The first one is the Veris mixer. The Veris mixer has a gauged spiral mixing element that emulsifies fluids very well. Its spiral geometry creates intense shear that breaks up lumps in thick mixtures. This mixer is ideal for homogeneous mixing in continuous operations when a very fine mix is needed.
The second one is the DeltaP mixer. The DeltaP mixer incorporates a tapered mixing element that generates pressure differentials between fluids. This zeotropic mixing is useful for immiscible liquids that require distinct phases to be mixed. The DeltaP is suited for continuous processing of two or more fluids that must be combined without separation.
Continuous mixers. Continuous spiral static mixers provide uniform mixing precisely because they do not have any moving parts.
Side charge mixers. Spiral static side charge mixers have additional side inlets for introducing powders, chemicals, or other fluids into a liquid bulk stream. This side charging capability allows for versatile additive injection, such as bulk powder dosage directly into slurry or concentrate streams.
Multi-stage mixers. Multi-stage spiral static mixers have more than one mixing element arranged sequentially in a series. Multi-stage mixers are useful for viscous slurries needing progressive mixing to achieve the highest homogeneity at the end of a multi-mixing process. The multi-stage design improves residence time and mixing quality over single-stage mixers.
Flow diverter mixers. Flow diverter mixers incorporate built-in flow diverters into their spirals to redistribute fluid flow path patterns. This mechanism improves fouling of heat exchangers downstream prone to deposition by constantly shearing and redirection of slurry or viscous fluid streams. The diverters break up aggregates and reorient material particles to cleanse sediment areas within the heat exchanger surfaces.
There are many industrial applications of a spiral static mixer, including the following:
Mining and mineral processing
Static mixers are used to mix ores with chemicals like cyanide during leaching operations in gold and silver mining. This ensures complete chemical extraction by evenly distributing the solution through the ore.
Chemicals and petrochemicals
In chemical manufacturing, static mixers blend reactants and catalysts for epoxy resin mixing saw in FRP. They also prepare polymer slurries for the production of artificial fibres.
Petrochemical applications include mixing fuels and additives for homogeneous gasoline and diesel production.
Pharmaceuticals
Static mixers are used to prepare drug solutions uniformly mixing pharmaceuticals with solvents and excipients. This ensures consistency for quality control in pharmaceutical manufacturing.
Food and beverage industry
In the food and beverage industry, static mixers blend liquids like milk with stabilizers and emulsifiers for yogurt and milk. They also mix juices with pulp for smoothies and other beverages.
Wastewater treatment
Static mixers help treat wastewater by blending chemicals with wastewater streams. This is to precipitate contaminants during varying treatment processes. The mixing enables effective pollutant removal.
Oil and gas
In the oil and gas industry, static mixers are used to inject chemicals into crude oil and gas streams. This is to condition the fluids for separation processes. They also mix drilling mud components before their application in drilling operations.
Plastics and polymers
Static mixers are employed to mix resin and hardener for fiberglass reinforced plastic composite applications. They also blend additives into polymer melts for consistency before shaping processes.
The spiral static mixer has the following specifications:
Typical operational conditions
Static mixers function normally across a wide range of temperatures, such as up to 100° C. For special applications, the mixers can withstand higher temperatures of 500° C. They also withstand pressure conditions of about 7 bars in standard cases. But they can also handle extreme pressures of 1000 bars for uncommon cases.
Materials of construction
A spiral static mixer can be made from a variety of materials. These include stainless steel, carbon steel, plastics like PVC and CPVC, Teflon, and ceramics.
Stainless steel is used for corrosion and chemical resistance. Carbon steel is used when cost is a factor. Plastic constructions are used for mixed chemicals that are so corrosive they will damage metals. Ceramics provide hardness and longevity for abrasive applications.
Dimensions
Static mixers come in standard lengths of 30 cm to 200 cm. They also come in diameters that range from 1.27 cm to 15.24 cm. Of course, custom configurations are available to meet specific needs.
Maintenance
The good thing about static mixers is that they require very little maintenance. This is because there are no moving parts.
However, to prevent fouling, users are advised to occasionally flush the mixer with water or an appropriate cleaning solution. The cleaning should be done based on the nature of the materials being processed. Secondly, after extended usage, users should inspect the mixer for wear or damage. This is especially common for abrasives or harsh chemicals. Thirdly, if the mixer has built-in static mixer elements, the user should ensure they are intact and not degraded. Fourthly, check the seals or gaskets, if any, and replace them as needed. The seals may wear out due to chemical exposure or mechanical stress. Lastly, users should check on the mounting or installation hardware and tighten any loose fasteners.
Buyers should consider these factors when purchasing a new spiral static mixer:
Application needs
Users should determine the type of fluid or material they want to mix. This is because the nature of the mixing ingredients largely impacts the choice of mixer. Buyers should also consider the viscosity of the materials. For instance, thinner liquids require less intensive mixing elements. On the other hand, thick slurries may need more complex spirals to ensure proper blending.
The other thing to consider is the required mixing quality. How homogeneous does the user want the final product to be? This is because spiral static mixers come in configurations that yield different levels of mixture homogeneity.
Users should also consider the flow rate they expect through the mixer. This will affect the amount of residence time the materials spend in the mixing unit. Finally, buyers should consider the operating conditions of the mixer. These include things like temperature and pressure ranges. Users should also consider the corrosive properties of the chemicals they will be running through the mixer. This is because these factors typically affect the material construction of the mixer.
Customization
Buyers should ensure the stationary spiral mixer they purchase meets their customization needs. So, if the users require customizations, they should ensure they place their order early. It will take time to tailor the mixers to their specific requirements.
Durability and reliability
Users should settle for spiral static mixers made from high-quality materials and certified by reputable manufacturers. This is because trustworthy brands normally ensure their products are durable and reliable. Moreover, if users intend to run the mixers for long periods without failure, they should go for durable mixers. This is because durability often translates to reliability.
Maintenance requirements
The good thing about a static mixer is that it has no moving parts. Therefore, it requires very little maintenance. However, buyers should go for those mixers that can easily be cleaned. This will help prevent fouling.
Cost and budget
Static mixers have a wide range of prices. The price depends on their size, customization options, and materials. Buyers should set a budget to help them narrow down their choices. So go for the one that offers the user the best value for their money. Moreover, ensure the long-term costs of operating the mixer do not exceed the budget.
Spare parts
Users should ensure the spiral static mixer they purchase has readily available spare parts. This is because, over time, some of its components will wear down and require replacement. Buyers should also consider the cost of these parts. The price of the replacement parts should not exceed the cost of getting a new mixer.
A1. A spiral static mixer is used to blend and homogenize various fluids, slurries, and chemicals. This is more so in industrial processes requiring consistent and uniform mixing. Its helical mixing elements provide efficient axial and radial flow and dispersion. This allows it to handle a wide range of viscosities, from low to high.
A2. The first benefit is the elimination of moving parts. This feature makes static mixers low-maintenance and reliable. Note that static mixers have no mechanical wear from rotating elements, leading to lower energy consumption.
The second benefit is that it has a simple installation process. This makes it relatively easy to integrate into existing piping systems. The other thing is that static mixers have a compact design that minimizes space requirements.
The last benefit is that static mixers provide consistent mixing across varying flow rates. This ensures homogeneity, which is critical in chemical, food processing, and pharmaceutical manufacturing.
A3. Yes, a static mixer can handle abrasive materials. However, only those made from high-quality materials like stainless steel, carbide, or specialized polymers will do the job. These materials are corrosion-resistant and will prevent damage from a mixer.
A4. Yes, some static mixers are customizable. They can be tailored to meet specific applications in terms of diameter, length, and mixing element design. This makes them suitable for unique requirements. However, ensure you order them early for better delivery timelines.
A5. A static mixer can be cleaned using methods like chemical flushing, backwashing, and mechanical wiping. Yes, it can be sanitized using steam or disinfecting chemicals, especially when used in the food and pharmaceutical industries.
