News and Information
Keeping pace with the times, daring to pioneer and strive, moving forward into the new.
Maintenance of High-Shear Emulsifiers
2024-02-03
Author:
Source:
High-shear emulsification technology integrates mixing, grinding, dispersion, and emulsification functions. It delivers particularly remarkable particle‑size reduction for polymeric materials, effectively addressing challenges in grinding and emulsifying various feedstocks and replacing conventional colloid mills. Compared with traditional production processes, it offers four major advantages: lower energy consumption, reduced production costs, superior product quality, and enhanced ultrafine processing. The equipment is suitable for operation under atmospheric, vacuum, or pressurized conditions. It features stable operation, low noise, easy cleaning, and flexible maneuverability, enabling continuous use while achieving ultrafine dispersion and emulsification of materials.
Maintenance of high-shear emulsifiers:
1. During installation or operation, handle the emulsification equipment with care to avoid severe vibrations.
2. Maintenance personnel shall regularly inspect and tighten connection bolts, paying particular attention to bolts and nuts that are prone to loosening, as well as checking whether any foot plates are loose.
3. During rotor maintenance and replacement, it is recommended to use specialized tools and avoid striking with excessive force to prevent deformation or damage to components.
4. The shaft sleeve of a high-shear emulsifier is a wear part; its material can vary depending on the properties of the user’s process material. However, maintenance personnel should regularly inspect the sleeve for wear to ensure that the rotor and stator do not come into contact.
Features of a High-Shear Dispersing Emulsifier
High-shear dispersing and emulsifying machines have a wide range of applications and feature six key capabilities: high-speed mixing, dispersion, rapid particle size reduction, dissolution, homogenization, and emulsification. These machines are suitable for processes that require high peripheral speeds, which further enhance material processing, resulting in faster and more effective dispersion, homogenization, emulsification, and mixing.
Working principle of a high-shear dispersing emulsifier
The high-shear dispersing and emulsifying machine features six key functions: high-speed mixing, dispersion, rapid particle size reduction, dissolution, homogenization, and emulsification. Mechanical and hydraulic high-shear forces are central to its operation. The precisely engineered rotor and stator, rotating at high speed, generate high tangential velocities and intense mechanical and hydraulic shear effects. These forces ensure that the material undergoes hundreds of thousands of shear cycles per minute. Within the narrow clearance between the rotor and stator, the material is subjected to a complex interplay of centrifugal compression, shear, jetting, interlayer friction, impact, tearing and refinement, as well as turbulence, chaotic flow, and vortices. Under these combined actions, immiscible liquid–liquid, liquid–gas, and liquid–solid phases are instantaneously and uniformly mixed, dispersed, homogenized, and emulsified when exposed to optimized process conditions. This cyclical process repeats continuously, ultimately yielding a high-quality product.
Shear working process of a high-shear dispersing emulsifier:
1. Under the centrifugal force generated by the high-speed rotating rotor, the material shown in the figure is axially drawn into the working chamber simultaneously from the upper and lower feed zones of the work head.
2. Powerful centrifugal force throws the material radially into the narrow, precision gap between the stator and rotor. Simultaneously subjected to centrifugal compression, impact, and other forces, the material undergoes preliminary dispersion and emulsification.
3. At the outer end of the high-speed rotating rotor, a linear velocity of at least 15 m/s is generated, reaching up to 40 m/s, creating intense mechanical and hydrodynamic shear, interlayer friction, and impact-induced breakup to thoroughly disperse, emulsify, homogenize, and fragment the material, which is then ejected through the stator slots.
4. The material is continuously ejected radially at high speed, changing direction due to resistance from the material itself and the container wall. Simultaneously, the axial suction forces generated in the rotor zone create strong upward and downward turbulent flows. After several cycles, the material ultimately completes the dispersion, emulsification, and homogenization processes.
Contact Us
Service Hotline:
400-186-9661
Email:
Yel@zicionpumps.com
Company Address:
No. 26, Beilu Road, Yuewang Town, Shaxi Town, Taicang City, Suzhou, Jiangsu Province
Zichen Pump Industry (Jiangsu) Co., Ltd.
Service Hotline: 400-186-9661
Email: Yel@Zicionpumps.com
Company Address: No. 26, Beilu Road, Yuewang Town, Shaxi Town, Taicang City, Jiangsu Province
在线客服
E-mail：
Telephone：