The Application Challenge
Conventional in-tank mixing is commonly used to disperse powders and immiscible liquids into other liquids. However, traditional in-tank dispersion methods are hit or miss. Powders introduced into the vessel of liquid must find their way to the batch mixer’s impeller to be effectively sheared and dispersed. While in theory the impeller draws the powder down into the action zone, the reality is that only a portion of the introduced material reaches the tooling for processing.
The result? Use of traditional liquid agitators or high shear mixers in the vessel can cause random, uncontrollable rates of shear, overprocessing and incomplete dispersion. Incomplete dispersion causes lumps and fish eyes, and results in waste as materials “raft” on the tank surface or build up on walls and baffles. Even low shear jet mixing equipment, which eliminates hard-to-clean tank baffles and reduces air entrainment, does not solve all the problems inherent to in-tank mixing.
The Quadro® Solution
What is inline processing? Instead of adding the material to be mixed directly into the process vessel, the powder phase is added into the liquid phase at some point in the piping. Single-pass powder addition can occur in a pipeline between two vessels, in the water supply line leading to a batch tank, or at some point in the pipeline that is part of a continuous process. As an alternative to single-pass addition, the powder can be introduced into a recycle or recirculation loop that includes a tank.
Our unique batch inline processing technology maximizes yields and creates high-quality dispersions. Adding powder to a process line compared to traditional in-tank mixing means no waiting for floating powders to wet. Also, the buildup on tank walls, mixer shaft and baffles is eliminated, which reduces cleaning time, lowers the risk of cross-contamination and reduces powder loss. Finally, air entrainment is less, so expensive de-aeration equipment is not needed.
The Quadro Ytron® ZC provides for single-pass inline processing, which significantly reduces batch times. It also eliminates the overprocessing that negatively affects heat- and/or shear-sensitive products.
Quadro® application specialists will help you determine which inline arrangement is right for the needs of your particular process.