Application and influence factors of high shear emulsifier
A high shear emulsifier is a process that efficiently, rapidly and uniformly enters one or more phases (liquid, solid, gas) into another mutually incompatible continuous phase (usually a liquid). In the usual case, the phases are mutually incompatible. When external energy is input, the two materials are reorganized into a uniform phase. Due to the high tangential speed and high-frequency mechanical effects generated by the high-speed rotation of the rotor, the material is subjected to strong mechanical and hydraulic shear, centrifugal extrusion, liquid layer friction and impact in the narrow gap between the stator and the rotor. A combination of tearing and turbulence forms a suspension (solid/liquid), an emulsion (liquid/liquid) and a foam (gas/liquid). Therefore, the incompatible solid phase, the liquid phase and the gas phase are uniformly and finely dispersed and emulsified under the action of the corresponding mature process and the appropriate amount of additives, and the high-frequency cycle reciprocates to finally obtain a stable high-quality product.
The high shear emulsifier consists of 1-3 working chambers. Under the high speed drive of the motor, the material moves at a high speed in the narrow gap between the rotor and the stator, forming a turbulent flow, and the material is subjected to stronger hydraulic shearing and centrifugal extrusion. Pressure, high-speed cutting, impact and grinding, etc., to achieve dispersion, emulsification, and crushing effects. The material itself and the physical properties and the number of working chambers and the time that the material stays in the working chamber determine the particle size distribution range and the effect of homogenization, refinement and yield.
â—† Large processing capacity, suitable for industrial online continuous production; â—† The particle size distribution range is narrow and the formation is high; â—† Time saving, high efficiency and energy saving; â—† Precision-cast monolithic frame and each rotor tested by precision dynamic balance ensure low noise and stable operation of the whole machine; â—† Eliminate the quality difference between batch production; â—† No dead angle, 100% of the material is pulverized and sheared; â—† With short distance and low lift conveying function; â—† Easy to use and easy to maintain; â—† Can realize automatic control; â—† Cartridge mechanical seal to ensure no leakage of materials; â—† The processing capacity of single machine is from 1 to 120m3/h. |
Application of high shear emulsifier
1 Fine chemical pigment dye coating paint plastic resin ink paste slurry hot melt adhesive flame retardant adhesive finishing agent surfactant leveling agent anti-adhesive agent defoamer brightener rubber additive plastic auxiliary dye auxiliary flocculant coagulation Surfactant solvent silicone oil emulsion resin emulsified carbon black dispersion
2 petrochemical lubricating oil heavy oil mixed heavy oil emulsified oil-in-water oil-water diesel emulsified modified asphalt emulsified asphalt catalyst wax emulsified
3 pesticides, fertilizers, fertilizers, pesticides, emulsification, pesticides, pesticides, pesticides, intermediates, emulsifiers, insecticides, herbicides, seed coatings, fungicides, plant hormones, urea compound fertilizer, oil emulsion, wet powder
4 biomedical cytoplasmic serum vaccine protein dispersing agent medicine cream antibiotic sugar coating
5 Day Chemical Cream, Skin Cream, Detergent, Preservative, Hair Products, Toothpaste, Daily Essence
6 Food Industry Food Additives Flavors and Fragrances Juice Jams Ice Cream Dairy Chocolate Creamer
7 paint ink interior and exterior wall paint latex paint nano-coating construction adhesive light-curing coating ink ink carbon black paint additive glaze bentonite
8 Paper industry pulp adhesive rosin dispersed calcium carbonate filler additives pigment mixed resin emulsified
9 Environmental protection: wastewater, sewage treatment, upgrading, recycling
10Others: paper making, ceramic glaze, rust remover, talcum powder
The factors affecting the high shear emulsification results are as follows
1 Form of emulsification head (batch and continuous) (continuous type is better than batch)
2 The shear rate of the emulsification head (the bigger the better the effect)
3 The tooth structure of the emulsification head (divided into primary teeth, middle teeth, fine teeth, superfine teeth, the better the fine teeth effect)
4 The residence time of the material in the dispersion wall, the emulsification dispersion time (can be regarded as the same motor, the smaller the flow rate, the better the effect)
5 The number of cycles (the more, the better the effect, the time limit for the device, it can't be better)
Line speed calculation
The shear rate is defined as the relative velocity of the liquid layer between the two surfaces.
– Shear rate (s-1) = v rate (m/s)
g stator-rotor spacing (m)
From the above, the shear rate depends on the following factors:
– the linear rate of the rotor
– The distance between the two surfaces in this case is the rotor-stator spacing.
IKN stator-rotor spacing ranges from 0.2 to 0.4 mm
Rate V = 3.14 X D (rotor diameter) X speed RPM / 60
From the above, the precision of the rotation speed and the emulsification head determines the emulsification effect.
The high rotational speed and shear rate of ultra-high speed dispersion homogenizers are of the utmost importance for obtaining ultrafine suspensions. According to the special requirements of some industries, the company has developed the ERX2000 ultra-high speed shear emulsifier machine based on the ERS2000 series. The shear rate can exceed 200.00 rpm and the rotor speed can reach 66 m/s. In this speed range, the turbulence caused by the shear force combined with a specially developed motor can make the particle size range as small as nanometer. The shear force is stronger and the emulsion has a narrower particle distribution. Due to the extremely high energy density, no additional auxiliary dispersing equipment is required, and the particle size under the 400BAR pressure of the ordinary high-pressure homogenizer can be achieved.
REACTOR | Standard flow | Output speed | Standard line speed | Motor power | Import and export size |
model | l/h | Rpm | m/s | kW | |
ER 2000/4 | 300-1,000 | 9,000 | twenty three | 2.2 | DN25 / DN15 |
ER 2000/5 | 3,000 | 6,000 | twenty three | 7.5 | DN40 / DN32 |
ER 2000/10 | 10,000 | 4,200 | twenty three | 15 | DN50 / DN 50 |
ER 2000/20 | 20,000 | 3,000 | twenty three | 37 | DN80 / DN 65 |
ER 2000/30 | 40,000 | 1,500 | twenty three | 55 | DN150 / DN 125 |
ER 2000/40 | 70,000 | 1,500 | twenty three | 95 | DN150 / DN125 |
ER 2000/50 | 125,000 | 1,100 | twenty three | 160 | DN200 / DN150 |
Emulsifying head (set of rotor and stator)
To ensure that the equipment meets the needs of a wide range of applications, the company has a range of optional stators and rotors (emulsifier heads) for all equipment. Different emulsification head designs are well suited to meet the needs of different energy levels. In addition, the design of the emulsification head is also well suited to meet the needs of different viscosities and particle sizes. The difference between the on-line stator and rotor (emulsifier head) and the batch head design is mainly due to the requirements for transportability, while the on-line machine has lower requirements for transport.
It is particularly important to note that the difference between coarse, medium, fine and other head types is not only the arrangement of the specified rotor teeth, but also a very important difference is that the geometry of the different heads is not same. The number of slots, slot width, and other geometric features can change the different functions of the stator and rotor heads.
According to past practice, the work head is specified according to previous experience to meet a specific application. In most cases, the construction of the machine is matched to the specific application, so it is important to make the final product. When it is uncertain whether the construction of a work head satisfies the intended application. We recommend that you do an experiment or test in the lab. Iken encourages customers to use our equipment, and we have a complete set of test labs to help customers choose for you.
Batch (emulsifier head) different combinations and different applications
Pipeline emulsification head
Fixed rotor (dispersive emulsification head) technology
2P rotor (coarse precision) 2G stator (coarse precision)
The coarse precision working head can meet the mixing and homogenization process of medium shear. It consists of a coarse-precision stator and a pump-blade rotor (2P): a coarse-precision stator is usually used in conjunction with a specific rotor, and the rotor can provide high output. This is called “Pâ€. . Compared to other forms of work heads, this combination of stator and rotor has a four-fold increase in throughput, which produces a moderate level of shear and produces the pumping effect of the pump. This type of work head can be used in place of the pump at the pump location, or it can assist the pump to increase flow, and can also be used to assist multi-stage machines in delivering high viscosity fluids.
2G rotor (coarse precision) 2G stator (coarse precision)
Rough precision (2G) dispersion head: mainly used for extrusion, chopping, dissolving and coarse precision crushing. It is especially suitable for pre-crushing before coarse particle suspension and chopping and pressing operations of the resin.
4M rotor (medium precision) 4M stator (medium precision)
Medium precision (4M) emulsification head: mainly used for extrusion, pigment dispersion, accelerated dissolution and good fracture. Such emulsification heads are commonly used in emulsification and suspension production, especially in the field of pigment processing, and are generally used in production in a low viscosity range.
6F rotor (fine precision) 6F stator (high precision)
High-precision (6F) homogenizing head: mainly used for extrusion, catalysis, accelerated dissolution, and requires relatively high-precision pulverization. It is especially suitable for micro-emulsification and suspension. It is often used in the fields of lotion, cream and other fields. It is mainly used for materials with low viscosity range and can also be connected with a feed pump.
8SF rotor (extra high precision) 8SF stator (extra high precision)
Ultra-high precision (8SF) homogenizing head: mainly used for extrusion, catalysis, accelerated dissolution and high precision crushing. It is especially suitable for micro-emulsification and fine suspension, and can make the particle size range as small as nanometer. The shear force is stronger and the emulsion has a narrower particle distribution. It is especially used in vaccines, cell disruptions, colloidal solutions, metal oxide suspensions, inks, printing coatings, pigment mixing and more. Mainly for low viscosity range materials, it can also be connected to a feed pump.
Zhejiang Daoming New Material Co., Ltd, established on 2007, is a high-end Release Material enterprise integrating Research & Development, Manufacturing and Sales. In 2012, our company invested 6 million Euros to equip Germany BMB production equipment with the affiliated advanced coating machine, printing machine, slitting machine, detection device and Class 10000 Clean Workshop.
By "leading technology, customer first", our company takes extensive research & development strength and management practices to improve and enhance our products continuously, offer customized solutions.
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