Super Duplex ZQM Static Mixer

A Static Mixer is an efficient mixing device without moving parts. Besides being widely used in the petroleum refining and chemical industries, it is also extensively applied in fields such as medicine, food, mining, plastic extrusion, and environmental protection. The Super Duplex ZQM Static Mixer, particularly the Super Duplex ZQM-SD Static Mixer, is renowned for its high strength and corrosion resistance, making it ideal for demanding applications. Compared to traditional mixing equipment like mixers, colloid mills, homogenizers, and Venturi tubes, it offers advantages such as a simple process, compact structure, low energy consumption, low investment, high operational flexibility, no maintenance requirements, and excellent mixing performance.

The Tube static mixer, like the Sd Static Mixer With Pp, consists of vertically intersecting blades designed to create a polished static mixer ensuring a low-pressure drop mixer. Helical Static Mixers, with their internal units made of rotating blades twisted 180° to form a spiral line type, are typical representatives like the Kenics type, known for their simple structure and wide applicability. Stainless steel Static Mixers, including the Super Stainless Sd Static Mixer, consist of vertically intersecting blades arranged in a way that multiple units are connected to form D-shaped units, creating a staggered multi-chamber state.

Any process involving the mixing, emulsification, neutralization, absorption, extraction, reaction, and enhanced heat transfer of liquid-liquid, liquid-gas, liquid-solid, and gas can replace traditional related equipment with these mixers. The advantages of continuous fluid flow, easy maintenance, and reliable operation make static mixers, such as the Auto self-cleaning Filter and Self-cleaning brush filter, widely used across all industries.

Operational Principle

The mixing process of a static mixer is carried out by a series of mixing units of different specifications installed in a hollow pipeline. Due to the action of the mixing unit, the fluid sometimes rotates left and sometimes turns right, constantly changing the flow direction. This not only pushes the central fluid towards the periphery but also pushes the peripheral fluid towards the center, resulting in a good radial mixing effect. At the same time, the rotational action of the fluid itself also occurs at the interface of adjacent components, and this perfect radial circulation mixing effect achieves the goal of uniform mixing of materials.

Application Scope

Static mixers can be applied to the mixing, emulsification, neutralization, absorption, extraction, reaction, and enhanced heat transfer processes of liquid-liquid, liquid-gas, liquid-solid, and gas-gas. They can be applied in different flow patterns (laminar, transitional, turbulent) within a high viscosity range, for intermittent and continuous operations. Below, we will briefly introduce the scope of different application scenarios:

1. Liquid-liquid mixture: From the flow layer to turbulence, fluids with viscosity within the range of 10 Mpa·s can achieve good mixing. The minimum diameter of dispersed droplets can reach 1-2 μm, and the size distribution is uniform.
2. Liquid-gas mixture: The static mixer can continuously update and fully contact the phase interface of the liquid-gas two-phase components and can replace the bubbling tower and sieve plate tower under certain conditions.
3. Liquid-solid mixture: When a small amount of solid particles or powder (solid accounts for about 5% of the liquid area) is mixed with the liquid under turbulent conditions, a static mixer can be used to force the solid particles or powder to fully disperse, which can achieve the requirements of extracting or decolorizing the liquid.
4. Gas-gas mixture: Can be used for mixing cold and hot gases, as well as mixing different gas components.
5. Enhanced heat transfer: Due to the static mixer, the contact area of the fluid is increased, which increases the heating coefficient. Generally speaking, for gas cooling or heating, if a static mixer is used, the heating coefficient of the gas can be increased by 8 times; for the heating of viscous liquids, the heating coefficient can be increased by 5 times; for gas condensation with a large amount of non-condensable gas, the heat transfer coefficient can be increased by 8.5 times; the heat transfer of polymer melt can reduce the temperature and viscosity gradient on the pipe section.

Product Advantages

• Continuous process, the mixing process is not interrupted;
• Minimal shear force does not damage the mixture, such as flocs;
• The mixing effect is computationally controllable (CoV deviation), with a maximum CoV range of 5% according to customer requirements. The fluid concentration across the entire cross-section is continuous and balanced, so the measured values have high representativeness and can effectively control the device;
• The mixing distance and installation space are very small, and the static mixer itself is a part of the pipeline, which can be regarded as a special pipeline, avoiding the shortcomings of traditional mixing tanks and so on;
• High mass transfer efficiency, very low pressure drop and energy consumption;
• No moving parts, no wear, and almost no maintenance costs;
• It will not be blocked, and the installation method and material can be of any shape, size, and material;
• Compulsory mixing of the entire process logistics can greatly reduce the volume of storage tanks, and static mixers can even eliminate the use of storage tanks.

Product Pressure Drop

The pressure drop calculation of the product is based on the hydraulic diameter and takes into account the influence of porosity and friction coefficient. The static mixer is used in pipelines and does not produce a significant pressure drop. When the system pressure using a static mixer is relatively high, the pressure drop generated by the static mixer can be ignored. If the system pressure using a static mixer is relatively low, it is necessary to verify the pressure drop of the static mixer. The pressure drop calculation method for static mixers varies depending on the model of the mixer.

Static Mixer Installation Model and Installation Form

• SV gas-liquid phase: vertical installation (parallel and reverse flow), liquid-gas phase: horizontal or vertical (bottom-up) installation, with similar device effects;
• Gas-gas phase: horizontal or vertical (with small density difference in gas phase and unlimited direction) installation;
• SX liquid-liquid phase: horizontal or vertical (from bottom to top) installation, similar device effect;
• SL liquid-liquid phase: horizontal or vertical (from bottom to top) installation, similar device effect;
• Liquid-solid phase: horizontal or vertical (bottom-up) installation;
• SH gas-liquid phase: the flange size at both ends is determined by enlarging the nominal diameter of the product by one grid. Products using SL type installation form of SK active unit usually have one end without a positioning device as the inlet end;
• Liquid-liquid phase: installed horizontally or vertically (from bottom to top), with similar device effect. Liquid-solid phase: vertical device (from top to bottom).