PREPARED BY KIRAN.S.SALIAN B.E. CHEMICAL ROLL NO. 73 DATTA MEGHE COLLEGE OF ENGINEERING.

CONTENTS SR.NO. 1 2 3 4 5 6 CHAPTER INTRODUCTION TYPES OF HIGH SHEAR MIXERS SOME INDUSTRIAL APPLICATION OF HIGH SHEAR MIXERS CASE STUDY CONCLUSION REFERENCES

y Mixing of solids is the distribution of at least one

component through another. The mixing of granular solids is a widely employed process in Chemistry, Pharmacy, Food manufacturing, Ceramics industry, and ore beneficiation y Williamssays, Although the mixing of particulate solids is one of the oldest and most important operations in the process industries, it is one of the least well understood (Williams, 1990). y The mixing process with solids is influenced by disperse properties such as grain shape, grain size, particle-size distribution (gradation), and friction in the bulk material.

MIXER

POWDER Free-flowing component of similar particle size Slightly cohesive powders, free-flowing powders. Cohesive powders, free-flowing, segregating mixtures

y
Tumbling mixers Tumbling mixers with shear Shear mixers

1.2) Mixture Quality

To determine mixture quality Danckwerts defines a scale of segregation and an intensity of segregation (Danckwerts, 1953), which describe the size and amount of dilution of patches or volumes of unmixed material within the mixture, respectively.

y Throughput y Batch integrity y Product containment y Product sensitivity y Cleaning

1.4) What are High-Shear Mixers

y High-shear mixers are industrial developments of

the alchemist s mortar and pestle and the miller s millstone for the grinding of grain (Harnby, 2000). y High shear mixers (also know as high intensity mixers) are equipped with mechanical agitator rotating at moderately high speed.

Powder is pinched between a moving and a static surface as in a comil or between two moving surfaces as in a pair of pressurized rolls Some high shear mixers are equipped with cooling jacket, because the temperature may rise markedly due to the high energy input supplied by the mixing tools

A major use of these mixers is in the

agglomeration of powders by addition of liquid binders, for example in the manufacture of granular products in the fine chemical, pharmaceutical, foodstuff, household product, metallurgical and microbiological product industries.

y y y y y y y y y y y

2.1) Pan Muller Mixers 2.2) Roller Compactors 2.3) Helical Blade Mixers 2.4) Banbury Mixers 2.5) High Speed Mixers/Granulators 2.6) Double-Arm Kneading Mixers 2.7) Roll Mills 2.7.1) Two-Roll Mills 2.7.2) Three-Roll Mills 2.8) Gate Mixers 2.9) Shear-Bar Mixers

2.1) Pan Muller Mixers

These mixers can be used if the paste is not too fluid or too sticky.

2.2) Roller Compactors

Roller Compactor: (a) Alexanderwerk and (b) Hutt types.

Roller compaction is an alternative gentler method, the powder mix being squeezed between two rollers to form a compressed sheet .

2.3) Banbury Mixers

Preeminent in the field of high-intensity mixers, with power input up to 6000 kW/m3 (30 hp/gal), is the Banbury mixer (Figure 5). It is used mainly in the plastics and rubber industries.

2.4) High Speed Mixers/Granulators

This type of granulator (e.g. Diosna, Fielder) is used extensively in pharmaceutics.

2.5) Double-Arm Kneading Mixers

2.6) Roll Mills:

2.6.1) Two-Roll Mills

2.6.2) Three Roll Mills

y 3.1) High shear dispersion of Bentonite y 3.2) High shear dispersion of Titanium dioxide y 3.3) High shear dissolving of viscosity index improves y y y y y y

in Luboils 3.4) Preparation of paper coatings 3.5) Redispersion of filter cake 3.6) Production of polymer modified asphalt for road surfacing 3.7) Agrochemical industry manufacture of pesticides 3.8) Preparation of drilling fluids 3.9) High shear Preparation of rubber solution

4) Case Study:Following case studies (taken from mixes.com) show how a particular high shear mixer is selected for a given system:-

4.1) Mixing of Plastisols 4.2) Mixing of Silicone Sealant

4.1) Mixing of Plastisols:Application Pigmented plastisols. Similar mixing applications might include: Dental whitening gels, polyester compounds, epoxies, transdermal drugs. Ingredients - Plasticizers, pigments, fillers (Cabosil, calcium carbonate), powdered PVC resins. Viscosity - Final: 50,000 centipoise (cps); max during the process: 2 million cps or 2.5 million cps, depending on mixer used. Application Batch Size - 500 gallons. Other Key Parameters - Pigments require high shear for fast and thorough dispersion. Vinyl resins are temperature sensitive and therefore indirectly shear sensitive, too, since localized heat is always produced by a high shear agitator.

Process - The manufacturer in this case had been mixing a Plastisol with a High Speed Disperser. The Disperser provided enough shear to disperse the pigment, but as viscosity went up it failed to maintain adequate circulation and product turnover in the vessel. Zones of unmixed material remained, even after very long batch cycles.

4.2) Mixing of Silicone Sealant:Application - Viscous silicone gel used to manufacture an industrial sealant. Similar mixing applications might include: dental composites, butyl sealants, propellants, automotive sound absorbing compounds, color pigment compounding pastes, and chewing gum formulations. Ingredients - Silicone resin and fumed silica.

Viscosity - Final: 6-7 million cps. Application Batch Size - 200 gallons. Other Key Parameters - None. Process - Materials over 2.5 million cps generally require a switch from a conventional Double Planetary Mixer to a Double Arm Kneader. However, because of the high cost of a Kneader, it would be preferable to stick with the Double Planetary, if it is equipped to handle viscosities as high as 78 million cps, far beyond the normal range of classic rectangular planetary blades.

5) Conclusion:The use of High Shear Mixers for agglomeration of powders is common throughout the pharmaceutical and detergent process industries (especially in the case of compact laundry detergents) due to their fast operation and ability to produce granules with high density and strength. Moreover power consumption by high shear mixers is high so it can be used only for specialty chemical for which product value is immaterial infront of the market appeal of the final product form.

6) References:-

1.)Danckwerts, P.V., Theory of Mixtures and Mixing, Chem. Eng. Res., 6, pp 355 (1953) 2.)Fischer, J.J., Solid-Solid Blending, Chem. Eng., 67(16), pp 107 (1960). 3.)Miller, S.A., et al, Liquid-Solid System , in Perry s Chemical Engineer s Handbook, 6th ed, Green, D.W., et al (Eds.) , McGraw-Hill Book Company, pp 19-14 to 19-24 (1984). 4.)Roseman, B., Mixing of Solids, Ind. Chemist, 39, pp 84 (1963). 5.)www. mixes.com