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Statiflo Motionless Mixers are
Driving the Costs out of Continuous Process Industry

Inline Static Mixers can be used in almost every Continuous Process Industry

Statiflo Static Mixers are used in almost all continuous processes throughout the world. By using the same concepts which are applied to other industries, Statiflo have developed an offering to improve almost any process.

At a time when increased efficiency of all process industries, both in an economical and environmental sense, is becoming an increasingly important issue, there is a high demand for technologies which can provide both cost savings and energy savings.

Applications such as general chemical production, polymer processing, metal smelting and the production of synthetic oils all use Statiflo Inline Static Mixers to improve their effiiciency, product purities and consistently produce on-spec products.

With environmental factors ever-more important in today’s industries, increased focus is being placed on DeNOx, DeSOx and other Selective Catalytic Reduction (SCR) and Selective Non-Catalytic Reduction (SNCR) processes. A Statiflo Static Mixer can be used for the makeup of treatment chemicals or within the gas scrubbing process itself.

Using a Statiflo Inline Mixer allows chemicals to be dosed effectively and efficiently – reducing the need to compensate for poor mixing by overdosing chemicals and therefore helping to minimise the quantities of chemical dosed.

Another added benefit is that, more often than not, representative sampling can be done immediately at the Static Mixer discharge which means the shortest possible control loop times and results in the very best control of your process.

Continuous Process Industries
General Industrial Inline Static Mixer for Continuous Process in Stainless Steel
In assessing the benefits of Statiflo Motionless Mixers. It is important to remember.

  • Overall length can be varied to suit space limitations.
  • Element geometry can be designed for both high and low head loss systems.
  • Large diameter – no theoretical upper limits.
  • Elements for rectangular or other unusually shaped ducts and open channels
  • Special designs for incorporating in bends, offer space saving and minimal disturbance to piping systems.
  • Guaranteed highly efficient mixing.
  • No moving parts provide a maintenance free operation.
  • Reduction in operational energy costs, as no direct power is required.
  • Ease of installation.
  • Minimal space requirements with no upstream or downstream pipe lengths required. Providing short control process times in applications where quick process response control is critical.
  • Short process chemical dosing control loops provide optimum performance in response to rapidly changing process conditions, as well as reducing chemical costs.
  • Available in a wide ranges of sizes and material to suit most applications.
  • Each unit is custom designed benefiting from Statiflo’s long term experience in designing and manufacturing static mixers to the highest of standards.
  • Total support is provided by highly trained engineers situated in Statiflo regional country offices and a world wide representative network.

Application Examples and Case Studies

How is it possible to optimise the temperature of washwater used for cooling and removing trace contaminants from fibres during the final stages of rayon manufacture?

A robust method for heating acidified recycled washwater was required. Direct steam injection into cold fluids in an empty pipe is thermally efficient, but results in other serious problems associated with vibration, noise and poor temperature control.

Dispersing steam, or some other phase, in a liquid flowing in an empty pipe, with its unpredictable and uncontrolled shear history, results in a very wide bubble or droplet size distribution. The larger bubbles of steam, formed in this way, tend to violently condense causing vibration, noise and, in extreme circumstances, equipment failure.

Statiflo Static Mixers have been successfully used in this operation.

For further information see case study.

Continuous Process Industries

The Statiflo Series 700 Motionless Mixer is designed specifically for polymer processing. The mixer has continuous edge sealed construction to prevent short-circuiting of the mixing process and to provide mechanical integrity at high pressure drop. The Mixer housing is machined to precisely match the customers adjacent piping dimensions. Reducers and sudden diameter changes are avoided.

Laminar flow mixing takes place by flow division and radial mixing, rapidly eliminating radial differences in polymer temperature. Mixers are positioned immediately before each flow split in the manifold delivery system, to develop a thoroughly mixed condition and ensure identical polymer is pumped to the next mixer and split flow.

Very high quality internal surface finish in the mixer is essential for efficient flow and to prevent material hang up, especially where colour change occurs often.

For further information see case study.

Process with highly viscous polymer melts

Continuous Process

Problem A “man-made” fiber spinning plant produces thousands of individual threads simultaneously. All threads come from a polymer melt, which is provided with a very high viscosity, high pressure, and…

See Full Case Study

High Viscosity Polymer Processing

Continuous Process

Problem High Viscosity Polymer Processing: A man-made fibre spinning plant simultaneously produces thousands of individual filaments. All the filaments originate from a single source of high viscosity, high temperature and…

See Full Case Study

Related Products 

Continuous Process Industries

General Industrial Static Mixer (Series 100/150)

Statiflo General Industrial Inline Static Mixers suitable for all process industries supplied with fixed or removable mixing elements. Usually supplied…

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PTFE Corrosion Resistant Static Mixer (Series 300)

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400 Series Pvc Static Mixer

Plastic Static Mixer (Series 400)

Statiflo Series 400 Pipe Mixers: Plastic construction for cost effective general purpose and corrosion resistant duties. (Sometimes known as a…

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GRP/FRP Static Mixer (Series 500/550)

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Series 850 Statiflo Steam Sparger, Used For Direct Steam Injection.

Steam Heater/Direct Steam Injection Static Mixer (Series 800/850)

Direct steam heaters in steel and exotic alloys for all industries. Fixed elements with integral steam injector or injector jacket.…

Statiflo DesalMixer - A Short Length Wafer-style Mixer

Compact Static Mixers

A range of Inline Compact (sometimes called Wafer-Style) Static Mixers originally developed to meet the special requirements of the global…

Inline Static Mixer, CHEMICAL DOSING LANCES

Chemical Dosing / Injection Lances

Statiflo Chemical Dosing Lances / Injection Lances are specifically designed to meet the needs of industry and maximise the mixing…

S-Type Mixers

S-Type Static Mixer (Available in stock)

Statiflo Inline Static Mixers suitable for all process industries. Pre-fabricated and packed - meaning you can have rapid delivery of…

Contact us for more information

The above is a brief example of applications for Statiflo Motionless Mixers in Continuous Process Industries.

For further details and information on other applications, please complete the attached contact form or visit our contact us page to get in touch with us.

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