Basic features

Spiral heat exchangers - faster refresh, better mixing

The design of the spiral shaped element naturally takes care of an increased heat transfer - by up to a factor 3. This is caused by the strong radial flow which causes an increase in the refresh rate on the inner walls of the process pipe.

20 to 100% more heat transfer

The applied Advanced Connection Technology (ACT), between the tube and mixing elements has a resistance to heat transfer which is equal to the resistance of the base material of the tube and element. Due to this characteristic, the surface area of each mixing element starts to behave like an additional heat-exchanging surface, which in comparison with the conventional heat exchangers results in a 20 to 100% improved heat transfer.

Static mixer heat exchanger is suitable for challenging media for example

If a standard pipe and plate heat exchanger is no longer working properly, the heat exchanger spiral elements come into the picture. Stretching and folding over the liquid layers has a positive effect on the heat transfer.

Some applications for specific industries:

Heat exchanger for viscous liquids like polymers

• Cooling a polymer to a constant temperature in the PET mill feed
• Cooling of hot melt
• Heating
• Polymer heat exchanger for mill

Heat exchanger for food

• Heating and cooling foods mildly
• Very suitable for viscous process media such as starch

Heat exchanger with an insulating sheath

The heat exchangers can be supplied optionally with an insulating sheath. The heating and/or cooling of liquids in a continuous process is a frequent operation in the chemical industry but also in the food industry.

Design

The static mixer heat exchanger

The reliable alternative to a plate heat exchanger, scraped heat exchanger, tube heat exchanger or spiral shaped tube heat exchanger.

The following types of stationary heat exchangers can be distinguished:

• Plate heat exchanger

• Tube heat exchanger

• Spiral shaped tube heat exchanger

• Static mixer heat exchanger

Usability of heat exchangers; working pressure, process temperature and viscosity

The usability of each type of heat exchanger is largely determined by the applied working pressure, the process temperature and the corresponding viscosity of the process medium. The desired capacity is achieved by choosing a certain construction size or by linking several heat exchangers in parallel.

The heat exchanger types mentioned above are placed in order of increasing usability, the heat exchanger with static mixing elements is the most usable.

Is a static mixer heat exchanger better for viscous media than a plate heat exchanger?

In applications where it is about the thermal treatment of viscous process media and processes where, for example, starch can be gelatinized, a system with a wider applicability should be chosen. . The plate heat exchanger in particular, is limited in the allowable work pressure. Pressures above about 6 bar are too high for this type, while in processes where long heating and cooling down schedules are included, the limit is reached quickly.

Better heat exchange than spiral shaped and tube heat exchanger because of the lack of tunnel effects

The applicability limits of the tube heat exchanger are mainly during the cooling of viscous process media, where - as a result of the tunnel effect occurring by fouling product - an insulating layer of product is formed on the inner wall, which can severely impede the transfer of heat. In addition, the remaining insulating product layer may have a negative effect on the quality of the final product. The spiral shaped heat exchanger has similar problems in this field of application to the tube heat exchanger. The static mixer heat exchanger has in relation to the above mentioned heat exchangers the great advantage that the temperature differences over the cross section of the flow surface are reduced, so that no insulating layer is formed and therefore this type is very useful for heat exchange in process media with a high viscosity.

More information about the application of the static mixer heat exchanger

Further applications of the static mixer heat exchangers can be found in our case studies data sheets and under the menu item industries.

It’s all-in the design

At PRIMIX design is more. It includes the engineering and thinking through the process with the client. Clearly defining the relevant parameters and where necessary daring to ask critical questions. This with the aim of obtaining maximum performance in the process . The intended design is entirely calculated in our own PRIMIX Dynamics software and afterwards is designed in SolidWorks® . The design instructions and calculations are based on strict criteria formulated in the current industrial design standards for high pressure devices. Read more about the PRIMIX design perspective.

Technical specifications

Product range static mixer heat exchangers

The PRIMIX heat exchangers can be produced, for example, from the following materials:

• (Low temperature) carbon steel and low alloyed steel, for example A106 Gr. B, A333 Gr. 6, A335 Gr. P11, etc.
• Stainless steel, e.g. 316L(1.4404), 304L(1.4306), 321(1.4541), 316Ti (1.4571), etc.
• Duplex & super duplex (1.4462)
• Exotic materials such as: alloys, Hastelloy^®, titanium, nickel, Incoloy^®

Surface finish heat exchangers

The surface of the static mixer heat exchanger can be finished, treated or cleaned to specification. A number of treatment techniques are:

• Staining and passivating
• Grinding & glass-grit blasting or sandblasting
• Honed finish for a perfectly smooth surface
• (Electro) polish
• Chromium plated
• Ultrasonic cleaning

Applied flanges and connectors

The static mixer heat exchanger can be provided with various types of flanges and connectors. The connection will depend on the process, the pipe diameter and the desired seal.

Connector type (more available on request)

• Bevelled weld ends ASME B16.25
• EN1092‐1 flanges: type 01, type 11, etc.
• ASME B16.5, B16.47 flanges. FF, WN RF, RTJ, etc.
• Loose flanges and sleeves for plastic construction materials
• Sanitary flanges, e.g. DIN11851, bio-connect, tri‐clamps, aseptic DIN11864, SMS
• Thread ends, e.g. union joints, Swagelok^®

Options and implementations of the heat exchanger

• Demountable
• Honed inflow sides
• Polished

Downloads

Brochure and leaflet

Company brochure

Static mixer leaflet (English)

Staattiset sekoittimet ja lämmönvaihtimet (Suomalainen)

Mieszacze statyczne i wymienniki ciepła w jednym (Polski)

Static mixer leaflet (Taiwanese)

Certificates

ISO-9001:2015 certificate

Achilles JQS certificate

Achilles FPAL certificate

EC Certificate - Module H

EC Certificate - Module H1

Quote request

Static mixer request form

Technical specifications

Mixer element strands

When cooling or heating highly viscous products, the risk of tunnel effects is high. Because of the formation of a boundary layer, the product near the inner wall almost comes to a stand still; the consequence is that the heat transfer is restricted. There is a real chance that because of fouling the exchanger will continue to clog up with product. Due to the occurring differences in speed, there will also be a large residence time spread.

By applying PRIMIX mixer elements strands, the resulting boundary layer is reduced to a minimum; the result is that the stationary boundary layer is broken and there is a continuous replenishment and addition of new product, which will have a positive effect on the heat transfer. Also, the residence time spread will be better because the mixing improves. By using PRIMIX mixer elements strands the system pressure drop becomes larger; your feed pump must be suited for this naturally. Heat transfer improvements of 40 % with respect to an empty pipe are no exception.

PRIMIX manufactures mixer element strands from 4 mm diameter, and in the usual materials, such as the various types of stainless steel. Special versions, for which the inlet and outlet side of each mixing element is made with a sharp or rounded edge, are possible. Also, various surface treatments can be used.

Turned ribbon or Twisted tape

Twisted tape is a long strip of material of a defined diameter which is turned up into a spiral; it can be turned both left or right; this in contrast to PRIMIX mixer elements strands of which the rotation changes in fact after every 180 degrees. Also, the twisted tapes can be applied in order to increase the heat transfer, and can be supplied for both existing and new exchangers. Twisted tapes are manufactured to client specifications in our own production facility to a diameter of 100 mm in the standard types of material. Ask our specialists about the possibilities.

Basic features

Sanitary static mixers are suitable for the following, and many other, applications:

Foodstuff production:

• Homogenising product temperatures after a heat exchanger in a production line for sauces.
• Controlled cooling and mixing of pastas and sauces.
• Mixing tomato concentrate and water into a sauce base with the desired viscosity.
• Temperature homogenization of curd cheese after heat exchanger.
• Marbling of products.
• Pasteurising and cooling sauces.
• Homogenising the temperature of chocolate after the tempering machine.
• Mixing colouring or flavouring into chocolate, fondant or marshmallow.
• Rework melters for margarine production lines.
• Mixing sugar-based syrups and water into a desired Brix value.
• But also: Producing CIP liquid.

Drinks production:

• Decreasing product degradation in juices by mixing in nitrogen.
• Carbonising by mixing in CO₂.
• Mixing juice concentrates and water.
• Mixing coffee concentrates and water.

Dairy production:

• Pre-mixer for the homogeniser.
• Pre-mixer for spray tower.
• Mixing pieces of fruit into yogurt.
• Temperature homogenisation after a heat exchanger in ice production.
• As a heat exchanger in the UHT lines for viscous medical foodstuffs.

Read more about the applications in the applications tab.

CIP cleaning

Within the foodstuffs industry, aspects like CIP cleaning, smooth and/or polished surfaces, and sanitary connectors are important for keeping germ counts as low as possible. Practice has shown that the use of PRIMIX static mixing elements and the increased speed of the product along the pipe wall, results in a significantly cleaner result after CIP cleaning, as compared to an empty pipe. The germ count afterwards is immeasurable.

The PRIMIX sanitary static mixers are easy to clean in a standard CIP or disinfection cleaning cycle. The mixers are fitted with removable mixer elements as standard, to facilitate any desired pipe inspection. This is very convenient, for example, when processing extreme viscous materials.

Retention of flavour and product characteristics – through rapid heating and cooling

Retention of flavour during pasteurisation and sterilisation processes is achieved by heating the product to a high temperature quickly, maintaining that temperature, and then cooling the product again relatively quickly. Good heat transference is essential to ensure the rapid heating and cooling. Static mixing elements ensure the continuous supply of new product to the contact surface, so that optimal heat exchange is achieved. With the sanitary static mixers, the sterilisation sections can be made significantly more compact while improving the efficiency.

Sanitary static mixers are maintenance free

What does the maintenance process look like after adding a PRIMIX static mixer to the process? To be very honest, there isn’t really a process to speak of. Simply because PRIMIX mixers require little to no maintenance at all.

Applications

Colouring and flavouring chocolate

One specific activity where the use of static mixers has proven very effective, is in mixing colouring and/or flavouring into white chocolate. In this process, a relatively small flow of colouring and/or flavouring is added to the chocolate flow. Due to the clever design, the additives are completely mixed in over the course of a very short installation length. This results in low loss of product and fewer cleaning activities. The same mixing principle is also applied to fondant or marshmallows.

Reworking margarine

In the Benelux, many margarine installations operate a PRIMIX rework mixer. In the supply line towards the packaging installation, a relatively small margarine flow is fed back, so that it is on standby. In the event of a sudden stoppage in the packaging line, the full quantity of cold margarine (6°C) is put through the rework installation and returns readily melted to the supply tank. The PRIMIX systems with hot water or steam connections have fully proven their effectiveness as rework installations in practice.

Improving temperature distribution in sauces and ice

Heat exchangers in production processes for sauces and ice have outgoing diameters of more than 50 mm. Because the products are syrupy (with high viscosity) a laminar flow profile arises in the output pipe. This means that at the centre of the pipe, the product is flowing much faster than it does at the edges. In consequence, the temperature measurements fluctuate, causing system controls to be unstable. Installing a PRIMIX sanitary static mixer will solve this issue. Due to good homogenisation, the product will have the same characteristics throughout, including consistent temperature distribution.

Making first class sauce bases

Many sauces begin their production process as a mixture of (tomato) puree concentrate which, together with water, is mixed to the desired viscosity. Whereby it is important that the mixture is perfect, otherwise the consumer will see colour and consistency variations. Today, PRIMIX static mixers are ensuring the production of first class sauce bases in many different production lines.

Pre-mix for a better homogeneity in milk

There is a lot more to modern milk production than simply milking a cow. For the right texture and consistency, milk is made smooth using a homogenisator. A PRIMIX sanitary static mixer in the supply line of the homogenisator ensures a perfect pre-mix, allowing the homogenisator to do its work even better.

Mixer design

Mixer design

At PRIMIX, there is more to the design of a sanitary static mixer. It encompasses engineering and thinking about the client’s process as a whole. Clearly determining the relevant parameters and, where necessary, daring to ask critical questions. This, with the aim of obtaining maximum performance in a mixing, heating, and/or cooling process. The intended design is calculated through completely in the PRIMIX Dynamics’ own software and then designed in SOLIDWORKS®. Read more about the PRIMIX static mixer design.

Type of mixing element

Within the sanitary static mixers, two types of mixing elements are used; the PMS screw type or helix element, and the PMX mixing element, also referred to as x-crossed type element.

Turbulent or laminar mixing

Depending on the selected element, mixing can be divided into turbulent and laminar. In case of turbulent mixing, we mean mixing materials with a watery or slightly higher viscosity. The flow speeds are relatively high. There is a relatively high amount of radial mixing and within a short process a technically homogenous mixture is obtained.

Laminar mixing occurs with materials with a high to very high viscosity. Here, the speeds are lower, and the pressure drops high. Very little or no radial mixing occurs. The mixing effects are focused on the transition between the mixing elements. There, the two layers are forcibly mixed, creating four layers, and so on. At the menu option operating principle, you can read more about turbulent and laminar mixing.

Technical specifications

Mixer design

The PRIMIX sanitary static mixers can be manufactured from, among others, the following materials:

• Stainless Steel; 316L(1.4404) , 304L(1.4307), 321(1.4541), 316Ti (1.4571)
• PTFE (with FDA approval)
• PP Food grade
• Do you require specific materials? Please contact PRIMIX.

Downloads

Brochure and leaflet

Company brochure

Static mixer leaflet (English)

Staattiset sekoittimet ja lämmönvaihtimet (Suomalainen)

Mieszacze statyczne i wymienniki ciepła w jednym (Polski)

Static mixer leaflet (Taiwanese)

Case study data sheets

#52 Additive static mixer

#54 Cip static mixer for food homogenization

Company

Bedrijfscompetentie

Algemene verkoop- en leveringsvoorwaarden

Primix standaard werkmethoden

Certificates

ISO-9001:2015 certificate

EC Certificate - Module H

EC Certificate - Module H1

Quote request

Static mixer request form