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1、TheArtofHighShearMixingThehigh-shearrotor/statormixer(HSM),oncerelegatedtoarelativelynarrownicheofmixingapplications,hasbecomeamainstayinmanyapplicationsinthechemicalprocessindustries(CPI).Theabilitytoapplyintenseshearandshortenmixingcyclesgivesthesemixersbroadappealforapplicationsthatrequirei
2、mmisciblefluidstobeformulatedintoemulsions,oragglomeratedpowderstobedispersedintoaliquidmedium.Especiallyduringthelastdecade,theemergenceofnewvariationsontheoriginalrotor/statormixerconcepthasextendedtheHSM’susefulnesstomorediverseapplications.Forinstance,conventionalHSMsinbothtop-enteringbatc
3、hconfigurationsandinlineversions,arewidelyusedtodayforhigh-intensitymixing,dispersion,disintegration,emulsificationandhomogenization.Applicationsrangefromdispersionsinvolvinggums,pigments,fumedsilica,calciumcarbonateandactivedrugs,toemulsionssuchascosmeticcreams,lotions,andflavors.However,desp
4、itethegrowingpopularityofHSMsinmanyindustries,theyarestillwidelymisunderstood.Industry-basedanduniversityresearchershavefocusedmainlyonworkingoutthedynamicsofconventionallow-shearmixingtechnologies,suchasaxial-andradial-flowturbines.Withonlyafewnotableexceptions,high-shearmixinghasbeenlargelyo
5、verlookedintermsoffundamentalresearchtounlockitsmysteriesandhelpuserstobetterpredictmixingoutcomes,particularlyduringscale-up.Sincethebodyofliteratureavailableforpredictiveengineeringrelatedtorotor/statormixingisextremelythin,theapplicationofHSMsisoftenapproachedempirically—withheavyemphasison
6、application-specifictestinganddevelopmentbyindividualmanufacturersintheprocessindustries.AfewusershaveinvestedheavilyandachievedimpressivesuccesswithHSMsinnarrowlydefinedapplicationssuchasonesinvolvingemulsionpolymersandpigmentdispersions.Othershavebeenlesssuccessfulontheirown.Mostprospectiveu
7、sersofHSMsrelyontherecommendationofmixermanufacturers,whooftenkeeptheirproprietaryapplicationguidelinesacloselyguardedsecret.Theresultofthislackofavailableknowledgeabouthigh-shearmixingisthatmisconceptionsregardingtheproperapplicationan
