Inline Static Mixers can be used in almost every Continuous Process Industry
Statiflo Static Mixers are used in almost all continuous processes throughout the world. By using the same concepts which are applied to other industries, Statiflo have developed an offering to improve almost any process.
At a time when increased efficiency of all process industries, both in an economical and environmental sense, is becoming an increasingly important issue, there is a high demand for technologies which can provide both cost savings and energy savings.
Applications such as general chemical production, polymer processing, metal smelting and the production of synthetic oils all use Statiflo Inline Static Mixers to improve their efficiency, product purities and consistently produce on-spec products.
With environmental factors ever-more important in today’s industries, increased focus is being placed on DeNOx, DeSOx and other Selective Catalytic Reduction (SCR) and Selective Non-Catalytic Reduction (SNCR) processes. A Statiflo Static Mixer can be used for the makeup of treatment chemicals or within the gas scrubbing process itself.
Using a Statiflo Inline Mixer allows chemicals to be dosed effectively and efficiently – reducing the need to compensate for poor mixing by overdosing chemicals and therefore helping to minimise the quantities of chemical dosed.
Another added benefit is that, more often than not, representative sampling can be done immediately at the Static Mixer discharge which means the shortest possible control loop times and results in the very best control of your process.
- Overall length can be varied to suit space limitations.
- Element geometry can be designed for both high and low head loss systems.
- Large diameter – no theoretical upper limits.
- Elements for rectangular or other unusually shaped ducts and open channels
- Special designs for incorporating in bends, offer space saving and minimal disturbance to piping systems.
- Guaranteed highly efficient mixing.
- No moving parts provide a maintenance free operation.
- Reduction in operational energy costs, as no direct power is required.
- Ease of installation.
- Minimal space requirements with no upstream or downstream pipe lengths required. Providing short control process times in applications where quick process response control is critical.
- Short process chemical dosing control loops provide optimum performance in response to rapidly changing process conditions, as well as reducing chemical costs.
- Available in a wide ranges of sizes and material to suit most applications.
- Each unit is custom designed benefiting from Statiflo’s long term experience in designing and manufacturing static mixers to the highest of standards.
- Total support is provided by highly trained engineers situated in Statiflo regional country offices and a world wide representative network.
Application Examples and Case Studies
How is it possible to optimise the temperature of washwater used for cooling and removing trace contaminants from fibres during the final stages of rayon manufacture?
A robust method for heating acidified recycled washwater was required. Direct steam injection into cold fluids in an empty pipe is thermally efficient, but results in other serious problems associated with vibration, noise and poor temperature control.
Dispersing steam, or some other phase, in a liquid flowing in an empty pipe, with its unpredictable and uncontrolled shear history, results in a very wide bubble or droplet size distribution. The larger bubbles of steam, formed in this way, tend to violently condense causing vibration, noise and, in extreme circumstances, equipment failure.
Statiflo Static Mixers have been successfully used in this operation.
For further information see case study.
The Statiflo Series 700 Motionless Mixer is designed specifically for polymer processing. The mixer has continuous edge sealed construction to prevent short-circuiting of the mixing process and to provide mechanical integrity at high pressure drop. The Mixer housing is machined to precisely match the customers adjacent piping dimensions. Reducers and sudden diameter changes are avoided.
Laminar flow mixing takes place by flow division and radial mixing, rapidly eliminating radial differences in polymer temperature. Mixers are positioned immediately before each flow split in the manifold delivery system, to develop a thoroughly mixed condition and ensure identical polymer is pumped to the next mixer and split flow.
Very high quality internal surface finish in the mixer is essential for efficient flow and to prevent material hang up, especially where colour change occurs often.
For further information see case study.
Process with highly viscous polymer melts
Problem A “man-made” fiber spinning plant produces thousands of individual threads simultaneously. All threads come from a polymer melt, which is provided with a very high viscosity, high pressure, and…
High Viscosity Polymer Processing
Problem High Viscosity Polymer Processing: A man-made fibre spinning plant simultaneously produces thousands of individual filaments. All the filaments originate from a single source of high viscosity, high temperature and…
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