innovation in fluid mixing

8/3/2019 Innovation in Fluid Mixing

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Advanced Process Technologies

Maelstrom

INNOVATION

IN FLUID

MIXING


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About Maelstrom

Fluid Mixing - an introduction

Mixer Selection - which technology?

Mixing Technologies

FDM High ShearFDM Low Shear

IPMCDDM

Machines

FDMbatch high shearinline high shear

inline low shear

IPM batch

inline

Nano & Custom


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About Maelstrom

Since 1998, Maelstrom has been a full service supplier of industrial fluid mixingmachines and associated equipment to the process industries. Specialisingin high energy mixing for difficult-to-mix materials, we have a range of noveland advanced mixing technologies at our disposal, some of which we havedeveloped in-house and some of which are licensed from third parties. Wedesign all of our equipment ourselves which gives us complete control over the

design process and allows us to tailor solutions for our customers easily andquickly. Manufacturing is typically performed by our well-developed base ofISO 9002 certified contractors and we take full advantage of being located inthe prime aerospace, automotive and nuclear manufacturing region of the UK.

We started out by taking on fluid processing problems for certain largecompanies who had already tried alternative, standard approaches and hadmet with failure, either in product performance or cost over-runs. Working withthese companies to solve their often complex problems led us to develop theMaelstrom business as an innovative mixing solutions provider and provider oflast resort. Quite simply, this means that we consistently aim to provide thebest and most cost-effective solution to any fluid mixing problem that cannot

be addressed by conventional means.

Operating from our base in Glossop within the High Peak area of Derbyshire,England, we have been servicing the UK market for advanced mixing solutionssince 1998. Our expanding client-base includes some of the worlds largestprocess companies, but we also work with smaller companies seeking tointroduce new, disruptive products which present special processing challenges.A good example of this is the recent development of nanotechnology, an areawhere we see an increasing number of our clients needing special, high-energydispersion solutions for improved product performance. We have developedsome special-purpose dispersion technology and equipment targeted at thissector.

Peter Brown

Managing Director

Location

Maelstroms main offices are in Glossop within the beautifulHigh Peak area of Derbyshire, England and we also havea demonstration and laboratory facility in Denton, nearerManchester. All of Maelstroms design and assembly is donehere with the exception of our range of Distromix FDM mixerswhich are also available through our local licensees in Japan,

China and India.

Website

For more information and latest news on Maelstrom products and services,please visit our website. An online product configurator and quotation systemis also available on the website for quick and easy pricing of our standardmixer ranges.


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In an ideal world, it would be possible to choose the appropriate

mixing action to suit the requirements of the fluid and then

select either a batch or continuous form. In practice, many

mixing technologies are offered in either batch or continuousform but not both. In situations where both are offered, there

are normally some performance trade-offs.

Fluid Mixing Mechanisms

In terms of mechanical mixing mechanisms, a number of actions

are employed by different types of mixers to create different

effects for particular process results.

For distributive action, swirl created by rotating parts causes

laminar thinning of the material interfaces, thereby increasing

volumetric combination of the materials. A repeated cutting and

folding action of the mixture also increases the distribution of

different material components. The effectiveness and efficiency

of a mixer in distributive mixing is therefore a function of how

the machine interacts with the fluid in a geometric sense.

Conversely, the effectiveness and efficiency of a mixer in

dispersive mixing is a function of how the machine interacts

with the fluid in a stressing sense. For most materials, the

higher the stress, the smaller the resulting particles or droplets

in the mixture. However, another very important consideration

is the uniformity of the stress field. Without a reasonable

uniformity, it is impossible to guarantee that the same stress

is applied to all parts of the fluid. This would result in a wide

range of final droplet or particle sizes rather than a narrow range

obtained with uniform stressing.

One or more of the three primary stressing mechanisms are

used in most fluid mixers. These mechanisms are:

Of these mechanisms, the most effective is extensional

stressing. This is why nozzle valve homogenisers are used to

create many of the ultra-fine dispersions demanded by process

industries, despite their many practical disadvantages, and why

common high shear mixers do not give the best dispersions.

The mixing of one or more components or materials in a

fluid system can be described in terms of two separate but

interlinked physical processes:

Blending (distribution) of different components of the mixture

to create uniformity throughout the mix, and

Droplet or particle size reduction (dispersion) of one or more

components of the mixture to give increased homogeneity of

the system or to alter the nature of the system by increasing

the contact surface area between the components, i.e. reducing

the particle or droplet sizes increases their contact surface area

to volume ratio.

A fluid system in this context means a combination of materials

which combine to form a fluid, where a fluid is defined as

matter which cannot sustain a shear force while at rest. In

particular, we are considering liquid-liquid and solid-liquid mixing

systems here, as distinct from dry powder or gas-liquid mixing

systems.

Most fluid mixing problems can be considered in terms of the

miscibility (the ease of mixing) of the system components.

Miscibility can in turn be thought of as the ease of distributionand the ease of particle size reduction - this affects the

mixing approach to be adopted. For instance, where the rate

of reaction between miscible components is to be improved,

mixing efforts are focused on maximising distribution, while for

mixing immiscible fluids, efforts are focused on reducing droplet

or particle size to maximise the area of contact between the

phases.

A further consideration is the type of production process

involved, of which the fluid mixing is normally only a part. The

most important distinction that affects the mixing operation is

whether the process is batch or continuous in nature. In a

batch process, a discrete volume of material is mixed, usually

within a vessel; in a continuous process, a stream of material is

mixed, usually piped to and from the mixer.

FLUID MIXINGAN INTRODUCTION

EXTENSION

IMPACT

SHEAR

Distributive

Mixing

Dispersive

Mixing

Fn(energy)

Fn(geometry)


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Maelstrom is a relatively unusual company in the field of fluid

mixing in that it offers more than one technology solution.

Understanding that there is no such thing as the perfect mixer

and that different technologies must be applied to achieveparticular results for different materials means that customers

can be sure of getting the correct solution for their situation. In

fact Maelstrom will go further and will also integrate third party

equipment to make sure the customer gets the right results.

The three key Maelstrom technologies of FDM, IPM and CDDM

are intended to fill the dispersion/distribution space which has

largely been neglected and to extend performance into new areas

for higher energy nanomaterial dispersions and other leading-

edge applications. The Maelstrom product range comprises

machines and systems based on these three technologies which

are normally used in isolation but can, on occasion be combined

to good effect, e.g. using FDM as a pre-processor for IPM or

CDDM machines.

The flowchart below provides a starting point for the selection

of a particular Maelstrom mixing technology based on user

requirements but please consult Maelstrom directly for more

detailed advice.

MIXER SELECTIONWHICH MAELSTROM TECHNOLOGY?

ControllableDeformation

DynamicMixing(CDDM)

IntegralPumpMixing(IPM)

Fluid

DivisionMixing(FDM)

Rotor-stator highshear & jet mixers

Impellers &static mixers

Highpressurenozzles& valves

Rotor-statorhomogenisers

DISPERSION

DISTRIBUTION

Batchor

inline?

Solidsincludedin mix?

Hardparticlesin mix?

Mixingdispersionpriority?

Very highviscosityblending?

Extremedispersionneeded?

Hardparticlesin mix?

Solidsincludedin mix?

Mixingdispersionpriority?

IBV(Integrimix)Batch IPM

DB(Distromix)Batch FDM

DCL(Distromix)Inline FDM

DC(Distromix)Inline FDM

ICV(Integrimix)Inline IPM

CDDMInline

Nano Mixer

BATCH MIXERS INLINE MIXERS

START

THE DISPERSION / DISTRIBUTIONPERFORMANCE SPACE

MAELSTROM MIXING TECHNOLOGYSELECTION FLOWCHART


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FDM low shear technology uses the same patented rotor-

stator geometry as its high shear variant but is operated at low

speeds, keeping fluid in the laminar flow regime. The geometrycomprises a concentric rotor and stator with spherical segment

cavities machined into their facing surfaces. The predominant

mixing effect in the laminar mode is inter-cavity transfer, a well-

proven distributive mixing phenomenon suited to high viscosity,

shear sensitive fluids.

FDM FLUID DIVISION MIXINGTECHNOLOGY - LOW SHEAR

WHAT IS IT?

FDM low shear machines provide extremely good inline

distributive mixing (blending) of high viscosity fluids such as

pastes, syrups, gels and plastics. The even distribution of small

amounts of additives such as colours, flavours, inhibitors etc.

into these kinds of materials is normally very difficult. However

with FDM, it is achieved it with ease. The temperature of

the fluid can also be controlled by jacketing the stator of the

machine and by providing heating or cooling to a hollow rotor.

This allows FDM low shear machines to be used in a wide

range of high viscosity inline mixing applications, replacing pin

and paddle mixers for higher flowrates and improved mixing

quality.

WHAT IS IT FOR?

HOW DOES IT WORK?

As fluid is pumped into the inlet of the low shear FDM machine,

it meets the cavities in the rotor before being forced through the

gap between the rotor and stator and encountering the statorcavities. The fluid is transferred between the rotor and stator

components as it progresses along the tortuous flowpath as it

is simultaneously being cut and folded by the movement of the

rotor. The large gaps and gentle cutting and folding action give

rise to the low-shear blending properties with no material able

to bypass the mixing zone.

Dosing injectors mounted around the conical outer surface of the

stator allow multiple stream to be added directly into the mixing

cavities for the best possible mixing results. Rotational speeds

are typically in the range of tens to hundreds of rpm, ensuring

that flow remains laminar such that potentially undesirable

turbulent shear is avoided.

WHAT ARE THE ADVANTAGES OF FDM?

Inter-cavity transfer action provides proven blending

performance benefits over pin and paddle mixers.

Ultra-low shear mixing protects shear-sensitive materials and

allows effective blending and texturing without heating

Simple rotor-stator design with conical geometry allows

easy access and dismantling for cleaning and maintenance

Multiple additive streams can be dosed directly into the

mixing head for optimum blending performance

A wide range of options is available including hygienic and

hazardous area versions, various construction materials,

special seals and performance tuning add-ons for specific

tasks.

HOW DOES FDM COMPARE TOCAVITY TRANSFER MIXERS?The Cavity Transfer Mixer invented in 1980 by RAPRA is a

cylindrical rotor-stator mixer with geometry and intent similar

to the FDM. The FDM is essentially an improvement on the

cylindrical design to overcome three major problems:

Cost reduction - the conical FDM geometry is much easier

and cheaper to produce than the clam-shell design of the

cylindrical form

Cleanability - the quarter-spherical segments of the FDM are

inherently easier to clean than the hemispherical segments

of the Cavity Transfer Mixer and are able to self-clean in

many instances. It is also easier to open the FDM.

Short-circuiting of low viscosity additives - the cylindrical

geometry of the Cavity Transfer Mixer allows low viscosity

additives to bypass the cavities by keeping to the gap

between rotor and stator. This is not possible with FDM.

1.

2.

3.

Dosinginjector

Rotational speed~50-100rpm

Rotor-statorgap ~1mm

STATOR

STATOR

ROTOR

Dosinginjector


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IPM is a fluid mixing technology developed and patented by

Maelstrom that combines elements of existing technologies

to provide high performance with some unique features. Byintegrating internal positive displacement pumping and nozzle

geometries, IPM machines are essentially medium-pressure

multi-nozzle homogenisers that can be operated either inline or

directly immersed in the batch vessel. The extent of dispersive

and distributive blending can be tuned by varying parameters

such as nozzle diameter, rotation speed and other factors for

each model type and for different models in the range.

IPM INTEGRAL PUMP MIXINGTECHNOLOGY

WHAT IS IT?

Tight tolerances and sliding surface internal parts make IPM

machines best suited to liquid-liquid emulsification and the

dispersion of soft solids. IPM has many applications in areas

ranging from food and pharmaceuticals through to lubricants,

speciality chemicals and clays where high quality dispersions

are needed at low cost.

WHAT IS IT FOR?

HOW DOES IT WORK?

The key to IPM performance is the use of an integrated positive-

displacement pumping to drive fluid through defined flowpaths,

including nozzles. This action ensures extensional, shear andimpact stressing of the fluid, leading to high energy transfer and

significant particle or droplet size reduction. Additional blending

effects are provided by cutting and folding actions within the

head so that microscopic-scale fluid blending (distribution)

effects are also obtained.

OPERATING PRINCIPLE

Fluid Entry (Induction)

As the vanes move around with the central element, the

chambers formed by the vanes and central and outer elements

start to expand as they approach the inlet holes in the outer

element. Fluid is drawn from the mixing vessel or a piped feed

into the inlet holes by the low pressure in these chambers and is

sheared by the vanes as it passes through these holes.

Compression and Nozzle Flow

As the chambers move past the last set of inlet holes, theybecome sealed from the outside and their volume starts to

reduce. This pressurises the fluid through the nozzles in the

central element to develop extensional flow. Fluid passes

through the nozzles at very high velocities (e.g. at over 250

mph in water) and impinges on the wall of the inner element,

providing a high degree of impact stressing.

Post-Stress Conditioning and Exhaust

Once the fluid has impacted on the inner element wall, it

moves under low pressure into the open space within the

inner element, experiencing turbulent mixing and post-stress

conditioning which is known to be beneficial in allowing

time for electrostatic charge balance and membrane formation

around droplets or particles. The fluid finally passes out axially

through the bottom of the mixing head back into the vessel

(batch mixers) or outlet piping (inline/continous mixers).

Mechanical

seal

Central element(rotor)

Top locking ring

Outer element

Vanes (x8)

Inner element

Bottom locking ring

Nozzles

(8 rows of 3)

WHAT ARE THE ADVANTAGES OF IPM?

IPM occupies a unique performance space between rotor-

stator high shear mixers and high pressure homogenisers

offering homogeniser performance at a small fraction of the

cost

Homogenisation of batches can be done directly in the

vessel

Integrated pumping means no external high pressure

pumps

Dosing of additives into inline systems can be done at low

pressure - cheaper than with high pressure homogenisers

Few moving parts and simple maintenance means lower

running costs and total cost of ownership


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CDDM is a proprietary technology developed and patented by

Unilever plc and licensed to Maelstrom. It combined elements

of high pressure homogenisation with inter-cavity transferprinciples to provide an ultra-high performance inline dispersion

system beyond the capabilities of the traditional homogeniser.

Essentially, CDDM machines are inline cylindrical rotor-stator

mixing devices with high pressure feed pumps. Rotational

speeds are very high.

CDDM CONTROLLABLEDEFORMATION DYNAMIC MIXINGTECHNOLOGY

WHAT IS IT?

CDDM is ideally suited to liquid-liquid and solid-liquid dispersions

where droplet and particle sizes need to be smaller than can be

achieved using high pressure and ultrasonic homogenisers or

where multiple streams need to be well mixed. High throughput

dilution of super-concentrates is another ideal application. All

industrial sectors can benefit from CDDM technology although

customers in the food and personal care sectors who compete

directly with Unilever may not be eligible as users.

WHAT IS IT FOR?

HOW DOES IT WORK?

CDDM combines the principles of multi-stage high pressure

homogenisation with inter-cavity transfer mixing to create an

extremely high performance dispersive and distributive inlinemixer.

The form of the CDDM can be customised to suit individual

requirements but normally comprises a cylindrical rotor (which

may contain heating or cooling channels) within a cylindrical

stator (that may be jacketed for external heating or cooling).

The rotor is turned at high speed, usually greater than 5000rpm.

As the gap between the rotor and stator is typically less than

100 microns, very precise bearings and seals must be used and

rotor balance is critical.

A high pressure pump (external to the mixer) forces fluid

into one end of the rotor-stator pair. Fluid moves within and

between the cavities of the rotor and stator in a similar way

to that seen in the FDM, i.e. with cutting and folding and

turbulent shearing actions for good dispersion and distributive

mixing. When the fluid reaches the far end of each rotor-stator

cavity pair, it must travel through a very tight gap (nip) in order

to progress to the next cavity pair. This nip can be adjusted

by altering the relative axial positions of the rotor and stator to

obtain a virtual nozzle effect. In sophisticated applications,

CDDM machines incorporate a mechanism to adjust the nip on

the fly in real time. Simpler or well-characterised applications,

such as those for continuous production, can use less complex

CDDM machines with a fixed nip.

The virtual nozzles provide extensional stressing to the fluid in

the same way as a nozzle homogeniser. However, as there are

multiple nozzles in the CDDM, the effect is multiplied.

WHAT ARE THE ADVANTAGES?

Extremely tight running clearances and high rotational

speeds deliver exceptional levels of inline dispersion energy

on a sustained basis. Ideal for nanomaterial dispersions and

emulsions.

Production-ready machines are available with capacities over

1 tonne/hour - the technology is not confined to research

Maelstrom can provide complete solutions from automated

dosing, pumping and mixing through to drives, controls and

system integration to maximise returns on investment

Over 20 years of R&D is invested in CDDM, making it a

thoroughly developed and characterised, cost-effective

technology with low barriers to entry

AVAILABILITY

The licensing restrictions and specialised nature of

CDDM machines mean that they are customised to each

application. Please contact Maelstrom directly to discuss your

requirements.

Dosinginjectors

Rotationalspeed

>5000rpm

Rotor-statorgap


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Bringing the unique FDM high shear

mixing performance to the laboratory

bench, the DB25 is both a flexible

laboratory tool and a test bed forscaling larger machines.

Simple stirrers and agitators are

useful tools in the lab but for fast,

effective dispersion of powders, de-

agglomeration of suspended solids,

emulsification and a range of other

difficult processes, a high shear

mixer is the correct tool for the job.

The DB25 allows confident scaling

of lab processes to production

volumes by using a scaled version

of a geometry which is common to

all larger DB machines.

Up to five times the energy input of other high shear mixers ensures excellent all-

round mixing performance and the ability to interchange mixing heads means that

the DB25 can cope with a wide range of fluid volumes and mixing problems.

Special versions of DB25 using air motors are available for hazardous environments

whilst hygienic food and pharmaceutical applications are catered for with cleanable

design and autoclavable head and shaft assemblies.

Careful, intelligent design and use of state-of-the-art mixing technology make the

DB25 the ideal general mixing partner in the laboratory.

Dispersing

Homogenising

Rapid blending

De-agglomerating

Emulsifying

Reacting

Powder addition

DB25LABORATORY FDM BATCH MIXER

MaelstromAdvanced Process Technologies

DB25STANDARD

DB25WITH 50MM HEAD OPTION

Nominal rotor diameter mm 25 50

Rotor speed (typical) rpm 1500 to 15000

Typical minimum mixing volume at

low viscosity (e.g. water)litres (gals)

0.5 (1/8) 1 (1/4)Typical maximum mixing volume atlow viscosity (e.g. water)

litres (gals) 10 (2.5) 20 (5)

Typical maximum mixing volume athigh viscosity (e.g. thick cream)*

litres (gals) 4 (1) 8 (2)

Viscosity range (approx.) cP (Pa.s) 0.1 (0.0001) to 30000 (30)

Materials of construction 316 stainless steel wetted parts with polymer bush bearing

Control & InstrumentationPower ON/OFF, Mixer START/STOP, speed control pot.,LCD displays of power (load) and speed, optional PC link

Weight** kg (lbs) 25 (55)

Motor power kW (hp) 0.4 (0.5)

Electrical 240V/120Vac, fused, 500W max.Approvals / Certification (standard) CE marking (Europe), UL/ASME components (US) + others

* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required.** Excluding control panel

SPECIFICATIONS


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CODE DETAILS

DB25-50 50mm mixing headFor mixing larger volumes, a 50mm rotor and stator can beinterchangeably fitted to the DB25

DB25-ROT-SSDB25-ROT-TSDB25-ROT-ZR

Spare rotorSS - 316 stainless steelTS - 400 series toolsteel - 5x improved wearZR - zirconia - 10x improved wear

Other materials are available on requestincluding Hastelloy and titanium

DB25-P Datalogging portA serial connection port fitted to the DB25 control panelallowing load and speed data signals (0-10V) to be fed to aPC datalogger. Note that this option must be specified at thetime of ordering.

LAB-USB USB data interfaceMulti-channel external data acquisition device with USB

connection to a PC to allow logging of load and speed data.Basic Windows datalogging software included. Note thatoption DB25-P is required.

LAB-CBL Datalogging interface cableSerial connection cable linking the DB25-P port to the LAB-USB interface.

LAB-XL Excel datalogging upgradeUpgrade to the basic datalogging software of the LAB-USB option to enable data export to Microsoft Excel fordetailed analysis.

DB25 _1 2

Model

DB25

Type

E - electric lift

M - manual lift

F - flameproof/ATEX option(manual lift)

EXAMPLE

DB25E means a DB25 mixer with electric lift.

PART CODES AND ORDERING DB25LABORATORY FDM BATCH MIXER

CODE

POSITION

DETAILS

2 TypeThe DB25 motor, shaft and head assembly can be movedvertically up and down to enable easy insertion of the mixinghead in a vessel. The mixer can be provided with an electriclift (E) with motorised up/down movement controlled by aswitch on the control panel. Alternatively, a manual lift (M)

allows the user to raise and lower the head with the supportof a balanced gas strut and clamp. The flameproof/ATEXoption (F) has a manual lift with an air motor main drive andother special features to ensure compliance with the relevanthazardous area legislation. Please contact Maelstrom formore details of the DB25F.

OPTIONS AND ACCESSORIES

SS - 316 stainless(standard)

ZR - zirconiaceramic

TS - toolsteel


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DB_ _ _-_-_-_ _ _ _ _ _ _

Seal FlushOUT

FlushIN

Filler &levelgauge Quench

cup

Lip or V-ring Seal Double Mech. SealSingle Mech. Seal

1 2 3 5 6 7 8Model

DB Size

_75

100125150175200

Cavity rows

-2-3-3-4

Mounting

F - flange

P - pedestal

C - crane hoist

B - bottom entry

High flow option

N - no high-flow

F - high flow impeller

Seal

N - no seal

L - lip (dust) seal

S - single mechanical

D - double mechanical

Special options

N - no special options

H - hygienic option

F - flameproof/ATEX option

EXAMPLE

DB125-2-3-110FFNH means a DB mixer with

125mm diameter rotor, 2 cavity rows on the

stator and 3 on the rotor, 11kW motor, flange

mounted with high flow impeller, no seal.

Special hygienic design option included.

PART CODES AND ORDERING DB75-200PRODUCTION FDM BATCH MIXERS

Vented top plate

Impeller

3 row rotor

2 row stator

Impeller Types

Crane hoist Pedestal Bridge

Bottom entry

2 row stator3 row rotor


4

Motor size

In kW x 10

CODEPOSITION

DETAILS

3 Cavity rowsThe number of rows of mixing cavities onthe stator and the rotor. A 2-3 configurationgives more pumping (agitation) and less mixingwhilst a 3-4 option provides the opposite.

5 MountingThe mixer can be mounted above a vessel ona bridge using a simple flat flange plate (F) orit can be mounted directly onto the top of alidded vessel using a pedestal (P).A crane hoist mount (C) allows the mixer tobe suspended above the vessel for frequentremoval whilst a bottom-entry mounting (B)enables the mixer to be fitted into the vesselfrom underneath using a mechanical seal.

6 High flow optionThe unique design of the DB mixing head allowsan axial flow impeller (F) to be mounted on theupper surface of the rotor. This can providegreatly increased agitation for low viscosityfluids in the vessel where it is impractical orexpensive to use a separate impeller/stirrer toimprove batch uniformity.

7 SealA seal can be selected for a pedestal mountedmixer. A lip (dust) seal (L) is suitable fornon-critical, non-pressurised applications

whereas a single (S) or double (D) mechanicalseal is needed for pressurised, hygienic andtoxic applications. A bottom entry mountedmixer must be fitted with a single or doublemechanical seal.There are many options relating to sealsincluding materials of construction, pressureratings, hygienic assessment ratings etc.Please contact Maelstrom for advice on sealselection for a particular application.

8 Special optionsMachines designed specifically for hygienic (H)and flameproof/ATEX (F) applications.


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For consistent, repeatable

mixing results in the laboratory,

the DC50 inline high shear

mixer is hard to beat. Using

high performance FDM high

shear technology in a simple,

convenient benchtop format,

many common laboratory mixing

tasks can be performed with the

minimum of effort.

Whilst batch mixers are very

familiar and convenient for small vessels, ensuring that all of the mixture has

seen the same stress history and that the process can be reliably scaled up to

production levels demands inline mixing.

Simple, quick-release pipe couplings and excellent flushing/cleaning performance

are critical to ease of use in the lab. Combined with a powerful and flexible

electric motor and controller and discrete fluid injection port, the DC50 offers all

of these features and many more, making it simply the easiest and most flexible

inline high shear mixer to use in the lab environment.

Special versions of DC50 are available for hazardous environments and dedicated

hygienic food and pharmaceutical applications.

Dispersing

Homogenising

Rapid blending

De-agglomerating

Emulsifying

Reacting

Diluting

DC50LABORATORY FDM INLINE MIXER


DC50

Nominal rotor diameter mm (inch) 50 (2)

Rotor maximum speed (typical) rpm 6000*

Typical maximum flowrate litres/hr (gpm) 800 (3.5)


Ports1 diameter inlet and outletRJT, Triclamp, threaded and ANSI options

Materials of construction316 stainless steel wetted parts with stainlesssteel baseplate and aluminium bearing housing

SealSingle component mechanical seal with carbon/ceramic faces and Viton o-rings (EPDM option)

Control & Instrumentation(optional)

Power ON/OFF, Mixer START/STOP, speed controlpot., LCD control panel, optional PC link



Electrical (typical values)

Motor only: 3 phase 240Vac, 50/60Hz,

Optional controller: 1 phase, 240Vac, 50/60Hz

Approvals / Certification(standard)

CE marking (Europe), UL/ASME components (US)+ others

* Using optional frequency inverter/speed controller at 100Hz.** Excluding control panel

SPECIFICATIONS


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DC50-_-_-_ _ _ _1

Model

DC50

DC50-4-4-11SH means a DC50 mixer

with 4 cavity rows on the rotor and

stator, 1.1kW motor, a single mechanical

seal and hygienic design option.

PART CODES AND ORDERING DC50LABORATORY FDM INLINE MIXER

CODE

POSITION

DETAILS

2 Cavity rowsThe number of rows of mixing cavities on the statorand the rotor. A 2-3 configuration gives lowerstress than the standard 4-4 option for materialsthat are more sensitive to shear.

4 SealA single mechanical seal (S) is fitted as standardbut a double (flushed) mechanical seal (D) can bespecified, if required.

5 Special optionsMachines designed specifically for hygienic (H) andflameproof/ATEX (F) applications.

Note that although the DC50 will provide some centrifugal pumping action for low viscosity fluids, additional upstream pumpingis highly recommended to ensure independent control of flowrate and mixing speed for best performance.

2

Cavity rows

-2-3

-4-4

Seal

S - single mechanicalD - double mechanical

4 5

Special options


H - hygienic option


3

Motor SizeIn kW x 10

TRUE

INLINE

MIXING

RECIRCULATING

BATCH

MIXING

MULTI-PASS

INLINE

MIXING

RECOMMENDED SYSTEM CONFIGURATIONS

DC50

MIXERDC50

MIXER

DC50

MIXER

PUMP PUMP


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EXAMPLE

DCL200-4-4DH means aDCL200 mixer with 4 rows of

cavities in the rotor and stator,

double mechanical seal and

hygienic design option.

PART CODES AND ORDERING DCL100-350ULTRA-LOW SHEAR FDM INLINE MIXER

CODE

POSITION

DETAILS

3 Cavity rowsThe number of rows of mixing cavities on the statorand the rotor. A 2-3 configuration gives lowerstress than the standard 4-4 option, for materialsthat are more sensitive to shear and which mayrequire very light processing. The 4-4 option is

standard.

5 SealA single mechanical seal (S) is fitted as standardbut a double (flushed) mechanical seal (D), stuffingbox with gland packing (B) or reverse pumpinggroove (R) can be specified, if required. The choiceof seal depends on how the mixer is used and thelubricating/cooling properties of the process fluid.

6 Special optionsMachines designed specifically for hygienic (H) andflameproof/ATEX (F) applications.

Seal


B - stuffing box

R - reverse pumping groove

Note that as the DCL range is designed to provide a pure low shear mixing action and cannot be assumedto provide any pumped pressure. An upstream pump suited to the viscosity of the process fluid is required in all cases.

EXTRUDER FED DCL

(PLASTICS)


DCL

MIXER

GEAR PUMP FED DCL

(PASTES)

DCL

MIXER

DCL_ _ _-_-_-_ _ _ _ _1 3

Model

DCL

Cavity rows

-2-3

-4-4

5 6

Special options


H - hygienic option


2

Size100150

200250300350

4



20/2920

The IBV40 makes it possible to homogenise small volumes

of fluids inside the vessel. In a laboratory environment,

the ability to perform homogenisation and emulsification

in a beaker has traditionally been the domain of rotor-

stator (high shear) mixers but these cannot produce the

results of nozzle homogenisation.

Using Maelstroms unique, patented IPM technology,

the IBV40 combines internal pumping with integrated

nozzles to bring new levels of batch mixing performance

to the benchtop. Smaller droplet and particle sizes

with narrower size ranges allow finer and more stable

emulsions and dispersions to be formed directly in the

vessel. The results are easily scalable too, with larger

batch and inline IPM mixers able to translate laboratory

processes into the factory.

IBV40 machines are supplied with a separate controller

boasting infinitely variable speed, displays of both speed and load and optional outputs

to datalogging software.

In terms of both performance and versatility, the IBV40 package is the ideal

homogenisation partner in the laboratory.

Emulsifying

Homogenising

De-agglomerating1

Stabilising

IBV40LABORATORY IPM BATCH MIXER


IBV40

Nominal rotor diameter mm 40

Rotor speed (typical max.) rpm 1500

Typical minimum mixing volume atlow viscosity (e.g. water)

litres (gals) 0.5 (0.13)

Typical maximum mixing volume at

low viscosity (e.g. water)litres (gals)

5 (1.25)Typical maximum mixing volume athigh viscosity (e.g. thick cream)*

litres (gals) 3 (0.8)


Materials of construction 316 stainless steel wetted parts + PEEK vanes & bearings

Control & InstrumentationPower ON/OFF, Mixer START/STOP, speed control pot.,LCD displays of power (load) and speed, optional PC link



Electrical controls 240V/120Vac, fused, 2000W max.

Approvals / Certification (standard) CE marking (Europe), UL/ASME components (US) + others

* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required.** Excluding control panel

SPECIFICATIONS

1 The sliding nature of internal components makes

the IBV40 unsuited to the processing of hard orabrasive solids.


21/2921

CODE DETAILS

IBV40-P Datalogging portA serial connection port fitted to theIBV40 control panel allowing load andspeed data signals (0-10V) to be fed to aPC datalogger. Note that this option mustbe specified at the time of ordering.

LAB-USB USB data interfaceMulti-channel external data acquisitiondevice with USB connection to a PC toallow logging of load and speed data.Basic Windows datalogging softwareincluded. Note that option IBV40-P isrequired.

LAB-CBL Datalogging interface cableSerial connection cable linking the IBV40-P port to the LAB-USB interface.

LAB-XL Excel datalogging upgradeUpgrade to the basic dataloggingsoftware of the LAB-USB option toenable data export to Microsoft Excelfor detailed analysis.

IBV40IBV40 laboratory batch IPM mixer

1.0mm diameter nozzle rotor

1.1kW 4-pole induction motor

Single mechanical shaft seal

Stainless steel base and support column

Separate control panel with speed control

and digital speed and load displays

Cables and user manual

PART CODES AND ORDERING IBV40LABORATORY IPM BATCH MIXER

0.5mm 1.0mm 2.5mm

VSP TBP RBP

OPTIONS AND ACCESSORIES

SPARESCODE SPARES

IBV40-ROT Rotor (Central Element)The rotor carries the nozzles which providethe extensional stressing action of the IBVmachine. Rotors with different nozzle diametersare available to suit particular fluid viscosities.

IBV40-VSP

IBV40-TBP

IBV40-RBP

Vane set - PEEKSpare set of 8 vanes in PEEK polymer

Thrust bearings - PEEKSpare set of 2 thrust bearings in PEEK polymer

Radial bearings - PEEKSpare set of 2 radial bearings in PEEK polymer


22/2922

The IBV range of production IPM batch mixers provides

multi-nozzle homogenisation of fluids directly in the vessel.

Delivering dispersion and shearing performance between

that of high pressure homogenisers and rotor-stator high

shear mixers, IBV machines offer a unique combination of

performance and flexibility at a very competitive price.

Improved emulsion stability, shelf-life and texture results

from reducing the droplet size of the dispersed phase.

IBV mixers can be used to achieve droplet sizes down to

1 micron in typical oil/water systems with a very narrow

range of sizes across the sample, compared to the typical

3-5 micron range for a rotor-stator mixer.

IPM technology is based on an arrangement of multiple

nozzles combined with a vane pumping effect that enables

mixers to develop high levels of extensional fluid stress as

fluid is pressurised through the nozzles. This stress breaks

up droplets in a similar way to high pressure homogenisers

which is why IBV mixers are so effective, even without the

expensive high pressure pumps that are the key feature

of the traditional inline homogeniser. The self-pumping nature of the mixing head

is also what makes it suitable for use as a batch machine, meaning that all of the

homogenisation benefits are available in batch processes.

Emulsifying

Homogenising

De-agglomerating1

Stabilising

IBV60-100PRODUCTION IPM BATCH MIXERS


IBV60 IBV100


Typical maximum mixing volume atlow viscosity (e.g. water)

litres 200 1000

gals 50 250

Typical maximum mixing volume athigh viscosity (e.g. thick cream)*

litres 50 250

gals 15 65Viscosity range (approx.) Pa.s (cP) 0.0001 (0.1) - 30 (30,000)

Weight**kg 33 65

lbs 73 145

Motor power range (standard**)kW 5.5 25

hp 3 7.5


Approvals / Certification (standard)CE marking (Europe), UL/ASME components (US)

+ others

* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required .** Typical for alloy motors. Larger and non-standard motors available on request

MODEL RANGE

1 The sliding nature of internal components makes

IBV mixers unsuited to the processing of hard orabrasive solids.


23/2923

IBV_ _ _-_ _ _ _ _1 2 4 5

Model

IBV Size

_60

100Mounting

F - flange

P - pedestal

C - crane hoist

High flow option

N - no high-flow

F - high flow impeller

EXAMPLE

IBV60-55PF means an IBV60 mixer with 5.5kW

motor, pedestal mounted with high flow impeller.

Single mechanical seal fitted within mixing head.

PART CODES AND ORDERING IBV60-100PRODUCTION IPM BATCH MIXERS

CODE

POSITION

DETAILS

4 MountingThe mixer can be mounted above a vessel ona bridge using a simple flat flange plate (F) orit can be mounted directly onto the top of alidded vessel using a pedestal (P). Note thatthe mechanical seal is mounted inside themmixing head so that only a static seal (o-ring) isneeded for the mixer shaft as it passes throughthe vessel wall or lid.A crane hoist mount (C) allows the mixer tobe suspended above the vessel for frequentremoval.

5 High flow optionThe design of the IBV mixing head allows thedriveshaft to be extended through the centre ofthe mixer and a radial impeller (F) to be fitted toit. The impeller can provide greatly increasedagitation for low viscosity fluids in the vesselwhere it is impractical or expensive to use aseparate impeller/stirrer to improve batchuniformity.

Crane hoist Pedestal Bridge

3

Motor size

In kW x 10

1mm 2.5mm 5mm

VSP TBP RBP

SPARESCODE SPARES

IBVxxx-ROT Rotor (Central Element)The rotor carries the nozzles which providethe extensional stressing action of the IBV

machine. Rotors with different nozzle diametersare available to suit particular fluid viscosities.

IBVxxx-VSP

IBVxxx-TBP

IBVxxx-RBP



Radial bearings - PEEKSpare set of 2 radial bearings in PEEK polymer


24/29


25/2925

ICV40-11_ _1

Model

ICV40

EXAMPLE

ICV40-11SH means an ICV40 mixer

with 1.1kW motor, a single mechanical


PART CODES AND ORDERING ICV40LABORATORY IPM INLINE MIXER

2

Seal


4

Special options


H - hygienic option


3


CODE

POSITION

DETAILS

3 SealA single mechanical seal (S) is fitted as standardbut a double (flushed) mechanical seal (D) canbe specified, if required.

4 Special optionsMachines designed specifically for hygienic (H)and flameproof/ATEX (F) applications.

0.5mm 1.0mm 2.5mm

VSP TBP RBP

CODE SPARES

ICVxxx-ROT Rotor (Central Element)The rotor carries the nozzles which providethe extensional stressing action of the ICVmachine. Rotors with different nozzle diametersare available to suit particular fluid viscosities.

ICVxxx-VSP

ICVxxx-TBP

ICVxxx-RBP



Radial bearings - PEEK

Spare set of 2 radial bearings in PEEK polymer

TRUE

INLINE

MIXING

RECIRCULATING

BATCH

MIXING

MULTI-PASS

INLINE

MIXING


PUMP

ICV40

MIXER

ICV40

MIXERPUMP

ICV40

MIXER


26/2926

Bridging the gap between high

shear rotor-stator mixers and high

pressure nozzle homogenisers,

ICV mixers provide exceptionalmixing performance at a low

price point.

High flow rates and efficient

mixing energy transfer are

key benefits of Maelstroms

proprietary IPM mixing

technology, making ICV

machines ideally suited to

a wide range of emulsification and homogenisation tasks. IPM combines

shear, extensional flow and impact stress mechanisms with an integral positive

displacement pumping action to ensure that all fluid passing through the mixing

head experiences the same levels of stress. This results in finer droplets and

particles with a narrower dispersion range normally associated with high pressure

homogenisers. Typical droplet sizes down to 1-2 microns are achievable in oil/

water systems without emulsifying agents.

Simple operation and integrated pumping action make ICV mixers simple to

integrate into most production processes and maintenance costs are low

due to the user of low-cost polymer wear parts and quick-assembly modular

construction. ICV machines are offered with either single or double mechanical

seals and a range of options including special hygienic design features for food

and pharmaceutical use.

Emulsifying

Homogenising

De-agglomerating1

Stabilising

ICV60-100PRODUCTION IPM INLINE MIXERS


ICV60 ICV100


Typical maximum flowrate (water)litres/hr 4000 10000

gals/min 20 45

Viscosity range (approx.) Pa.s (cP) 0.0001 (0.1) - 100 (100,000)*

Ports (RJT, Triclamp and ANSI options) inch 1 2

Weight**kg 65 300

lbs 145 660

Motor power range (standard**)kW 5.5 30

hp 7.5 45


Approvals / Certification (standard)CE marking (Europe), UL/ASME components (US)

+ others

* For fluids towards that upper end of this viscosity range, the addition of a pump upstream of the mixer is highly recommended.** Typical for alloy motors. Larger and non-standard motors available on request*** Achievable using optional frequency inverter drive

MODEL RANGE

Note that although the ICV range will provide good positive displacement vane pumping action for low and medium viscosity fluids, additionalupstream pumping is highly recommended to ensure independent control of flowrate and mixing speed for best performance. Care must betaken in specifying pumps that match or exceed the flowrate of the ICV machine to avoid starvation at the ICV inlet.

1 The sliding nature of internal components makesICV mixers unsuited to the processing of hard or

abrasive solids.


27/2927

ICV_ _ _-_ _ _ _ _1 3

Model

ICV

Motor size

In kW x 10

EXAMPLE

ICV100-300SH means an ICV100 mixer

with 30kW motor, single mechanical


PART CODES AND ORDERING ICV60-100PRODUCTION IPM INLINE MIXERS

CODE

POSITION

DETAILS

5 SealA single mechanical seal (S) is fitted as standardbut a double (flushed) mechanical seal (D) canbe specified, if required.

6 Special optionsMachines designed specifically for hygienic (H)applications.

Seal


4 5

Special options


H - hygienic option

TRUE

INLINE

MIXING

RECIRCULATING

BATCH

MIXING

MULTI-PASS

INLINE

MIXING


2

Size

_60100

CODE SPARES

ICVxxx-ROT Rotor (Central Element)The rotor carries the nozzles which provide theextensional stressing action of the ICV machine.Rotors with different nozzle diameters areavailable to suit particular fluid viscosities.

ICVxxx-VSP

ICVxxx-TBP

ICVxxx-RBP



Radial bearings - PEEK

Spare set of 2 radial bearings in PEEK polymer

1mm 2.5mm 5mm

VSP TBP RBP

PUMP

ICV

MIXER

ICV

MIXERPUMP

ICV

MIXER


28/29


29/29

HEAD OFFICE

Maelstrom Advanced Process Technologies LtdFirst Floor59-61 High Street WestGlossop

Derbyshire SK13 8AZUnited Kingdom

LICENSEES / DISTRIBUTORS

Japan

Satake Chemical Equipment Mfg. Ltd66 NiizoToda-shiSaitama 335-0021

Japan

China

Yiyang Rubber & Plastics Machinery Group Co. Ltd(part of ChemChina Group)64 Huilong RoadYiyangHunanChina

India

Chempro Technovation Pvt. Ltd3 Sukhshine Complex, Sunrise ParkDrive-In RoadAhmedabad 380054GujaratIndia

Tel:Fax:email:web:

Tel:Fax:email:web:

Tel:Fax:web:

+81 48 433 8711+81 48 433 8541www.satake.co.jp

+86 737 429 9404+86 737 429 [email protected]

+91 079 268 51135+91 079 268 [email protected]

Tel:Fax:email:web:

+44 (0)1457 867777+44 (0)1457 [email protected]

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