Agitated systems can benefit from the use of expert design software and CFD simulation as well as the use of high efficiency impellers to minimise energy consumption and reduce batch mixing times to achieve specific targeted objectives. Images below show multistage agitated cascade reaction vessels and a 3D CFD image modelling flow patterns in a gas liquid reactor.

Static mixer reaction systems can be employed in many traditionally batch processes. Static mixer reactors offer benefits in both capital cost, plant size and reaction selectivity. Image below shows a typical skid mounted continuous static mixer reactor system.

Flow regime	Mixer type	Image
Laminar (Reynolds<100)	KMX (structured) or KM (helical)
Transitional (Reynolds 100-5000)	KM (helical)
Turbulent (Reynolds >5000)	HEV Vortex inducing) or KM (helical)

Selection of the correct type of static mixer can reduce energy consumption by 3-4 times for the same quality
of mixing (CoV or Coefficient of Variation).

Choose the correct type of agitator impeller dependent on the flow regime:

Flow regime	Impeller type	Image
Laminar	Helix, anchor
Transitional	HE-3, MW4, 4P
Turbulent	HE-3, SC-3, MW4

Selecting the correct type of impeller for the duty and optimising the impeller diameter and speed can
potentially reduce energy consumption by up to 10 times for the same blend time.

Summary:

• Select the correct technology for the process objectives.
• Allow your supplier to select the correct type of static mixer for the process. Don’t assume that all
  static mixers are the same.
• Allow your supplier to select the correct type of agitator impeller, speed and diameter to minimise
  blend time and energy consumption. Don’t impose agitator specifications without expert advice.

Press Release

Bubble-Free
In-Tank Atmospheric Deaeration
with Reversible Homogenizer

The Greerco Reversible Homogenizer from Chemineer can produce high quality shampoos, gels, creams, and lotions – without the need for vacuum processing vessels or in-line vacuum deaeration devices.

Designed with atmospheric deaeration and flow-direction control, the Greerco Homogenizer is effective across a wide viscosity range, including both liquid and powder components, and has the flexibility to consistently produce bubble-free end-products in different batch sizes.

When the powder or liquid addition phase of the process is complete, the Homogenizer is switched to run briefly at full speed to fully homogenize the batch and completely disperse any remaining agglomerates.

At this point in the manufacturing, when the deflector plate is located precisely at the surface level of the liquid-at-rest, deaeration begins.

The operator adjusts the speed of the homogenizer to provide a smooth, laminar, non-splashing flow that moves 360 degrees away from the circular deflector plate. Entrained air bubbles are drawn up from the bottom of the batch and distributed gently at the surface of the liquid. After approximately 30 minutes of atmospheric pressure deaeration (depending on viscosity), the batch is fully deaerated.

In addition to the Greerco Homogenizer, Chemineer also designs and builds the Greerco Pipeline Mixer for use in continuous in-line homogenization, particle size reduction or dispersion, and also the Greerco Colloid Mill, which allows the user to easily modify the shear rate in batch, batch-continuous or in-line applications.

Press Release

Chemineer agitator expertise
set for Lucite International’s
new plant in Singapore

Key to promoting superior gas dispersion and mass transfer, as well as yielding more than conventional mixing arrangements, Chemineer’s MW4 and BT6 impellers are set to go into full operation at Lucite International’s soon-to-be opened Alpha 1 plant in Singapore.

The first in a series of new technology Alpha-based production facilities being built by Lucite International, the methyl methacrylate (MMA) producing plant on Jurong Island will see Chemineer’s specially developed impellers provide optimum gas-liquid operation for a Reactor Agitator.

Innovatively, Chemineer designed-in two moveable impellers, saving considerable weight on the impellers, giving far greater stability to the shaft.

Chemineer’s design for the Alpha 1 Project was carefully developed and detailed using state-of- the- art 3D CAD software integrated with FEA (finite element analysis). The 3D CAD then exported various component files to CAD/CAM in order to aid in the fabrication process.

Utilising ethylene as a starting material, this first Lucite International Alpha technology plant will produce methyl methacrylate (MMA) at a capacity of 120kte per annum.