static mixing technology...static mixer comparison, viscosity ratio = 53,000:1 kmx-4 kmx-8 kmx-12...

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  • Since 1965, in thousands ofinstallations worldwide,

    Kenics® Static Mixers have

    set the standard for in-line

    mixing and heat transfer

    performance. Chemineer

    incorporates advanced

    technology into every Kenics

    Mixer to give you reliable,

    uninterrupted performance

    that you can depend on for the

    long term. The result: maximum

    operating efficiency and overall

    cost savings.

    In the KM Static Mixer, a patentedhelical mixing element directs theflow of material radially toward thepipe walls and back to the center.Additional velocity reversal and flowdivision result from combining alter-nating right- and left-hand elements,increasing mixing efficiency. Allmaterial is continuously and com-pletely mixed, eliminating radial gra-dients in temperature, velocity andmaterial composition.

    In the HEV Static Mixer, the patented tab geometry maximizes the conversion of turbulent energyinto efficient mixing. The HEV pro-duces complete stream uniformitythrough controlled vortex structures


    generated by the mixing elements.The element geometry takes advan-tage of the naturally occurring vor-tices induced by the element edges.

    These mixing principles result in anapplications technology that can be

    easily reproduced and reliablyscaled. Numerous independent stud-ies have shown Kenics Static Mixersmaximize mixing efficiency —withoutthe wasted energy and materialblockage typically found in morerestrictive motionless mixers.



    KM Static Mixer

    HEV Static Mixer

    Side view

    Front view


    Kenics Static Mixers provideprecise blending and dispersionof all flowable materials, withoututilizing moving parts. Mixing isachieved by redirecting the flowpatterns already present in emptypipe. Kenics Static Mixers arecurrently being used in numerousprocessing applications, in orderto reduce overall cost and signifi-cantly improve efficiency, speedand control. Kenics Static Mixerscan be found in a wide range ofmarkets including chemical, refining, polymer, food, pulp and paper, water and wastewatertreatment. These high efficiencymixers also handle other criticalprocesses, such as:


    Kenics Mixers dramatically boostheat transfer rates over those typically found in open pipeunder both laminar and turbulentflow conditions.

    Residence Time Control

    By eliminating the parabolic velocity profile characteristic oflaminar flow in open pipes, thehelical element of Kenics Mixerspromotes plug flow in continuousprocesses.

    Temperature Uniformity

    The radial mixing action of the KM elements rapidly eliminates temperature gradients, reducing fouling and thermal degradation.


    Turbulent Blending HEV Static Mixer

    Each tab of the HEV Static Mixergenerates a pair of streamwisecounter-rotating vortices that produce vigorous cross-streammixing and rapid uniformity.

    Turbulent Blending KM Static Mixer

    The KM Static Mixer producesrapid mixing by inducing circularpatterns that reverse direction ateach element intersection.

    Laminar Blending KM Static Mixer

    The alternating helical elementsof the KM Static Mixer continuallydivide, stretch and reorient the flow stream to produce completemixing with minimum pressuredrop.

    Laminar BlendingKMX Static Mixer

    The intersecting blades of theKMX mixer create cross-streammixing and flow splitting toachieve rapid mixing even in themost demanding applicationssuch as those with extreme viscosity and volume ratios.

    Liquid/Liquid Dispersion

    The uniform turbulent shear fieldof the KM Mixer quickly dispersesimmiscible liquids and produces anarrow drop size distribution.

    Gas/Liquid Dispersion

    Gases can be incorporated intoturbulent liquids using the KMStatic Mixer. Mass transfer ratesare dramatically enhanced tomaximize absorption or reaction.

  • Kenics KM Series Static Mixers feature a patented helical mixing element which produces completeradial mixing and flow division for any combination of liquids, gases, or solids.

    Adapts to Any Piping System

    Mixer dimensions match all stan-dard pipe sizes. Mixer housingsfeature plain, threaded, weld prepor flanged ends for easy installa-tion. Flange styles include raisedface slip-ons, weld neck, lap joint ,ring joint and Grayloc-type hubsin all standard pressure ratings.Mixers are available in carbonsteel, 304SS, 304LSS, 316SS,316LSS, Alloy 20 Cb-3, Titanium,Monel 400, Nickel 200, Inconel,Hastelloy C-276, Hastelloy B-2, FRP, PVC, CPVC, PTFE, Kynar, PVDF, Tantalum, Zirconium and other high alloys.

    Fixed Element — KMS

    • Used for laminar, transitional,and turbulent flow applications;suitable for most blending ordispersion problems involvingliquids or gases

    • Mixing elements are attached to the housing wall

    Removable Element — KMR

    • Used for laminar, transitional,and turbulent flow applicationswhere periodic cleaning orinspection is required; suitablefor most blending or dispersionproblems involving liquidsor gases

    • Mixing elements are easilyremoved from housing

    Element Assembly — KMA

    • Mixing elements are inserted in the customer’s existing housing

    • Precisely controlled to assure proper fit and ease of installationin any standard or custom pipe size

    Edge-Sealed Element — KME

    • Used for maximum heat transfer,polymer reactors, certain fibrousapplications, and mixing liquids with wide viscosity ratios

    • Mixing element edges are furnace-brazed to the housing wall eliminat-ing dead areas

    • Continuous joining of elements to the housing eliminates wall clear-ance to maximize heat conductionand minimize thermal degradationor fouling

    • Available with internal surface finishes down to 8 microinches

    Construction options include:

    • ASME/B31.3 certification and testing

    • Design pressures to over 10,000 psi

    • Jackets, nozzles, fittings

    • Complete custom fabrication

    • Diameters to over 8 feet




    HEV high-efficiency static mixers handle all turbulent-flow mixing applications regardless of line size or shape. Mixing is accomplished bycontrolled vortex structures generated by the patented low-profile tab geometry. This providesuniform blending while limitingmixer length to less than 1-1/2pipe diameters. Complete mixingis achieved with pressure losses75% less than conventional static mixers.

    Typical applications for the HEVinclude all low-viscosity liquid-liquidblending processes, as well as gas-gas mixing. The HEV is ideal forprocesses where pressure loss andlength are critical.

    HEV Static Mixer features include:

    • Lowest pressure drop available

    • Unlimited sizes and shapes

    • Shortest possible mixer length

    • Easy retrofit to existing lines

    • Available in all metals and alloys,FRP, PVC, PFA, and epoxy-coated steel

    • Low cost, wafer design is availablefor installation between flanges

    HEV static mixers provide installationflexibility and can be configured tosquare, rectangular or 3-sided ducts.They are adaptable to open chan-nels typically found in water treat-ment systems.




    Static Mixer Comparison, Viscosity Ratio = 53,000:1

    KMX-4 KMX-8 KMX-12




    KMX Mixer with Concave BladesStatic Mixer with Flat Blades


    COV 0

    Laser induced fluorescence (LIF) images showing cross-sectional uniformity

    0 2 4 6 8 10 12 14L/D

    The KenicsKMX Static

    Mixer is thechoice fordemanding mix-ing applications,such as thoseinvolving fluidswith extreme

    viscosity or volumeratios. The

    common limiting factorin static mixer design is the allowable mixer length and thepatented element design offers a short length and the most efficient mixing performance.

    EXCLUSIVE MIXINGPRINCIPLEThe KMX utilizes cross-streammixing and flow splitting toachieve very rapid blending.Each element is approximatelyone pipe diameter in length andconsists of multiple intersectingblades, which generate fluid layers as the mixture flows downstream.

    KMX Mixer features include:

    • Superior mixing performance

    • Laminar flow and high-low viscosity mixing

    • Liquid dispersion/gas-liquid contacting

    • Cost effective solution

    • Short length

    • Standard diameters up to 24"

    Sheets of low viscosityadditives are driven alongthe trough of each bladeand abruptly sheared bystrong cross-stream velocity gradients as theypass around the upstreamsurface.

  • Temperature Uniformity

    Kenics Mixers eliminate hot or cold spots typical of flow in openpipes. Improved thermal uniformityoptimizes process performance.

    10 102 103 104








    D = Sauter Mean DropsizeD = Pipe I.D.We = Weber Number






    10 50 100Q



    D=150mmSG=1.0μ=1.0 cP




    Guaranteed Mixing Uniformity

    The standard technique used formeasuring the degree of mixingin pipe flow is the coefficient of variation, CoV. The coefficient of variation is the ratio of the standarddeviation of component concentra-tion to its mean concentration. Thecoefficient of variation achieved atthe mixer discharge is dependenton the inlet coefficient of variation(CoV)

    ˚. The initial coefficient of vari-

    ation is defined as:


    = [ 1-Va]1/2Va

    where Va is the volume fraction ofthe stream added. To allow plottingagainst geometrical factors such aselement style, as well as Reynoldsnumber, a normalized coefficient ofvariation is defined as:



    The correlations Chemineer hasdeveloped through fundamentalresearch, as well as years ofoperating experience, allow us toaccurately predict mixer perfor-mance and offer you 100% guar-anteed results.




    1000 100 000 1 000 000Re



    / C




    10 000



    Typical Viscous Flow Profile



    Flow Profile In Kenics Static Mixer(T1 - T2) < (T1 - T2)

    0.1 2 0.1 2 1.0 2 10



    With Mixer

    Empty PipeNu


    3-10 Times








    00 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

    Empty Pipe

    Ideal Plug Flow

    KenicsStatic Mixer

    θ, Dimensionless time


    Pressure Drop

    The pressure drop through KenicsStatic Mixers is the lowest in theindustry resulting in reduced operating costs and increasedprocess capacity.

    Drop Size Prediction

    Accurate drop size prediction allows optimization of mass trans-fer controlled processes whileavoiding problems with down-stream separation equipment.

    Heat Transfer

    Exclusive edge-sealed mixing elements give Kenics HeatExchangers transfer rates up to 10 times greater than open tubes.

    Reactor Engineering

    By interrupting the parabolicvelocity profile characteristic ofopen pipe, Kenics Static Mixersproduce residence time distribu-tions approaching plug flow.

    Mixing Uniformity

    By analyzing the inlet stream conditions, final mixture quality can be predicted for all Kenics Mixer designs.



    In addition to our standard staticmixer line, Chemineer manufac-tures a range of productsdesigned to meet your specializedprocess requirements.

    Sanitary Mixers

    • Polished internal and external surfaces

    • Removable element assemblies for fast, easy cleaning

    • Fitted with tri-clamp-style ferrules

    • Available in five diameters from 1/2" to 4"

    • 316L construction materials

    • Meet 3A standards

    • BPE option available

    Pilot Plant Heat Exchangers

    • Standard off-the-shelf design for immediate shipment

    • Direct scale-up with 100% process warranty

    • All stainless steel construction

    • Can be used in pilot plants orslip streams to full-scale process

    Heat Exchangers

    • Used for process applications,including polymers, plastics, adhesives, hydrocarbonprocessing, and food industries

    • Effective for both heating andcooling of viscous fluids

    • Three-to-ten times greater transfer rates than empty tubes

    • Boosts heat transfer with mini-mal flow disruption

    • Custom fabrication toASME/TEMA standards

    • Request Bulletin 808


    • Delivers uniformly mixed melt for extrusion applications

    • Offers improved gauge control

    • No radial temperature gradients

    • Reduced color concentrateusage by improving mixtureuniformity

    • One-piece design for easy installation and cleaning

    • Request Bulletin 806

    Tube Mixers

    • Used for applications with low flow rates in full-scale and pilot plant operations

    • Exclusive edge-sealed mixing elements attached to housing wall

    • Plain ends accommodate a wide variety of common fittings

    • Standard 22-gauge 316SS housings available in diametersfrom 3/16" to 1/2"

    Tubular Reactors

    • Continuous plug flow performance

    • Single or multi-tube construction

    • Continuous solution phase reac-tions and polymerizations

    • High heat transfer rates with lowpressure drop

    No matter what your process needs or system considerations,Kenics Static Mixers can handleyour mixing requirements.



    Commitment to Quality

    We manufacture Kenics StaticMixers and Heat Exchangers inour ISO 9001 certified facility inNorth Andover, Massachusetts.ISO certification allows us to offercustomers 100% guaranteedquality products, and representsour ongoing commitment to customer satisfaction.

    Computerized ProcessOptimization

    CEDS® (Chemineer Expert DesignSystem) is a comprehensive com-puter program developed byChemineer that interprets processdesign data and selects only thosemixers that it has verified for process and mechanical designintegrity. Chemineer field engineersuse this technology via laptop computers to provide you withimmediate design alternatives.

    Sharing Our Technology

    Our Applications Specialists are ready to bring the latest static mix-ing technology right to your frontdoor. Your process and develop-ment engineers are introduced tomixing principles for blending, dis-persion, heat transfer and reactordesign allowing them to optimizeplant operating performance.Contact your local ChemineerSales Engineer to arrange an in-house seminar.


    Factory Services and Field Engineering

    Every Kenics Static Mixer is backed by product and application engineering, a fully equipped mix-ing laboratory, and complete in-house manufacturing and qualitycontrol. Our process engineerscombine hands-on experiencewith fundamental technology toprovide you with optimal, cost-effective mixer performance.

    Worldwide Distribution

    Kenics Static Mixers are marketedglobally through locations in the United States, Canada,England, Mexico, Brazil, India,Singapore, China and Taiwan.Kenics worldwide distribution is ready to serve your mixing needs . . . anywhere . . . anytime.


    Kenics Mixers are used in numer-ous industries for a variety of blend-ing, dispersion, heat transfer andresidence time control applications.

    TYPICALAPPLICATIONSAgricultural Chemicals

    • Fertilizer and pesticide preparation

    • Gas/liquid dispersion

    • Dilution of feed concentrates


    • Chlorination and oxidation

    • Organic/aqueous dispersions

    • Dilution of acids and bases


    • Heating slurries and pastes

    • Additive blending

    • Dispersion of oils


    • Chemical addition for enhanced oil recovery

    • Injection of geothermal steam

    • Preheating coal/oil slurries

    • NOX/SOX control


    • Blending food constituents

    • Washing fats and oils with acid

    • Heating and cooling sugar solutions

    • Starch slurry cooking


    • Nutrient blending

    • pH control

    • Sterilization

    Grain Processing

    • Starch conversion

    • Chemical addition

    • Mud dilution

    • Steam injection

    Minerals Processing

    • Metals recovery by solvent extraction

    • Chemical addition and pH control

    • Oxidation and bleaching


    • Adhesive and epoxy dispensing systems

    • Adhesives heating

    • Monitoring and sampling systems

    Paints & Resins

    • Dilution of TiO2 slurries

    • Coloring and tinting

    • Solvent blending

    Petrochemical & Refining

    • Blending gaseous reactants

    • Washing hydrocarbon streams

    • Gas scrubbing

    • Lube oil blending

    • Crude oil sampling

    Polymers & Plastics

    • Blending reactants & catalysts

    • Thermal homogenization

    • Plug flow finishing reactors

    • Preheating polymers prior to devolatization

    Pulp & Paper

    • Stock dilution and consistency control

    • Chemical and coatings preparation

    • pH control

    • Pulp bleaching

    Rubber Processing

    • Blending latex compounds

    • Adding pre-polymers and activators

    • Heating and cooling adhesives


    • Blending additives

    • Eliminating thermal gradients

    • Heating and cooling polymers

    • Achieving uniform heat history

    Water & Waste Treatment

    • Polymer dilution

    • pH control

    • Chemical addition and flash mixing

    • Disinfection and aeration


  • Name_______________________________________________________ Title__________________________

    Address_____________________________________________________ Phone________________________

    City_________________________________________________________ FAX__________________________

    State/Zip____________________________________________________ E-Mail________________________

    Process Description: Mixing or Dispersion

    Units Stream 1 Stream 2 Stream 3 Mixture

    Component Name ____________ ____________ ____________ ____________

    Flow Rate ____________ ____________ ____________ ____________ ____________

    Density ____________ ____________ ____________ ____________ ____________

    Viscosity ____________ ____________ ____________ ____________ ____________

    Temperature ____________ ____________ ____________ ____________ ____________

    Pressure ____________ ____________ ____________ ____________ ____________

    Liquid/Gas/Solids ____________ ____________ ____________ ____________

    Process Requirement: ■■ Blending ■■ Dispersion ■■ Reaction ■■ Residence Time

    Components Miscible: ■■ Yes ■■ No Interfacial Tension:______________

    Required Droplet/Bubble Size:______________________ Allowable Pressure Drop:______________________

    Process Description: Heating/CoolingSpecific Thermal Flow Gravity T, in T, out Viscosity Sp. Heat Cond. Rate

    Process Fluid ________ ______ ______ ________ ________ ________ ______________

    Heating/Cooling Fluid ________ ______ ______ ________ ________ ________ ______________

    Allowable Pressure Drop: Jacket____________ Tube______________

    Mechanical Design

    Material of Construction:_________________________ Existing Line Size:______________________________

    End Connections: ■■ Plain ■■ THD ■■ Flanged Type:__________ Class:_________________________

    Design Temperature:____________________________ Design Pressure:_______________________________

    Other Process Details/Special Requirements:______________________________________________________




    Commercial Requirements:

    Pricing: ■■ Budgetary ■■ Immediate Purchase

    Delivery Requirement:____________________________

    Response needed by: ■■ Today ■■ Tomorrow

    ■■ One Week ■■ Other______

    Tel: 978-687-0101 Fax-Back Process Analysis Form FAX: 978-687-8500

    Comments: ____________________________




    Date________________ Items_______ of______

    Item ref. _________________________________


    B800E-mail: [email protected]

  • © 2009 by Chemineer, Inc.® Chemineer, Kenics, Greerco, Prochem, Thermogenizer and CEDS are registered trademarks of Chemineer, Inc.Chemineer, Inc. is a part of the Fluid Management Group of Robbins & Myers, Inc.

    Printed in U.S.A.3.5M PPI 1109

    For the nearest sales office call 1-800-643-0641 or go to

    Your Local Contact:

    Chemineer International Sales Offices:BrazilMexicoSingaporeChinaIndia

    Chemineer, Inc.125 Flagship DriveNorth Andover, MA 01845Telephone: (978) 687-0101Fax: (978)

    Chemineer, Inc.P.O. Box 1123Dayton, Ohio 45401Telephone: (937) 454-3200Fax: (937)

    Chemineer, Ltd.7 Cranmer RoadWest MeadowsDerby DE21 6XTEnglandTelephone: 44-1332-363175Fax: 44-1332-290323

    Bulletin 800

    Chemineer, Inc. is part of the family of businesses that

    comprise the Fluid Management Group of Robbins &

    Myers, Inc. The Robbins & Myers Fluid Management

    Group is a leading provider of innovative fluid man-

    agement solutions that deliver superior performance,

    long service life and exceptional value. The Group

    brings together its global resources — engineering,

    manufacturing, application expertise and cutting-

    edge, proprietary technology — to deliver high quali-

    ty, dependable products, effective system solutions

    and responsive support services to benefit customers


    Satisfying a broad range of application needs, the

    Fluid Management Group focuses its resources on

    the oil and gas discovery and recovery, chemical

    process, water and wastewater, food, biofuels,

    pulp and paper, pharmaceutical and numerous

    other industries.

    The Fluid Management Group’s parent company,

    Robbins & Myers, Inc., supplies highly-engineered,

    critical equipment and systems for global energy,

    industrial, municipal, chemical and pharmaceutical

    markets. Robbins & Myers provides innovative

    products, application engineering expertise, customer

    support and a competitive cost structure that create

    value for its customers.