One of the important elements in piping that greatly reduces the need for electric mixers is the static mixer . This component, which is placed in the pipe after the additive injection point, helps in better mixing of materials. The use and demand for static mixers in various industries in Iran is increasing rapidly.
Leading manufacturers of static mixers
- LIGHTNIN From USA (An SPX Brand)
- PLENTY From UK (An SPX Brand)
- FluidMix From Spain
- Instrumental Technique Control (Iran)
Static mixer production in Tehran
Mahar Fan Abzaar Company has started producing static mixers since 2010. The range of models produced by this company is very wide and, due to its engineering and manufacturing capabilities, it also includes special types such as all-Teflon.
Types of static mixers
Static mixers are usually produced in various types, but the most common are helical and elliptical types.
Static Helical Mixer
In this type of static mixer, it is produced by bending rectangular sections of sheet metal and gluing them together at a right angle, and is usually used in small sizes and low capacities.
Static Elliptical Mixer
In larger sizes, due to the thickness of the elements and their dimensions, bending may not be a suitable option. Therefore, we use semi-ellipses and their placement next to each other, and in large sizes, this is usually the most common model.
Static Cross Element Mixer
When the viscosity of two fluids increases sharply, it is necessary for the static mixer to be able to achieve maximum mixing without considering fluid turbulence. This mixing is only achieved in the crossed element method.
Static mixer with low pressure loss Low Headloss
This type of static mixer is used to reduce energy consumption and in some processes to prevent pressure drop. This model is also used more at high flow rates than other models.
Wafer-shaped static mixer
This model, also known as the cartridge model, is easily removed from the system, and this advantage, along with its simplicity and cheapness, makes it practical.
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In what industries is static mixer used?
- Water purification
- Chemical composition
- Solvent gases
- Polymer composition
- Flocculant composition
- pH control
- Drinking water
- Wastewater
- Chlorination
- Dechlorination
- Food processing
- Pharmaceutical
Materials used in static mixers
In general, the material used to make a static mixer depends on the process and piping, and the same piping material is usually used to make a static mixer. However, there are limitations to the production of a static mixer, for example, producing this part with Teflon material is very complicated. Different materials that are commonly used include:
- PVC
- FRP
- Stainless steel 316
- Titanium
- Hastelloy®
- Kynar®
- Polypropylene
- Carbon steel
- If additional protection is needed, a Teflon coating can be provided.
Static and rotary mixer
- Static Mixer or In-lined Static Mixer
- Static mixers are energy-efficient and effective equipment for use in a wide range of needs and applications.
- In the field of mixing 2 or more liquid solutions with different viscosity and line pressure or a mixture of gas and liquid.
- Static mixer is a simple and highly efficient equipment for various applications.
- The main requirement of a static mixer is a continuous flow of material.
- The static mixer receives its required energy from the fluid and performs the desired process.
- All static mixers consume fluid energy and create a pressure drop across the mixer.
- The type of mixer, the number of elements installed, and the Reynolds number of the fluid are important and vital parameters in the performance and pressure drop of the fluid.
- The two changeable parameters in a static mixer are size and number of elements.
- The static mixer size is usually determined by the buyer.
- And only the number of elements is determined by us. And this also depends on the Reynolds number of the fluid.
- The more elements, the better the result.
What is a static mixer?
- A static mixer is a device used to mix fluids.
- The diameter of this device can range from a few millimeters to several meters.
- This equipment provides a high degree of homogenization in a very short length of pipe.
- Also read about jet mixer.
Types of static mixers:
Kara Sanat Company’s static mixers are produced in various types:
KMS
- It has ribbons twisted to the left and right alternately.
- This type is suitable for both laminar and turbulent fluids.
SMX
It has guide edges intersecting at 45 degrees to the pipe axis.
This type is suitable for both laminar and turbulent fluids.
Especially used for laminar flow mixing
SMV
- It has corrugated sheets at an angle of 30 to 45 degrees to the pipe axis.
- This model can only be used in turbulent flow.
- It is suitable for mixing liquid into solid, gas into liquid, and vice versa.
LPD
- It has a number of semi-elliptical plates arranged asymmetrically in a tubular housing.
- They can be used in flows with high and low turbulence.
- They are suitable when low pressure drop is required.
Applications of static mixers in wastewater treatment
- Effluent entering the thickener
- Adjusting pH after injecting acid into water
- Wastewater balancing
- Making semi-homogeneous mixtures
Advantages of static mixers
- Minor pressure drop
- No electricity required
- Easy installation at different angles
- Very minor maintenance and repairs
- Self cleaning design
- Atx and explosion-proof
Essential oil powder mixer sprayer
- One of the best industrial mixer machines ever produced in Iran
- According to customers and domestic craftsmen, it is related to this project.
- This project is related to an essential oil powder mixer machine with a capacity of 1000 liters.
- The different design you see in this mixer
- In addition to the overall beauty of the device, it increases the strength of the structures and base of the device.
- Every detail of this mixer has been manufactured in compliance with global and fundamental standards.
- The essential oil spraying equipment in this project has the capacity to spray 1 liter of liquid essential oil onto materials.
- The essential oil spray mixer is considered a ribbon blender.
- And another capability of this model is the mixing of wet powders in addition to dry powders.
- Solid and sturdy body with different bases along with quality technical and engine indicators
- This makes this device one of the best mixers on the market.
With an essential oil powder mixer, you can apply essential oil evenly to the powders being mixed with just the push of a button.
- The type of blender is U-shaped with essential oil spray. This type of ribbon blender has a fixed tank.
- Also, with the new design in this model, the mixer is made compact and sturdy.
- Which is very suitable for use in heavy type
- The essential oil sprayer is also designed and installed on the device as an additional feature to evenly distribute essential oil onto the powder.
- The device operates with a fixed tank in a horizontal position.
- Inside their horizontal tank, mechanical blades are used around a powerful shaft.
- Instead of the tank rotating, these blades are rotated by the power of the gearbox motor.
- This machine is used for dry or low moisture powders and granules.
- And the ability of this model of powder mixer is to mix dry powders.
- But it also mixes powder with low moisture. The capacity of this blender with a fixed tank is 1000 liters.
- Not the total volume of its tank and it is sold at the same price as a 1000 liter powder mixer.
- The estimated mixing time with this device is 6 to 15 minutes.
- And only with the exact weight of the powder and its type can the time required to fully mix the powders be obtained.
- The body material of this powder mixer prototype is iron and its shaft is made of 304 steel.
- For this model, a mechanical (manual) outlet valve is installed under the fixed blender tank.
- Usually, a platform is installed at the location of the heavy-duty powder mixer.
- And they place the device on it to easily remove the mixed powders from the device.
Ribbon Blender
- A ribbon blender, or powder mixer, is a blender with a fixed tank, which is horizontal as shown in the photos.
- Inside the tank of this device, there is a chopper that distributes the powders throughout the tank.
- Another function of the chopper is to help the powders exit the tank after mixing.
- The output powders, which are placed in a special package, are weighed on a small weighing table.
- And then they are transferred to the conveyor. Then the powder packages are delivered to the closest possible point where the operator is located.
- They are guided by a conveyor so that the operator can easily pick up the packages and store them in a nearby location.
- The ability of this model of powder mixer to mix semi-heavy to heavy powders,
- It is powered by a powerful gearbox motor and mechanical components. This device is powered by 220V three-phase industrial electricity.
- But it can also be converted to single phase upon request.
- This product is more suitable for packaging dry powders.
- Its capacity is 2000 liters. The mixing time with this device is estimated to be between 3 and 9 minutes.
- The material of this ribbon blender prototype is iron.
- As mentioned and shown, this model has a chopper that multiplies its output power.
Static blender industrial mixer
- An industrial blender is a device used to mix and grind any food ingredient.
- This device is considered one of the most important coffee shop equipment, along with the juicer.
- It is used to make a variety of smoothies, cocktails, shakes, and sauces.
- To use a blender, simply pour the desired food into the pitcher of the machine.
- And by turning it on, you get a hand-held combination of your favorite ingredients.
- You can also adjust the amount of material that is crushed using a blender.
- Industrial blenders are sold in different capacities and with different powers.
- But its two-liter model is very popular as one of the most widely used industrial kitchen equipment.
Static mixer mixing machine
- The use of static mixers is not limited to coffee shops and juice bars.
- It can also be used as restaurant and fast food equipment.
- To make various types of mashed potatoes, carrots, tomatoes, etc.
- And also, blenders are used to make various sauces and seasonings in restaurants and fast food.
- Some types of blenders are multi-functional and can be used as a food processor, juicer, and mixer.
Mixer Static Patching System (Meter)
Raw materials such as grains enter special silos and tanks that have a certain volume.
At the end of these tanks, there are valves that are opened manually or automatically, and the materials inside the tanks enter the production line with a certain volume.
Weighing equipment
There are various pieces of equipment in animal feed production lines that are responsible for accurately weighing materials.
Such as equipment for weighing liquids and oils, or very precise weighing systems (microdosing) for adding vitamins
and other drugs to animal feed or a final weighing system used at the end of the production line for weighing the final product and packaging.
Grinding and crushing machines
- After measuring the raw materials, they must be ground using special grinders to prepare the dough needed to make pellets.
- Special equipment and mills are used to grind grains and raw materials, which are designed and manufactured in various types and sizes.
Hammer mill compared to static mixer
- This machine is used to crush cereal grains.
- This mill uses successive impacts to crush the grains.
- The faster the machine, the more and smaller the grains are divided into parts.
- Particle size depends on the design, hammer size, machine speed, and screen type and screen hole size.
Roller mill compared to static mixer
Roller mills, similar to old mills, grind grains and raw materials by rolling pieces together and applying pressure to the materials.
Mixing equipment
- Good mixing and a consistent mix of ingredients is the key to producing good animal feed.
- Animal feed is not produced in a factory according to the formulation unless the ingredients are mixed properly.
- To have a uniform mixture, you need equipment with proper performance.
- In the animal feed factory, various types of mixers are used to mix raw materials and supplements.
Static mixer feeder
Feeder mixers are equipment used to achieve a homogeneous and uniform mixture in production lines. Mixers are designed and manufactured in two vertical and horizontal shapes in various capacities. Other types of feeder mixers include pedal and ribbon mixers.
Processing and baking equipment
Conditioner
- The mixed animal feed ingredients must reach sufficient temperature and humidity in proximity to water vapor.
- And in other words, it is cooked. In animal feed production lines, there is a device called a conditioner.
- who is responsible for this task.
- Moisture and water vapor cause the powder to gelatinize.
- And it is prepared for pelleting.
- Time, humidity, and temperature are of great importance.
Extruder
Pelletizing equipment
The materials obtained from the previous steps are in powder form, storing and transporting powdered materials seems a bit difficult. Swallowing powdered materials is also very painful for animals, which is why these materials need to be produced in larger pieces (grains). Equipment is provided in the production lines for this purpose to present the materials in the form of pellets and granules after mixing and combining them.
Pellet press
By means of a pelletizing machine, the materials obtained from the conditioner machine are passed through special molds using a roller (die) and the powdered materials are converted into pellets. The quality and output of the pellet press machine depends on many parameters such as the quality of the mill, conditioning, feed formulation (oil percentage, fiber, etc.) and die configuration.
Supply of European static mixer
Due to its exclusive cooperation with its foreign partner AxFlow, Chagalesh has added a specialized unit to design and provide solutions in the field of static and dynamic mixers for existing tanks in the oil, gas, refineries, and petrochemical industries.
This company carries out all stages of designing, supplying and implementing mixers, including Top Entry Mixer or Side Entry Mixer, in cooperation with its foreign partners.