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.
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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.
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