The development of the fluid static mixer can be traced back to the early 1970s. Initially, this device was introduced as a new type of mixing technology, primarily to address the limitations of traditional dynamic mixers in some specific applications. For example, dynamic mixers were prone to problems such as leakage and complex maintenance due to their moving parts, and were not very efficient when dealing with highly viscous or non-Newtonian fluids.
As industry developed and the requirements for mixing efficiency and quality increased, static mixers gradually gained importance due to their unique advantages. During the 70‘s to 80’s, the design and manufacturing technology of static mixer has been developed rapidly, and a variety of models and specifications have appeared to meet different industrial needs.
Into the 1990s, with the advancement of material science and manufacturing technology, especially the application of laser etching, chemical etching and diffusion welding technology, the design of static mixer is more refined and the performance is more superior. Meanwhile, the development of microscale theory and technology provides a theoretical basis for further innovation of static mixers.
At the beginning of the 21st century, with the rise of nanotechnology and the development of microelectromechanical systems (MEMS) technology, static mixers began to develop in the direction of miniaturisation and integration, with the emergence of new types of products such as laminar plate interlaced sweating injection mixer and micro-mixer, which have shown great application potential in aerospace, biomedicine, environmental protection and other fields.
The technical principle of fluid chemical static mixer is based on fluid mechanics and molecular diffusion theory. By setting up a series of static mixing elements in the pipeline or reactor, the fluid is divided into several tiny flow bundles when passing through these elements, and mixing is achieved through diversion, merging, rotation and other movements. Compared with traditional dynamic mixers, static mixers utilise the fluid's own flow characteristics to achieve mixing without external energy input, and have a higher energy efficiency ratio.
New static mixers, such as laminar plate mixers and micro mixers, utilise modern manufacturing techniques and microscale theory to achieve more efficient and homogeneous mixing. Laminate mixers achieve uniform mixing of different fluids through the staggered arrangement of laminates and flow channel design; micro-mixers make use of the microscale effect to achieve rapid mixing of fluids through micro-channels or micro-nozzles.
1. Industrial production and process optimisation
Through its unique structural design, the static mixer significantly improves the mixing efficiency and enables efficient mixing of fluids without external energy input. This is particularly important in continuous production, as it not only improves productivity, but also enhances operational stability and reduces energy and time costs associated with intermittent operation. In addition, the continuous production capacity of the static mixer makes it an indispensable equipment in the chemical, petroleum and pharmaceutical industries.
For example, in the field of fine chemicals, a chemical company uses static mixers to mix different chemical raw materials to produce high-purity chemical products. Through the static mixer's efficient mixing ability, the enterprise significantly improved the quality of the product, while reducing energy consumption and raw material waste in the production process.
2. Equipment Lightweighting and System Integration
In aerospace and other areas with stringent requirements on equipment quality and volume, the compact structure and the absence of moving parts of the static mixer effectively reduces the burden on the system and improves the overall performance and reliability of the system. This lightweight design not only reduces the use of materials, but also reduces transport and installation costs, which is of great significance for enhancing system integration and optimising system layout.
For example, in the aerospace field, a satellite manufacturer uses a static mixer to mix fuel and oxidiser for the satellite propulsion system. Due to the lightweight nature of the static mixer, it helps to reduce the overall mass of the satellite, thereby reducing launch costs and increasing payload capacity.
3. Energy conservation and economic benefits
The low energy consumption and long life design of static mixers make them the preferred equipment for energy saving and environmental protection in modern industry. Compared with traditional dynamic mixers, static mixers reduce mechanical wear and tear, lowering maintenance costs while reducing energy consumption and meeting the requirements of sustainable development. This energy-saving and environmentally friendly feature brings both economic and environmental benefits to the enterprise.
For example, a large refinery uses static mixers for pre-mixing of crude oil during production, which not only reduces energy consumption, but also reduces product quality problems caused by uneven mixing. By improving mixing efficiency and reducing maintenance costs, the refinery realised significant economic and environmental benefits.
4. Technological innovation and research promotion
New static mixers, such as laminar mixers and micromixers, provide new tools and methods for research in areas such as microscale technology and microelectromechanical systems. The development of these technologies not only drives innovation in fields such as materials science, biomedicine and micro-electro-mechanical systems, but also provides new experimental platforms and teaching tools for research and education.
For example, in a university microfluidics lab, researchers use micromixers for rapid mixing and reaction studies of biological samples. The high precision and controllability of the micro-mixer provides reliable data for experiments and promotes the application of microfluidics in biomedical research.
5. Environmental protection and sustainable development
In the field of environmental protection, the application of static mixers can significantly improve the efficiency of wastewater and exhaust gas treatment by generating fine and homogeneous droplets to enhance the efficiency of gas-liquid contact, thus intensifying the removal of pollutants. The application of this technology helps to achieve cleaner industrial emissions and promotes environmental protection and sustainable development.
For example, a city wastewater treatment plant uses static mixers to improve wastewater treatment efficiency. Through the fine liquid droplets produced by the static mixer, the pollutants in the wastewater are in full contact with the treatment agent, which accelerates the chemical reaction process and improves the efficiency and water quality of wastewater treatment.
6. Pharmaceutical and biotechnological applications
The application of static mixer in the field of pharmaceutical and biotechnology improves the mixing, emulsification and extraction efficiency of drugs, and enhances the homogeneity and bioavailability of drugs. In the field of biotechnology, it can also be used for mixing and mass transfer in cell culture, enzyme reaction and other processes, providing strong technical support for the production and development of biologics.
For example, a pharmaceutical company uses a static mixer for mixing and emulsifying active ingredients in its drug manufacturing process. This type of mixer ensures a uniform distribution of the drug ingredients, improves the stability and efficacy of the drug, and also meets high production standards.
As an efficient and energy-saving mixing equipment, fluid static mixer has important application value in many fields. With the continuous emergence of new static mixers and the continuous progress of technology, its application scope will be further expanded, and the mixing efficiency and effect will be further improved. In the future, the static mixer will play a more important role in promoting industrial production efficiency, promoting the development of new technologies and protecting environmental quality. At the same time, with the in-depth study of the microscale effect and surface effect and other basic theories, the design and application of the static mixer will be more scientific and reasonable, to provide strong support for technological progress and industrial upgrading in related fields.
