In-line Mixing for Better Blends

https://www.chemicalprocessing.com/articles/2003/245/

The mixing of chemicals has come a long way. Once, the hand mixing of
large batches resulted in inconsistent mixes and waste. That was then. This
is now: Highly precise, computerized in-line machines make better-quality
emulsions, saving money on labor and transport.

A finer emulsion is just part of the picture. Even with a better-quality blend,
chemicals often are mixed in large batches, presenting storage,
transportation and degradation problems. Water is a large component of
many chemical mixtures and emulsions ," as much as 90 percent in most
cases ," so plants must devote considerable space and resources to storage.
It also costs more to transport these highly diluted chemicals. Some plants
do not have the capability to create these finishes on-site. Finally, large
quantities of stored chemicals are subject to degradation and bacteria
growth. Such large inventories often contribute to waste.

The textile industry began using technologies such as static (motionless)

mixing and in-line (continuous blend) mixing to address these challenges
and now is beginning to reap the rewards from the investments. The
lessons learned in textiles can be applied to many chemical processing
industries.

No moving parts

The first static mixers were developed in the 1960s. A static mixer has no
moving parts and works extremely well in creating emulsions ," stable
suspensions of one liquid in a second immiscible liquid. Static mixers create
stable emulsions because they reduce the particles to a smaller size so they
stay together in a stronger bond for a longer period of time.

Emulsion creation is critical to numerous chemical processes. In textiles,

emulsions are crucial to finishes ," chemical treatments applied to a yarn or
fabric to produce a desired effect. For example, chemical finishes can make
towels softer, slacks stain-resistant and blue jeans a deeper blue.

The diagram illustrates the setup of a typical in-line mixing system.

In general, static mixers work by dividing streams of ingredients that need

to be mixed. The ingredient stream typically is forced through the static
mixer by a pump. The ingredients then are split into substreams as they are
forced through the mixer. These substreams then are recombined and
divided once again. This process might be repeated numerous times.

The standard static mixer uses baffles to divide ingredients into two
streams, but some static mixing designs today divide ingredients into four
streams, creating a more homogenous mix. For example, if a stream of
water and a stream of chemical agent "A" were pumped into the static
mixer, the stream of water and the stream of agent A each would be
divided into four streams. These four streams would be recombined and
forced through the static mixer again. The four streams would be divided
into 16 streams, and so on.
Mathematically, the equation is: N = 4n, where 4 is the number of splits in
the stream, and "n" is the number of elements being mixed. As each
ingredient is pumped through the static mixer, pressure is applied to keep
the particle streams moving at a high rate of speed. Once the particles reach
a critical Reynold's number, the common measure of turbulence, they begin
to intermingle and form a uniform, consistent mix.

The smaller particles then impinge against one another according to

Newton's Second Law: The acceleration of an object is directly proportional
to the net force acting on it and is inversely proportional to its mass; the
direction of the acceleration is in the direction of the applied net force. This
"Newtonian movement" keeps the ingredients in suspension much longer.

Continuous blend

Continuous just-in-time blending came into its own in the 1990s when static
mixing was incorporated into an automated system.

To create an automated continuous mix system, the following components

generally are needed: an automated pump system, flowmeters to measure
chemical delivery and some type of intensive mixing. Because they are
being retrofitted into existing processes, in-line mixers often have to be
"back integrated" to satisfy the particular needs of a given process. The
components are selected based on the volume requirements and the type
and number of chemicals that have to go through them. In-line mixers can
be retrofitted into a production line economically and have a footprint no
larger than a typical office desk or even smaller.
The components

The major components of a static in-line mixer used in the textile industry
," and potentially in the chemical industries ," include:

Progressive cavity pumps.

Mass flowmeters.

Static mixers.

In-line heaters.

Programmable logic controllers (PLCs).

Progressive cavity pumps move the materials through the mixing process.
The pumps provide the mixer with a metered, uniform flow. Typically one
pump is used for each product in the mixture. The pumps are extremely
versatile, capable of handling materials ranging from abrasives to clear
fluids. Each progressive cavity pump can handle liquids with a viscosity as
great as approximately 100,000 centipoise.

Mass flowmeters control the amount of each product pumped into the
mixture. These devices provide feedback to the pumps to ensure accurate
delivery. Users simply enter the proportions of each component into the
computer, and the control loop ensures each mix is delivered accurately.
The flowmeters also provide on-line measurement of density and
temperature.

Traditional mixing devices used in the textile industry had a mixing

accuracy range of error between +1 and -1 percent. With a static in-line
mixing machine, this accuracy is significantly greater ," the range of error is
between +0.1 percent and -0.1 percent.

The static mixer provides the machine with its uniqueness. It allows users
to create more than a million mixes in a standard 10-element mixer, and it
is applicable for a wide viscosity range.

Another optional feature of the in-line mixing system is an in-line heater. In

most textile machines, this heater has a capacity of 4.5 kilowatts (kW) to 1.8
kW and a volume of 2 liters (l) to 3 l. The contact parts typically are
Inconnel high-nickel stainless steel or glass, which do not react unfavorably
with the chemical mix.

The PLC is the brain of the static in-line mixer. It controls the machine and
provides and stores important process information such as amount
produced, time of makeup or destination.
The PLC panel of an in-line mixing machine is its "brain."

The benefits

Realize just-in-time mixing.

Use more high-performance products.

Increase accuracy.

Save on labor and transport expenditures.

Gain remote access.

Customize applications.

The most important benefit of the in-line mixer is that it allows users to mix
chemicals just in time. Traditional mixers usually make large batches of
each emulsion. Often, these emulsions sit in storage awaiting use. Bacteria
growth can taint the emulsions, ruining them.
Just-in-time mixing allows users to make smaller amounts of each emulsion
and use the chemical compounds as they are needed. Because the smaller
batch uses a lesser quantity of chemical compounds, users can afford to
purchase higher-quality chemical compounds.

Another benefit of in-line mixing is accuracy. PLCs and mass flowmeters

ensure the mixer produces the exact same emulsion every time. Users of in-
line mixers can be confident they will produce a consistent and high-quality
product.

The automated in-line mixing system and just-in-time mixing reduce labor
requirements and transportation costs. Because in-line mixers allow
products to be made on-site, users do not have to rely on other companies
to mix and then ship large highly diluted batches of chemicals. Instead, they
can purchase the concentrated chemicals and make the dilution on-site. As
a result, companies that use in-line mixers quickly recoup the initial
investment in the machinery through cost savings.

In-line mixing also offers the opportunity for remote control. The
automated system can be connected to a centralized control center or
accessed by modem. Remote capabilities allow users to monitor the mixer's
operation from anywhere with phone access, whether the mixer is in the
same building or on the opposite side of the globe. Users also can choose to
outsource monitoring to the chemical provider or to control it internally. In
addition, basic troubleshooting and repairs can be controlled from afar.
One of the in-line mixer's advantages is its small footprint.

The future

Static in-line mixers offer numerous benefits not only to the textile
industry, but also to other industries. As static in-line mixing technology
advances, its benefits will become more important. Furthermore, static in-
line mixing is adaptable to changing user needs and technologies.

This technology has clear applications in segments of the chemical industry,

including synthetic lubricants, agricultural chemicals and adhesives. The
mixing process in these industries can be similar to the ones used in textiles
," the chemical ingredients account for the only change. As improvements
are made in the in-line mixing process, the static in-line mixer eventually
will be able to handle small solid particles such as powders, flakes and
pellets.
Further improvements in in-line mixing machines will be process-specific,
and each machine will be engineered specifically to meet the needs of the
industry and user.

Anderson is a mechanical engineer and is chemical systems manager for

Cognis Corp.'s textiles division in Charlotte, N.C. He developed a static-inline
mixer and has a number of patents related to plastics and textiles and
plastics. Contact him at (704) 945-8830.

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