STATIC MIXING TECHNOLOGY

For over 30 years, in thousands

of installations worldwide,

Kenics® Static Mixers have set

the standard for in-line mixing

and heat transfer performance.

Chemineer incorporates ad-

vanced technology into every

Kenics Mixer to give you reli-

able, uninterrupted performance

that you can depend on for the

long term. The result: maximum

operating efficiency and overall

cost savings.

In the KM Static Mixer, a patentedhelical mixing element directs theflow of material radially toward thepipe walls and back to the center.Additional velocity reversal and flowdivision result from combining alter-nating right- and left-hand elements,increasing mixing efficiency. Allmaterial is continuously and com-pletely mixed, eliminating radial gra-dients in temperature, velocity andmaterial composition.

In the HEV Static Mixer, the patented tab geometry maximizes the conversion of turbulent energyinto efficient mixing. The HEV pro-duces complete stream uniformitythrough controlled vortex structuresgenerated by the mixing elements.

PRINCIPLES OF OPERATION

The element geometry takes advan-tage of the naturally occurring vor-tices induced by the element edges.

These mixing principles result in anapplications technology that can beeasily reproduced and reliably

scaled. Numerous independent stud-ies have shown Kenics Static Mixersmaximize mixing efficiency —withoutthe wasted energy and materialblockage typically found in morerestrictive motionless mixers.

PRODUCTINNOVATION

2

KM Static Mixer

HEV Static Mixer

Side view

Front view

MIXINGAPPLICATIONS

Kenics Mixers provide preciseblending and dispersion of all flow-able materials, with no movingparts, by redirecting the flow pat-terns present in the open pipe.Many applications in the chemical,refining, polymer, food, pulp andpaper, water and wastewater treat-ment and other major processingindustries have shown significantimprovements in processing speed,control and cost savings usingKenics Mixers. These high-efficien-cy mixers also handle other criticalprocesses such as:

Heating/Cooling

Kenics Mixers dramatically boostheat transfer rates over those typically found in open pipe underboth laminar and turbulent flow conditions.

Residence Time Control

By eliminating the parabolic velo-city profile characteristic of laminarflow in open pipes, the helical ele-ment of Kenics Mixers promotesplug flow in continuous processes.

Temperature Uniformity

The radial mixing action of the KM elements rapidly eliminates temperature gradients, reducing fouling and thermal degradation.

3

Turbulent Blending HEV Static Mixer

Each tab of the HEV StaticMixer generates a pair ofstreamwise counter-rotat-ing vortices that producevigorous cross-stream mix-ing and rapid uniformity.

Turbulent Blending KM Static Mixer

The KM Static Mixer pro-duces rapid mixing by inducing circular patternsthat reverse direction ateach element intersection.

Laminar Blending KM Static Mixer

The alternating helical elements of the KM StaticMixer continually divide,stretch and reorient the flow stream to produce complete mixing with mini-mum pressure drop.

Liquid/Liquid Dispersion

The uniform turbulent shear field of the KM Mixer quicklydisperses immiscible liquids and produces a narrow drop size distribution.

Gas/Liquid Dispersion

Gases can be incorporatedinto turbulent liquids usingthe KM Static Mixer. Masstransfer rates are dramati-cally enhanced to maximizeabsorption or reaction.

Kenics KM Series Static Mixers feature a patented helical mixing element which produces completeradial mixing and flow division for any combination of liquids, gases, or solids.

Adapts to any piping system

Mixer dimensions match all stan-dard pipe sizes. Mixer housingsfeature plain, threaded, weld prepor flanged ends for easy installa-tion. Flange styles include raisedface slip-ons, weld neck, lap joint ,ring joint and Grayloc-type hubsin all standard pressure ratings.Mixers are available in carbonsteel, 304SS, 304LSS, 316SS,316LSS, Alloy 20 Cb-3, Titanium,Monel 400, Nickel 200, Inconel,Hastelloy C-276, Hastelloy B-2, FRP, PVC, CPVC, PTFE, Kynar, PVDF, Tantalum, Zirconium and other high alloys.

Fixed Element — KMS

• Used for laminar, transitional,and turbulent flow applications;suitable for most blending ordispersion problems involvingliquids or gases

• Mixing elements are attached to the housing wall

Removable Element — KMR

• Used for laminar, transitional,and turbulent flow applicationswhere periodic cleaning orinspection is required; suitablefor most blending or dispersionproblems involving liquidsor gases

• Mixing elements are easilyremoved from housing

Element Assembly — KMA

• Mixing elements are inserted in the customer’s existing housing

• Precisely controlled to assure proper fit and ease of installationin any standard or custom pipe size

Edge-Sealed Element — KME

• Used for maximum heat transfer,polymer reactors, certain fibrousapplications, and mixing liquids with wide viscosity ratios

• Mixing element edges are furnace-brazed to the housing wall eliminat-ing dead areas

• Continuous joining of elements to the housing eliminates wall clear-ance to maximize heat conductionand minimize thermal degradationor fouling

• Available with internal surface finishes down to 8 microinches

Construction options include:

• ASME/B31.3 certification and testing

• Design pressures to over 10,000 psi

• Jackets, nozzles, fittings

• Complete custom fabrication

• Diameters to over 8 feet

KM SERIESSTATIC MIXERS

4

HEVSTATIC MIXERS

HEV high-efficiency static mixers handle all turbulent-flow mixing applications regardless of line size or shape. Mixing is accomplished bycontrolled vortex structures generated by the patented low-profile tab geometry. This providesuniform blending while limiting mixerlength to less than 1-1/2 pipe dia-meters. Complete mixing is achievedwith pressure losses 75% less thanconventional static mixers.

Typical applications for the HEVinclude all low-viscosity liquid-liquidblending processes, as well as gas-gas mixing. The HEV is ideal forprocesses where pressure loss andlength are critical.

HEV Static Mixerfeatures include:

• Lowest pressure drop available

• Unlimited sizes and shapes

• Shortest possible mixer length

• Easy retrofit to existing lines

• Available in all metals and alloys,FRP, PVC, PFA, and epoxy-coated steel

HEV static mixers provide installationflexibility and can be configured tosquare, rectangular or 3-sided ducts.They are adaptable to open chan-nels typically found in water treat-ment systems.

5

TECHNOLOGYDEVELOPMENT

From bench to production, KenicsStatic Mixers provide you with themixer performance to match yourprocess needs. Your guaranteedsatisfaction is the result of theadvanced technologies we use toanalyze and solve your mixingproblems.

RESEARCH LABThorough understanding of funda-mental fluid mechanics principles is a necessary starting point fordeveloping effective mixing equip-ment. In our state-of-the-art testlab, we use the latest technology to evaluate mixer concepts andgenerate the next evolution ofequipment to handle your most difficult mixing challenges.

Computational Fluid Mixing (CFM)

CFM analysis of the flow field isused to confirm and optimize the operating characteristics of mixing elements.

Digital Particle Image Velocimetry (DPIV)

DPIV, a laser-based analyticaltool used to validate computermixing models, has the capabilityof measuring the entire fluid velo-city field almost instantaneously.This makes it possible to studylarge-scale, time-dependent phenomena responsible for muchof the mixing process.

Laser Induced Fluorescence (LIF)

LIF is a computer-controlled dataacquisition technique used todetermine mixing uniformity.Because LIF allows you to “see”what is taking place inside theflow field, geometry parameterscan be evaluated to optimizeprocess performance.

6

Temperature Uniformity

Kenics Mixers eliminate hot or cold spots typical of flow in openpipes. Improved thermal uniformityoptimizes process performance.

10 102 103 104

1.0

0.1

0.01

.001

We

D

D

D = Sauter Mean DropsizeD = Pipe I.D.We = Weber Number

1

1000

100

10

1

10 50 100Q

P

Kenics

D=150mmSG=1.0µ=1.0 cP

Others

1

2

Guaranteed Mixing Uniformity

The standard technique used formeasuring the degree of mixingin pipe flow is the coefficient of variation, CoV. The coefficient of variation is the ratio of the standarddeviation of component concentra-tion to its mean concentration. Thecoefficient of variation achieved atthe mixer discharge is dependenton the inlet coefficient of variation(CoV)

˚. The initial coefficient of vari-

ation is defined as:

(CoV)˚

= [ 1-Va]1/2

Va

where Va is the volume fraction ofthe stream added. To allow plottingagainst geometrical factors such aselement style, as well as Reynoldsnumber, a normalized coefficient ofvariation is defined as:

CoV(CoV)

˚

The correlations Chemineer hasdeveloped through fundamentalresearch, as well as years ofoperating experience, allow us toaccurately predict mixer perfor-mance and offer you 100% guar-anteed results.

0.100

0.010

0.001

1000 100 000 1 000 000Re

C

oV

/ C

oV

o

.0001

10 000

HEV-4

T1

Typical Viscous Flow Profile

T2

T1T2

Flow Profile In Kenics Static Mixer(T1 - T2) < (T1 - T2)

0.1 2 0.1 2 1.0 2 10

10

1

With Mixer

Empty PipeNu

NRe

3-10 Times Improvement

1.0

0.8

0.6

0.4

0.2

00 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Empty Pipe

Ideal Plug Flow

KenicsStatic Mixer

θ, Dimensionless time

TECHNOLOGYAPPLICATION

Pressure Drop

The pressure drop through KenicsStatic Mixers is the lowest in theindustry resulting in reduced operating costs and increasedprocess capacity.

Drop Size Prediction

Accurate drop size prediction allows optimization of mass trans-fer controlled processes whileavoiding problems with down-stream separation equipment.

Heat Transfer

Exclusive edge-sealed mixing elements give Kenics HeatExchangers transfer rates up to 10 times greater than open tubes.

Reactor Engineering

By interrupting the parabolicvelocity profile characteristic ofopen pipe, Kenics Static Mixersproduce residence time distribu-tions approaching plug flow.

Mixing Uniformity

By analyzing the inlet stream conditions, final mixture quality can be predicted for all Kenics Mixer designs.

7

SPECIAL PURPOSEPRODUCTS

In addition to our standard staticmixer line, Chemineer manufac-tures a range of productsdesigned to meet your specializedprocess requirements.

Sanitary Mixers

• Polished internal and external surfaces

• Removable element assemblies for fast, easy cleaning

• Fitted with tri-clamp-style ferrules

• Available in five diameters from 1/2" to 4"

• 316L construction materials

• Meet 3A standards

• Request Bulletin 820

Pilot Plant Heat Exchangers

• Standard off-the-shelf design for immediate shipment

• Direct scale-up with 100% process warranty

• All stainless steel construction

• Can be used in pilot plants orslip streams to full-scale process

Heat Exchangers

• Used for process applications,including polymers, plastics, adhesives, hydrocarbonprocessing, and food industries

• Effective for both heating andcooling of viscous fluids

• Three-to-ten times greater transfer rates than empty tubes

• Boosts heat transfer with mini-mal flow disruption

• Custom fabrication toASME/TEMA standards

• Request Bulletin 808

Thermogenizers®

• Delivers uniformly mixed melt for extrusion applications

• Offers improved gauge control

• No radial temperature gradients

• Reduced color concentrateusage by improving mixtureuniformity

• One-piece design for easy installation and cleaning

• Request Bulletin 806

Tube Mixers

• Used for applications with low flow rates in full-scale and pilot plant operations

• Exclusive edge-sealed mixing elements attached to housing wall

• Plain ends accommodate a wide variety of common fittings

• Standard 22-gauge 316SS housings available in diametersfrom 3/16" to 1/2"

Tubular Reactors

• Continuous plug flow performance

• Single or multi-tube construction

• Continuous solution phase reac-tions and polymerizations

• High heat transfer rates with lowpressure drop

No matter what your process needs or system considerations,Kenics Static Mixers can handleyour mixing requirements.

8

CUSTOMERSERVICE & SUPPORT

Commitment to Quality

We manufacture Kenics StaticMixers and Heat Exchangers inour ISO 9001 certified facility inNorth Andover, Massachusetts.ISO certification allows us to offercustomers 100% guaranteedquality products, and representsour ongoing commitment to customer satisfaction.

Computerized ProcessOptimization

CEDS® (Chemineer Expert DesignSystem) is a comprehensive com-puter program developed byChemineer that interprets processdesign data and selects only thosemixers that it has verified for process and mechanical designintegrity. Chemineer field engineersuse this technology via laptop computers to provide you withimmediate design alternatives.

Sharing Our Technology

Our Applications Specialists are ready to bring the latest static mix-ing technology right to your frontdoor. Your process and develop-ment engineers are introduced tomixing principles for blending, dis-persion, heat transfer and reactordesign allowing them to optimizeplant operating performance.Contact your local ChemineerSales Engineer to arrange an in-house seminar.

9

Factory Services and Field Engineering

Every Kenics Static Mixer is backed by product and application engineering, a fully equipped mix-ing laboratory, and complete in-house manufacturing and qualitycontrol. Our process engineerscombine hands-on experiencewith fundamental technology toprovide you with optimal, cost-effective mixer performance.

Worldwide Distribution

Kenics Static Mixers are marketedglobally through locations in the United States, Canada,England, Mexico, Brazil, India,Singapore, China and Taiwan.Kenics worldwide distribution is ready to serve your mixing needs . . . anywhere . . . anytime.

PRODUCTAPPLICATIONS

Kenics Mixers are used in numer-ous industries for a variety of blend-ing, dispersion, heat transfer andresidence time control applications.

TYPICALAPPLICATIONS

Agricultural Chemicals

• Fertilizer and pesticide preparation

• Gas/liquid dispersion

• Dilution of feed concentrates

Chemicals

• Chlorination and oxidation

• Organic/aqueous dispersions

• Dilution of acids and bases

Cosmetics

• Heating slurries and pastes

• Additive blending

• Dispersion of oils

Energy

• Chemical addition for enhanced oil recovery

• Injection of geothermal steam

• Preheating coal/oil slurries

• NOX/SOX control

Foods

• Blending food constituents

• Washing fats and oils with acid

• Heating and cooling sugar solutions

• Starch slurry cooking

Pharmaceuticals

• Nutrient blending

• pH control

• Sterilization

Grain Processing

• Starch conversion

• Chemical addition

• Mud dilution

• Steam injection

Minerals Processing

• Metals recovery by solvent extraction

• Chemical addition and pH control

• Oxidation and bleaching

OEM

• Adhesive and epoxy dispensing systems

• Adhesives heating

• Monitoring and sampling systems

Paints & Resins

• Dilution of TiO2 slurries

• Coloring and tinting

• Solvent blending

Petrochemical & Refining

• Blending gaseous reactants

• Washing hydrocarbon streams

• Gas scrubbing

• Lube oil blending

• Crude oil sampling

Polymers & Plastics

• Blending reactants & catalysts

• Thermal homogenization

• Plug flow finishing reactors

• Preheating polymers prior to devolatization

Pulp & Paper

• Stock dilution and consistency control

• Chemical and coatings preparation

• pH control

• Pulp bleaching

Rubber Processing

• Blending latex compounds

• Adding pre-polymers and activators

• Heating and cooling adhesives

Textiles

• Blending additives

• Eliminating thermal gradients

• Heating and cooling polymers

• Achieving uniform heat history

Water & Waste Treatment

• Polymer dilution

• pH control

• Chemical addition and flash mixing

• Disinfection and aeration

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Name_______________________________________________________ Title__________________________

Address_____________________________________________________ Phone________________________

City_________________________________________________________ FAX__________________________

State/Zip____________________________________________________ E-Mail________________________

Process Description: Mixing or Dispersion

Units Stream 1 Stream 2 Stream 3 Mixture

Component Name ____________ ____________ ____________ ____________

Flow Rate ____________ ____________ ____________ ____________ ____________

Density ____________ ____________ ____________ ____________ ____________

Viscosity ____________ ____________ ____________ ____________ ____________

Temperature ____________ ____________ ____________ ____________ ____________

Pressure ____________ ____________ ____________ ____________ ____________

Liquid/Gas/Solids ____________ ____________ ____________ ____________

Process Requirement: ■■ Blending ■■ Dispersion ■■ Reaction ■■ Residence Time

Components Miscible: ■■ Yes ■■ No Interfacial Tension:______________

Required Droplet/Bubble Size:______________________ Allowable Pressure Drop:______________________

Process Description: Heating/CoolingSpecific Thermal Flow Gravity T, in T, out Viscosity Sp. Heat Cond. Rate

Process Fluid ________ ______ ______ ________ ________ ________ ______________

Heating/Cooling Fluid ________ ______ ______ ________ ________ ________ ______________

Allowable Pressure Drop: Jacket____________ Tube______________

Mechanical Design

Material of Construction:_________________________ Existing Line Size:______________________________

End Connections: ■■ Plain ■■ THD ■■ Flanged Type:__________ Class:_________________________

Design Temperature:____________________________ Design Pressure:_______________________________

Other Process Details/Special Requirements:______________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

Commercial Requirements:

Pricing: ■■ Budgetary ■■ Immediate Purchase

Delivery Requirement:____________________________

Response needed by: ■■ Today ■■ Tomorrow

■■ One Week ■■ Other______

Tel: 978-687-0101 Fax-Back Process Analysis Form FAX: 978-687-8500

Comments: ____________________________

______________________________________

______________________________________

______________________________________

Date________________ Items_______ of______

Item ref. _________________________________

_________________________________

B800

125 Flagship DriveNorth Andover, MA 01845Telephone (978) 687-0101Fax (978) 687-8500

For the nearest sales office call 1-800-643-0641

Visit our Website atwww.chemineer.comwww.kenics.com

Operating locations in:

Dayton, OH Mexico, D.F.North Andover, MA SingaporeDerby, England Taipei, Taiwan

Bulletin 800

10M-BK-7/98 LITHO IN U.S.A.

© 1998 by Robbins & Myers, Inc.® Kenics, Thermogenizer and CEDS are

registered trademarks of Robbins & Myers, Inc.