Emulsifiers

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Mixer Emulsifier

PTL Mixer Emulsifiers are accepted world-wide as a proven alternative to high speed dispersers, slow speed impellers or high pressure homogenizers for a wide range of processing requirements.

The versatility built into this rugged machine provides its users with new and more efficient approaches to traditional processing techniques. High speed mechanical and hydraulic shear forces are the real key to the success of our emulsifiers.

The close clearance between the rotor and stator generates a shearing action which insures that materials being processed are subjected to thousands of shearing actions each minute.

The positive shearing action results in short process cycles and a more uniform, high quality product. Several interchangable stator heads are available to maximize the desired results.

Installations cover a broad range of applications including emulsification, disintegration, dissolution, dispersion and homogenization.

Designs are available in both batch and continuous in-line models from 2 through to 200 HP. Batch models handle from 1 to over 6,000 gallons per minute.The largest production in-line models have a pumping capacity exceeding 2,600 gallons per minute.

Unequalled versatility and the concept of positive mixing combine to improve your operating efficiency.

Vessel Size

Standard Batch Mixer Emulsifiers are available through 100 HP. For most applications the rotor head should be mounted 2 to 3 head diameters above the bottom of the vessel. In general, a slender shaped vessel is preferred for use with the Mixer Emulsifier. Pilot testing enables accurate scale up.

Viscosity

Maximum efficiency is achieved on mixtures under 10,000 cps. The key to achieve the best efficiency with this design is to maintain a maximum circulation of all materials through the rotor/stator at all times during the process cycle. As viscosity increases, flow through the head decreases, thus lessening the work on a given volume of material while it is being circulated within the vessel. The In-Line Mixer Emulsifier is less susceptible to this problem as it may be fed by means of positive displacement pumps.

Flow Characteristics

The density, viscosity and rheology of each mixture is variable. The pumping capabilities of the unit on materials that have the same apparent viscosity may not be the same in actual practice. For example, many polymers have a low apparent viscosity and appear to be ideally suited to the units design/application criteria. On testing however, it may be observed that flow is poor and that the end result is marginal. Modified tank configuration, auxiliary agitation, different rotor speeds or head diameters in most instances will be successful.

Flow Rate

Calculated maximum flow rates for each of the various sizes are listed in the In-Line Mixer Emulsifier dimension chart. As viscosity rises from the published values, flow rate decreases. Please keep in mind that numerous factors play a part in the sizing of these units and theoretically calculated values are not a substitute for experience accumulated through test data collected in a controlled laboratory environment.

Size of Solids

As the horsepower of the mixers increase so does the size of the rotor and stator. For example: the laboratory model with a disintegrating head has a rotor diameter of 1 3/8" and a disintegrating head opening of 7/16". The 75 HP model has a rotor diameter of 12 1/2" and a disintegrating head opening of 2 3/4". It, therefore, follows that the size of solids to be reduced may be larger as the size of the machine is increased.

Application	Procedure	Benefits
Suspension	Charge all liquid components of the formulation into the tank. Start mixer and charge solid materials until a uniform particle size has been achieved. Add the dispersant as rapidly as possible.	Uniform particle size reduction. One step operation to suspend solids and add dispersant. Interchangeable stator heads may be used with solids of varying size. Short cycle time.
Emulsification	Charge continuous phase. Add surfactant. Externally heat and slowly add the dispersed phase through an open pipe line terminating below the rotor/stator assembly. Mix until emulsion completed.	Short cycle time. Intimate and immediate contact of dispersed phases. Fine droplet size. Potential surfactant savings through efficient use of high shear agitation.
Disintegration	Charge all liquids into vessel. Add to liquids any solids that are easily liquified and begin mixing. Add slowly the solids that are to be reduced in size. Continue operation until solids are reduced to a desired uniform particle size.	Single step process with potential materials handling and time savings. Drastically reduced cycle time. Substantial savings in electrical costs resulting from shorter cycle times. Floor space savings. Less capital equipment required.