The reaction mixer is a specialized stirring device designed and manufactured by our company, tailored for specific industrial processes including chemical reactions, biological fermentation, catalysis, crystallization, and gas-liquid/liquid dispersion. Unlike conventional mixing equipment, this system is engineered to achieve efficient mass transfer, heat transfer, and momentum transfer (collectively termed the "three transfers") under precisely controlled temperature, pressure, and flow field conditions. It is designed to meet the kinetic requirements of reaction processes in fields such as chemical engineering, pharmaceuticals, environmental protection, new energy, and bioengineering.
- Structure and Working Principle
- Core structural composition
The equipment is typically an integrated system designed for use with reaction vessels (reactors, tanks, or vessels), primarily comprising:
- Power and Transmission System: The system typically integrates explosion-proof motors with high-precision reducers (e.g., gear or planetary reducers) to reliably deliver the required torque and rotational speed under specific operating conditions.
- Sealing system: Mechanical seals, packing seals, or magnetic coupling seals may be selected for critical components based on the reaction medium and pressure requirements, designed to comply with pressure vessel standards and leak-proof specifications.
- Stirring shaft and impeller system:
- Stirring shaft: Made of high-strength materials (e.g., stainless steel or alloy steel), featuring excellent rigidity, corrosion resistance, and fatigue resistance.
- Special-purpose impellers: Designed to meet process requirements (e.g., dispersion, emulsification, suspension, heat transfer), common types include turbine, paddle, anchor-frame, screw-belt, and their combinations.
- Auxiliary system interface: can be designed with matching baffles, flow guide tubes, temperature/pressure measurement interfaces, intake/liquid distribution devices, etc., to optimize the flow field and process conditions within the reactor.
- Working Principle
The drive system rotates the impeller in the reaction medium via the stirring shaft. Its core function is:
- Macro mixing: generates large-scale circulation flow to reduce temperature and concentration gradients within the reactor, thereby achieving more uniform material distribution.
- Micro-mixing and dispersion: The high shear force generated at the tip of the impeller is designed to reduce the size of droplets or bubbles, increase the interfacial contact area, and thus enhance mass transfer and reaction rates.
- Heat conduction enhancement: Promotes the relative motion between the fluid and heat exchange surfaces (e.g., jackets, coils) to improve heat transfer efficiency and control reaction temperature.
III. Core Technical Features
- The design of the equipment can consider the viscosity change of the reaction system, the multiphase flow characteristics, the heat release/absorption intensity and the process scaling up law, aiming to better match the specific process.
- High parameter controllability: Typically supports precise speed control (e.g., variable frequency drive) and integrates sensors for temperature, pressure, pH, etc., designed to monitor and regulate process parameters.
- Emphasis on equipment safety and sealing: For reactions involving toxic, hazardous, flammable, explosive substances or requiring a sterile environment, the sealing grade, material compatibility, and structural safety are key considerations in design.
- The material selection offers extensive options: components in contact with materials can be selected from stainless steel (304/316L), Hastelloy, titanium, or PTFE/PFA-lined plastic, depending on corrosion resistance, wear resistance, and cleanliness requirements.
- Main technical parameters
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Parameter item
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Description / Customizable range example
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power bracket
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The range is broad, typically spanning from 0.75kW to several hundred kilowatts, depending on the reaction scale and process requirements.
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output speed
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According to the process design, the common range is from 10 rpm to above 300 rpm, enabling precise control.
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applicable volume
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Capable of adapting to reactors ranging from laboratory-scale (several liters) to industrial-scale (tens of thousands of liters)
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Work pressure/temperature
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According to design specifications, it can meet conditions such as atmospheric pressure, positive pressure, vacuum, high temperature, or low temperature.
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primary contact material
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Multiple corrosion-resistant materials including metals, alloys, and non-metallic options are available.
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- Typical application scenarios
This equipment is primarily used in scenarios with specific or stringent requirements for mixing and transfer processes:
- Chemical and petrochemical processes: polymerization, condensation, sulfonation, nitration, hydrogenation, oxidation, and other reaction processes.
- Pharmaceutical and Bioengineering: Drug synthesis, fermentation, cell culture, enzymatic reactions, crystallization and purification.
- Environmental Protection and New Energy: Advanced Oxidation (e.g., Fenton Reaction), Hydrometallurgy, Battery Material Synthesis, Homogeneous/Multi-Phase Catalytic Reactions.
- Food and fine chemical industry: flavor synthesis, emulsification, esterification, polymer synthesis.
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