Statiflo Mini-Guide: The Different Types Of Static Mixers We Offer

Written by Statiflo | Jan 20, 2025 9:24:07 AM

Industrial Static Mixers are widely used in a variety of industries to blend, mix, and disperse fluids without needing complex systems of moving parts that consume large amounts of electricity and are prone to wear and tear. At Statiflo, we specialise in providing a range of high-performance and durable static mixers for a variety of industrial applications, including general industrial processes, water treatment, and custody transfer operations.

In this short guide, we’ll explore the different types of static mixers we offer, their key features, and the applications for which they are designed.

Pipe Static Mixers

Designed for use in a variety of applications which require consistent and efficient mixing, our pipe static mixers are highly versatile and robust. Typically, these mixers are installed within pipes, but can also be retrofitted with ease, and can be used for both turbulent and laminar flow conditions.

The mixing elements inside our industrial pipe static mixers are central to their functionality. By creating multiple flow divisions, they recombine the fluid in a way that maximises mixing efficiency.

There are Two Primary Configurations for Pipe Static Mixers:

Fixed mixing elements which are permanently installed inside the pipe and are ideal for applications where the mixing requirements are consistent and the need for maintenance minimal.
Removable mixing elements which are designed for processes that may require cleaning or periodic maintenance, or hygienic/santiary applications where the presence of internal welds should be avoided.

There are also different styles of elements available for pipe static mixers: the classic helical-type elements, the more complex matrix-type elements and specialised non-ragging/non blocking-type elements.

Applications

General industrial static mixers are widely used in industries such as chemicals, pharmaceuticals, food and beverage, and petrochemicals. They are ideal for mixing chemicals, additives, and other fluids where uniformity is critical.

Benefits of Pipe Static Mixers

High efficiency in mixing without moving parts.
Can handle a variety of fluid viscosities.
Low maintenance due to the absence of mechanical components.
Available in a range of materials, including stainless steel and other corrosion-resistant alloys, to suit different industrial environments.

Channel and Duct Static Mixers

Our channel and duct static mixers, which are specifically designed for use in open channels and closed duct systems, are particularly suited for the water and wastewater treatment industries. The ability to provide homogeneous mixing with minimal pressure loss makes them ideal for these large-scale applications.

Applications

This type of static mixer is commonly used in:

Water treatment plants: Effective when mixing chemicals, such as coagulants and disinfectants, into water.
Wastewater treatment facilities: Used for mixing flocculants, pH adjustment chemicals, and other additives.
Industrial effluent treatment: Help in blending chemical treatments into waste streams for effective neutralisation and processing.

Benefits of Channel and Duct Static Mixers

Designed for low-pressure drop to maintain energy efficiency in large-scale applications.
Handles high-volume flow rates in open-channel operations.
Requires minimal maintenance, as there are no moving parts that wear and require disruptive maintenance or replacement.
Customisable to fit various channel or duct dimensions.

Desalination Mixers

In the desalination industry, efficient mixing with minimal energy consumption is critical. Our desalination mixers, also known as compact or short-length static mixers, are designed with these specific requirements in mind. Highly efficient, they enabling precise mixing with minimal dosing of additives, making them ideal for desalination processes where the quality of the final water output matters.

Applications

Desalination mixers are typically used in desalination plants to blend chemicals, such as anti-scalants, chlorine, and pH regulators, into the seawater or brine stream before it enters the desalination process. They are also used in the post treatment process and in the production of potable water brine stream as part of the pre-treatment process, to ensure that the final product meets strict safety and quality standards.

Benefits of Desalination Mixers

Extremely efficient at dosing and mixing chemicals, resulting in cost savings.
Compact design means they can fit into smaller spaces without sacrificing performance.
Minimises energy consumption and pressure drop, which is crucial to maintain the efficiency of desalination processes.
Reduces chemical usage by providing highly efficient mixing, which is crucial in a cost-sensitive industry such as desalination.

Custody Transfer Mixers

Custody transfer applications require a high degree of precision and consistency in the mixing process to ensure that the product being transferred meets the required standards. Our custody transfer mixers are specifically designed to achieve this, consistently meeting ISO 3171 and API 8.2 standards, which require that the C1/C2 ratio (a measure of the mixing effectiveness) is greater than 0.9.

Applications

Custody transfer mixers are ideal for:

Oil and gas custody transfer processes, in which they ensure that fluids - crude oil, refined petroleum, or natural gas - are uniformly mixed before measurement or transfer.

Benefits of Custody Transfer Mixers

Achieves a highly consistent C1/C2 ratio above 0.9, ensuring compliance with international standards.
Reduces measurement uncertainty in custody transfer, leading to more accurate fiscal metering and fewer disputes.
Requires minimal maintenance due to its static, non-moving design.
Available in a range of materials to withstand the harsh environments that are often found in the oil and gas industry.

Gas Dispersion Systems

Used in applications in which dissolving gases into liquids, such as oxygen, ozone, or carbon dioxide, is necessary, our gas dispersion systems combine multiple static mixing technologies to maximise the mass transfer efficiency between gas and liquid phases. By ensuring optimum dispersion, these mixers can significantly improve process efficiency and reduce operational costs.

Applications

Common industries that benefit from gas dispersion systems include:

Water treatment: Dissolving oxygen or ozone into water for aeration or disinfection.
Chemical processing: Efficient gas-liquid mixing for reactions, such as hydrogenation.
Food and beverage: Dissolving gases into liquids for carbonation or aeration purposes.

Benefits of Gas Dispersion Mixers

Enhanced mass transfer efficiency, leading to more effective gas dissolution.
Can handle a wide variety of gases and liquids.
Low maintenance and long service life
Customisable design for specific application needs, such as varying flow rates and gas compositions.

Find Our More From the Experts at Statiflo

At Statiflo we offer a range of industrial static mixers which are designed for a variety of uses and applications. Whether you require a general-purpose static mixer or a highly specialised solution customised to the needs of your business, our experts can design cost-effective and durable solutions.

For more information, please browse our products on our website or call us today to consult a member of our team.

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