Innovation in Fluid Mixing

Maelstrom
Advanced Process Technologies
INNOVATION IN FLUID MIXING
About Maelstrom
Fluid Mixing - an introduction Mixer Selection - which technology? Mixing Technologies FDM High Shear FDM Low Shear IPM CDDM
Machines FDM batch high shear inline high shear inline low shear IPM batch inline Nano & Custom
2
About Maelstrom
Since 1998, Maelstrom has been a full service supplier of industrial fluid mixing machines and associated equipment to the process industries. Specialising in high energy mixing for difficult-to-mix materials, we have a range of novel and advanced mixing technologies at our disposal, some of which we have developed in-house and some of which are licensed from third parties. We design all of our equipment ourselves which gives us complete control over the design process and allows us to tailor solutions for our customers easily and quickly. Manufacturing is typically performed by our well-developed base of ISO 9002 certified contractors and we take full advantage of being located in the prime aerospace, automotive and nuclear manufacturing region of the UK. We started out by taking on fluid processing problems for certain large companies who had already tried alternative, standard approaches and had met with failure, either in product performance or cost over-runs. Working with these companies to solve their often complex problems led us to develop the Maelstrom business as an innovative mixing solutions provider and provider of last resort. Quite simply, this means that we consistently aim to provide the best and most cost-effective solution to any fluid mixing problem that cannot be addressed by conventional means. Operating from our base in Glossop within the High Peak area of Derbyshire, England, we have been servicing the UK market for advanced mixing solutions since 1998. Our expanding client-base includes some of the worlds largest process companies, but we also work with smaller companies seeking to introduce new, disruptive products which present special processing challenges. A good example of this is the recent development of nanotechnology, an area where we see an increasing number of our clients needing special, high-energy dispersion solutions for improved product performance. We have developed some special-purpose dispersion technology and equipment targeted at this sector.
Peter Brown Managing Director
Location
Maelstroms main offices are in Glossop within the beautiful High Peak area of Derbyshire, England and we also have a demonstration and laboratory facility in Denton, nearer Manchester. All of Maelstroms design and assembly is done here with the exception of our range of Distromix FDM mixers which are also available through our local licensees in Japan, China and India.
Website
For more information and latest news on Maelstrom products and services, please visit our website. An online product configurator and quotation system is also available on the website for quick and easy pricing of our standard mixer ranges.
FLUID MIXING
AN INTRODUCTION
The mixing of one or more components or materials in a fluid system can be described in terms of two separate but interlinked physical processes: Blending (distribution) of different components of the mixture to create uniformity throughout the mix, and Droplet or particle size reduction (dispersion) of one or more components of the mixture to give increased homogeneity of the system or to alter the nature of the system by increasing the contact surface area between the components, i.e. reducing the particle or droplet sizes increases their contact surface area to volume ratio. For distributive action, swirl created by rotating parts causes
Dispersive Mixing Fn(energy)
In an ideal world, it would be possible to choose the appropriate mixing action to suit the requirements of the fluid and then select either a batch or continuous form. In practice, many mixing technologies are offered in either batch or continuous form but not both. In situations where both are offered, there are normally some performance trade-offs.
Fluid Mixing Mechanisms

In terms of mechanical mixing mechanisms, a number of actions are employed by different types of mixers to create different effects for particular process results.
laminar thinning of the material interfaces, thereby increasing volumetric combination of the materials. A repeated cutting and folding action of the mixture also increases the distribution of different material components. The effectiveness and efficiency of a mixer in distributive mixing is therefore a function of how the machine interacts with the fluid in a geometric sense.
Distributive Mixing Fn(geometry)
Conversely, the effectiveness and efficiency of a mixer in dispersive mixing is a function of how the machine interacts with the fluid in a stressing sense. For most materials, the higher the stress, the smaller the resulting particles or droplets in the mixture. However, another very important consideration is the uniformity of the stress field. Without a reasonable
A fluid system in this context means a combination of materials which combine to form a fluid, where a fluid is defined as matter which cannot sustain a shear force while at rest. In particular, we are considering liquid-liquid and solid-liquid mixing systems here, as distinct from dry powder or gas-liquid mixing systems.
uniformity, it is impossible to guarantee that the same stress is applied to all parts of the fluid. This would result in a wide range of final droplet or particle sizes rather than a narrow range obtained with uniform stressing. One or more of the three primary stressing mechanisms are
Most fluid mixing problems can be considered in terms of the miscibility (the ease of mixing) of the system components. Miscibility can in turn be thought of as the ease of distribution and the ease of particle size reduction - this affects the mixing approach to be adopted. For instance, where the rate of reaction between miscible components is to be improved, mixing efforts are focused on maximising distribution, while for mixing immiscible fluids, efforts are focused on reducing droplet or particle size to maximise the area of contact between the phases. A further consideration is the type of production process involved, of which the fluid mixing is normally only a part. The most important distinction that affects the mixing operation is whether the process is batch or continuous in nature. In a
used in most fluid mixers. These mechanisms are:
EXTENSION
IMPACT
SHEAR
Of these mechanisms, the most effective is extensional stressing. This is why nozzle valve homogenisers are used to create many of the ultra-fine dispersions demanded by process industries, despite their many practical disadvantages, and why common high shear mixers do not give the best dispersions.
batch process, a discrete volume of material is mixed, usually within a vessel; in a continuous process, a stream of material is mixed, usually piped to and from the mixer.
MIXER SELECTION
WHICH MAELSTROM TECHNOLOGY?
Maelstrom is a relatively unusual company in the field of fluid mixing in that it offers more than one technology solution. Understanding that there is no such thing as the perfect mixer and that different technologies must be applied to achieve particular results for different materials means that customers can be sure of getting the correct solution for their situation. In fact Maelstrom will go further and will also integrate third party equipment to make sure the customer gets the right results. The three key Maelstrom technologies of FDM, IPM and CDDM are intended to fill the dispersion/distribution space which has largely been neglected and to extend performance into new areas for higher energy nanomaterial dispersions and other leadingedge applications. The Maelstrom product range comprises
Rotor-stator homogenisers
THE DISPERSION / DISTRIBUTION PERFORMANCE SPACE

DISPERSION
Controllable Deformation Dynamic Mixing (CDDM)

High pressure nozzles & valves Integral
Pump Mixing (IPM)

Fluid Division Mixing (FDM) Rotor-stator high shear & jet mixers Impellers & static mixers
machines and systems based on these three technologies which are normally used in isolation but can, on occasion be combined to good effect, e.g. using FDM as a pre-processor for IPM or CDDM machines. The flowchart below provides a starting point for the selection of a particular Maelstrom mixing technology based on user requirements but please consult Maelstrom directly for more detailed advice.
DISTRIBUTION
START
MAELSTROM MIXING TECHNOLOGY SELECTION FLOWCHART
Batch or inline?
Solids included in mix?
Very high viscosity blending? Solids included in mix? Hard particles in mix?
Hard particles in mix?
Mixing dispersion priority?
Mixing dispersion priority?
Extreme dispersion needed?
IBV
(Integrimix) Batch IPM
DB
(Distromix) Batch FDM
DCL
(Distromix) Inline FDM
DC
(Distromix) Inline FDM
ICV
(Integrimix) Inline IPM
CDDM
Inline Nano Mixer
BATCH MIXERS
INLINE MIXERS
FDM FLUID DIVISION MIXING

TECHNOLOGY - HIGH SHEAR WHAT IS IT?
FDM high shear technology uses the same patented rotor-stator geometry as its low shear variant but is operated at much higher speeds. The geometry comprises a concentric rotor and stator with spherical segment cavities machined into their facing surfaces. The rotor and stator are based on a stepped conical form so that the diameter of the cone increases from inlet to outlet, giving a centrifugal self-pumping effect. At high rotational speeds, the combination of turbulent colliding vortices and inter-cavity transfer actions results in very high hydraulic shear forces being developed within the fluid. This gives a strong high shear mixing action with a number of advantages over traditional blade and screen type high shear mixers.
HOW DOES IT WORK?

Fluid moving from inlet to outlet through the mixing head is driven both axially and radially by the pumping and rotational forces generated by the rotor component. As fluid enters the mixing head, it fills the first paired rotor-stator row of cavities.
WHAT IS IT FOR?
The performance, robustness, simplicity and flexibility of FDM high shear mixers make them suitable for a very wide range of mixing duties where rapid dispersion and blending are required. FDMs are available in both batch and inline forms to suit the application and can be used wherever you would otherwise select a high shear mixer. Fast dispersion of powders into liquids, coarse homogenisation and coarse emulsification (2 to 5 micron typical range) are the main application areas for these rotor-stator device
The motion of the rotor initiates spin in the fluid and the direction of spin in the rotor cavities is opposite to that in the stator cavities. The fluid vortices formed by this action collide with one another, imparting hydraulic shear. It is this shearing action that transfers energy to the fluid for particle and droplet size reduction. An additional effect of the contra-vortex motion of the fluid is intimate microscopic-scale blending. This helps with rapid and complete powder dispersion in liquids.
WHAT ARE THE ADVANTAGES OF FDM?

Improved performance over conventional rotor-stator high shear mixers giving finer dispersions in a shorter time Low cost and improved wear resistance for applications involving abrasive solids Unique hydraulic shearing action means that tight tolerances are avoided so that machines can be more robust with consistent performance. Multiple additives can be injected directly into the mixing head to simplify dosing piping A wide range of options is available including hygienic and hazardous area versions, various construction materials, special seals and performance tuning add-ons for specific tasks. A weakness of standard high shear mixers is their high wear rates when used for mixing abrasive slurries. This wear causes a rapid fall-off in performance which FDM does not experience due to its use of the hydraulic shearing action. In addition, the rotor and stator components of FDM machines can be made from different materials to offer improved wear resistance over standard 316 stainless steel. Hardened toolsteels and zirconia ceramic offer up to 5x and 10x the working life respectively.
WHAT ABOUT WEAR RESISTANCE?
316 stainless
Toolsteel
Zirconia ceramic
FDM FLUID DIVISION MIXING

TECHNOLOGY - LOW SHEAR WHAT IS IT?
FDM low shear technology uses the same patented rotorstator geometry as its high shear variant but is operated at low speeds, keeping fluid in the laminar flow regime. The geometry comprises a concentric rotor and stator with spherical segment cavities machined into their facing surfaces. The predominant mixing effect in the laminar mode is inter-cavity transfer, a wellproven distributive mixing phenomenon suited to high viscosity, shear sensitive fluids.
HOW DOES IT WORK?

As fluid is pumped into the inlet of the low shear FDM machine, it meets the cavities in the rotor before being forced through the gap between the rotor and stator and encountering the stator cavities. The fluid is transferred between the rotor and stator components as it progresses along the tortuous flowpath as it is simultaneously being cut and folded by the movement of the rotor. The large gaps and gentle cutting and folding action give rise to the low-shear blending properties with no material able to bypass the mixing zone. Dosing injectors mounted around the conical outer surface of the stator allow multiple stream to be added directly into the mixing cavities for the best possible mixing results. Rotational speeds are typically in the range of tens to hundreds of rpm, ensuring that flow remains laminar such that potentially undesirable turbulent shear is avoided.
WHAT IS IT FOR?
FDM low shear machines provide extremely good inline distributive mixing (blending) of high viscosity fluids such as pastes, syrups, gels and plastics. The even distribution of small amounts of additives such as colours, flavours, inhibitors etc. into these kinds of materials is normally very difficult. However with FDM, it is achieved it with ease. The temperature of the fluid can also be controlled by jacketing the stator of the machine and by providing heating or cooling to a hollow rotor. This allows FDM low shear machines to be used in a wide range of high viscosity inline mixing applications, replacing pin and paddle mixers for higher flowrates and improved mixing quality.
Rotor-stator gap ~1mm
STATOR
Dosing injector
ROTOR
WHAT ARE THE ADVANTAGES OF FDM?

Inter-cavity transfer action provides proven blending performance benefits over pin and paddle mixers.
Rotational speed ~50-100rpm
STATOR
Ultra-low shear mixing protects shear-sensitive materials and allows effective blending and texturing without heating Simple rotor-stator design with conical geometry allows easy access and dismantling for cleaning and maintenance Multiple additive streams can be dosed directly into the mixing head for optimum blending performance A wide range of options is available including hygienic and hazardous area versions, various construction materials, special seals and performance tuning add-ons for specific tasks.
Dosing injector
HOW DOES FDM COMPARE TO CAVITY TRANSFER MIXERS?

The Cavity Transfer Mixer invented in 1980 by RAPRA is a cylindrical rotor-stator mixer with geometry and intent similar to the FDM. The FDM is essentially an improvement on the cylindrical design to overcome three major problems: 1. Cost reduction - the conical FDM geometry is much easier and cheaper to produce than the clam-shell design of the cylindrical form 2. Cleanability - the quarter-spherical segments of the FDM are inherently easier to clean than the hemispherical segments of the Cavity Transfer Mixer and are able to self-clean in many instances. It is also easier to open the FDM. 3. Short-circuiting of low viscosity additives - the cylindrical geometry of the Cavity Transfer Mixer allows low viscosity additives to bypass the cavities by keeping to the gap between rotor and stator. This is not possible with FDM.
IPM INTEGRAL PUMP MIXING

TECHNOLOGY WHAT IS IT?
IPM is a fluid mixing technology developed and patented by Maelstrom that combines elements of existing technologies to provide high performance with some unique features. By integrating internal positive displacement pumping and nozzle geometries, IPM machines are essentially medium-pressure multi-nozzle homogenisers that can be operated either inline or directly immersed in the batch vessel. The extent of dispersive and distributive blending can be tuned by varying parameters such as nozzle diameter, rotation speed and other factors for each model type and for different models in the range.
Mechanical seal
HOW DOES IT WORK?

The key to IPM performance is the use of an integrated positivedisplacement pumping to drive fluid through defined flowpaths, including nozzles. This action ensures extensional, shear and impact stressing of the fluid, leading to high energy transfer and significant particle or droplet size reduction. Additional blending effects are provided by cutting and folding actions within the head so that microscopic-scale fluid blending (distribution) effects are also obtained.
Top locking ring
WHAT IS IT FOR?
Tight tolerances and sliding surface internal parts make IPM machines best suited to liquid-liquid emulsification and the dispersion of soft solids. IPM has many applications in areas ranging from food and pharmaceuticals through to lubricants, speciality chemicals and clays where high quality dispersions are needed at low cost.
Inner element Nozzles (8 rows of 3) Vanes (x8) Central element (rotor) Outer element
WHAT ARE THE ADVANTAGES OF IPM?

IPM occupies a unique performance space between rotorstator high shear mixers and high pressure homogenisers offering homogeniser performance at a small fraction of the cost Homogenisation of batches can be done directly in the vessel Integrated pumping means no external high pressure pumps Dosing of additives into inline systems can be done at low pressure - cheaper than with high pressure homogenisers Few moving parts and simple maintenance means lower running costs and total cost of ownership
Bottom locking ring
OPERATING PRINCIPLE Fluid Entry (Induction)

As the vanes move around with the central element, the chambers formed by the vanes and central and outer elements start to expand as they approach the inlet holes in the outer element. Fluid is drawn from the mixing vessel or a piped feed into the inlet holes by the low pressure in these chambers and is sheared by the vanes as it passes through these holes.
Compression and Nozzle Flow

As the chambers move past the last set of inlet holes, they become sealed from the outside and their volume starts to reduce. This pressurises the fluid through the nozzles in the central element to develop extensional flow. Fluid passes through the nozzles at very high velocities (e.g. at over 250 mph in water) and impinges on the wall of the inner element, providing a high degree of impact stressing.
Post-Stress Conditioning and Exhaust

Once the fluid has impacted on the inner element wall, it moves under low pressure into the open space within the inner element, experiencing turbulent mixing and post-stress conditioning which is known to be beneficial in allowing time for electrostatic charge balance and membrane formation around droplets or particles. The fluid finally passes out axially through the bottom of the mixing head back into the vessel (batch mixers) or outlet piping (inline/continous mixers).
CDDM CONTROLLABLE
DEFORMATION DYNAMIC MIXING TECHNOLOGY WHAT IS IT?
CDDM is a proprietary technology developed and patented by Unilever plc and licensed to Maelstrom. It combined elements of high pressure homogenisation with inter-cavity transfer principles to provide an ultra-high performance inline dispersion system beyond the capabilities of the traditional homogeniser. Essentially, CDDM machines are inline cylindrical rotor-stator mixing devices with high pressure feed pumps. speeds are very high. Rotational The form of the CDDM can be customised to suit individual requirements but normally comprises a cylindrical rotor (which may contain heating or cooling channels) within a cylindrical stator (that may be jacketed for external heating or cooling). The rotor is turned at high speed, usually greater than 5000rpm. As the gap between the rotor and stator is typically less than 100 microns, very precise bearings and seals must be used and rotor balance is critical.
Virtual nozzle adjustment Rotational speed >5000rpm ROTOR Dosing injectors STATOR
HOW DOES IT WORK?

CDDM combines the principles of multi-stage high pressure homogenisation with inter-cavity transfer mixing to create an extremely high performance dispersive and distributive inline mixer.
WHAT IS IT FOR?
CDDM is ideally suited to liquid-liquid and solid-liquid dispersions where droplet and particle sizes need to be smaller than can be achieved using high pressure and ultrasonic homogenisers or where multiple streams need to be well mixed. High throughput dilution of super-concentrates is another ideal application. All industrial sectors can benefit from CDDM technology although customers in the food and personal care sectors who compete directly with Unilever may not be eligible as users.
WHAT ARE THE ADVANTAGES?

Extremely tight running clearances and high rotational speeds deliver exceptional levels of inline dispersion energy on a sustained basis. Ideal for nanomaterial dispersions and emulsions. A high pressure pump (external to the mixer) forces fluid Production-ready machines are available with capacities over 1 tonne/hour - the technology is not confined to research Maelstrom can provide complete solutions from automated dosing, pumping and mixing through to drives, controls and system integration to maximise returns on investment Over 20 years of R&D is invested in CDDM, making it a thoroughly developed and characterised, cost-effective technology with low barriers to entry into one end of the rotor-stator pair. Fluid moves within and between the cavities of the rotor and stator in a similar way to that seen in the FDM, i.e. with cutting and folding and turbulent shearing actions for good dispersion and distributive mixing. When the fluid reaches the far end of each rotor-stator cavity pair, it must travel through a very tight gap (nip) in order to progress to the next cavity pair. This nip can be adjusted by altering the relative axial positions of the rotor and stator to obtain a virtual nozzle effect. In sophisticated applications, CDDM machines incorporate a mechanism to adjust the nip on the fly in real time. Simpler or well-characterised applications, such as those for continuous production, can use less complex CDDM machines with a fixed nip. The virtual nozzles provide extensional stressing to the fluid in the same way as a nozzle homogeniser. However, as there are multiple nozzles in the CDDM, the effect is multiplied.
Rotor-stator gap <100m STATOR
AVAILABILITY
The licensing restrictions and specialised nature of CDDM machines mean that they are customised to each application. Please contact Maelstrom directly to discuss your requirements.
Maelstrom
DB25
LABORATORY FDM BATCH MIXER
Bringing the unique FDM high shear mixing performance to the laboratory bench, the DB25 is both a flexible laboratory tool and a test bed for scaling larger machines. Simple stirrers and agitators are useful tools in the lab but for fast, effective dispersion of powders, deagglomeration of suspended solids, emulsification and a range of other difficult processes, a high shear mixer is the correct tool for the job. The DB25 allows confident scaling of lab processes to production volumes by using a scaled version of a geometry which is common to all larger DB machines.
Dispersing Homogenising Rapid blending De-agglomerating Emulsifying Reacting Powder addition
Up to five times the energy input of other high shear mixers ensures excellent allround mixing performance and the ability to interchange mixing heads means that the DB25 can cope with a wide range of fluid volumes and mixing problems. Special versions of DB25 using air motors are available for hazardous environments whilst hygienic food and pharmaceutical applications are catered for with cleanable design and autoclavable head and shaft assemblies. Careful, intelligent design and use of state-of-the-art mixing technology make the DB25 the ideal general mixing partner in the laboratory.
SPECIFICATIONS
Nominal rotor diameter Rotor speed (typical) Typical minimum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at high viscosity (e.g. thick cream)* Viscosity range
(approx.)
DB25
STANDARD mm rpm litres (gals) litres (gals) litres (gals) cP (Pa.s) 0.5 (1/8) 10 (2.5) 4 (1) 25 1500 to 15000
DB25
WITH 50MM HEAD OPTION 50
1 (1/4) 20 (5) 8 (2)
0.1 (0.0001) to 30000 (30) 316 stainless steel wetted parts with polymer bush bearing Power ON/OFF, Mixer START/STOP, speed control pot., LCD displays of power (load) and speed, optional PC link
Materials of construction Control & Instrumentation Weight** Motor power Electrical Approvals / Certification (standard) kg (lbs) kW (hp)
25 (55) 0.4 (0.5) 240V/120Vac, fused, 500W max. CE marking (Europe), UL/ASME components (US) + others
* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required. ** Excluding control panel
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PART CODES AND ORDERING
DB25
LABORATORY FDM BATCH MIXER
DB25 _
1
Model DB25
2
Type E - electric lift M - manual lift F - flameproof/ATEX option (manual lift)
EXAMPLE DB25E means a DB25 mixer with electric lift.
CODE POSITION 2
DETAILS Type The DB25 motor, shaft and head assembly can be moved vertically up and down to enable easy insertion of the mixing head in a vessel. The mixer can be provided with an electric lift (E) with motorised up/down movement controlled by a switch on the control panel. Alternatively, a manual lift (M) allows the user to raise and lower the head with the support of a balanced gas strut and clamp. The flameproof/ATEX option (F) has a manual lift with an air motor main drive and other special features to ensure compliance with the relevant hazardous area legislation. Please contact Maelstrom for more details of the DB25F.
OPTIONS AND ACCESSORIES

CODE DB25-50 DETAILS 50mm mixing head For mixing larger volumes, a 50mm rotor and stator can be interchangeably fitted to the DB25 Spare rotor SS - 316 stainless steel TS - 400 series toolsteel - 5x improved wear ZR - zirconia - 10x improved wear Other materials are available on request including Hastelloy and titanium DB25-P Datalogging port A serial connection port fitted to the DB25 control panel allowing load and speed data signals (0-10V) to be fed to a PC datalogger. Note that this option must be specified at the time of ordering. USB data interface Multi-channel external data acquisition device with USB connection to a PC to allow logging of load and speed data. Basic Windows datalogging software included. Note that option DB25-P is required. Datalogging interface cable Serial connection cable linking the DB25-P port to the LABUSB interface. Excel datalogging upgrade Upgrade to the basic datalogging software of the LABUSB option to enable data export to Microsoft Excel for detailed analysis. SS - 316 stainless (standard) TS - toolsteel ZR - zirconia ceramic
DB25-ROT-SS DB25-ROT-TS DB25-ROT-ZR
LAB-USB
LAB-CBL
LAB-XL
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Maelstrom
DB75-200
PRODUCTION FDM BATCH MIXERS Dispersing Homogenising Rapid blending De-agglomerating Emulsifying Reacting Powder addition
High quality dispersions and emulsions are at the heart of most fluid production processes. Maelstroms DB range of production high shear mixers offers the benefits of patented Fluid Division Mixing (FDM) technology in a cost-effective, flexible format. With standardised hoist, bridge and vessel mountings and a wide range of options for abrasive, flameproof and hygienic applications, the DB range really is the all-round performer in high shear mixing. The unique FDM high shear action uses the principles of inter-cavity transfer and hydraulic shear to deliver high levels of mixing energy to the fluid. Using its centrifugal self-pumping action, fluid is drawn into mixing head and subjected to strong cavity vortex actions which shear the fluid against itself. In contrast to conventional rotor-stator mixers, all of the material passing through the head experiences the same mixing actions. This reduces the number of passes needed and therefore the mixing time.
MODEL RANGE
Nominal rotor diameter Typical maximum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at high viscosity (e.g. thick cream)* Viscosity range
(approx.)
DB75
mm litres gals litres gals Pa.s (cP) 75 50 15 20 5
DB100
100 200 50 80 20
DB125
125 1000 250 400 100
DB150
150 2000 500 800 200
DB175
175 5000 1500 2000 500
DB200
200 10000 2500 4000 1000
0.0001 (0.1) - 30 (30,000) 33 73 2.2 3 6000 65 145 5.5 7.5 120 265 11 15 165 365 18.5 25 3600 CE marking (Europe), UL/ASME components (US) + others 270 595 30 40 365 800 45 60
Weight**
kg lbs kW hp rpm
Motor power range (standard**) Rotor speed (typical max.) Approvals / Certification (standard)
* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required . ** Typical for alloy motors. Larger and non-standard motors available on request
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DB75-200
PRODUCTION FDM BATCH MIXERS
DB_ _ _-_-_-_ _ _ _ _ _ _
1
Model DB
8
Special options N - no special options H - hygienic option F - flameproof/ATEX option Seal N - no seal L - lip (dust) seal S - single mechanical High flow option D - double mechanical N - no high-flow F - high flow impeller
Size _75 100 125 150 175 200
Cavity rows -2-3 -3-4
Motor size In kW x 10
EXAMPLE DB125-2-3-110FFNH means a DB mixer with 125mm diameter rotor, 2 cavity rows on the stator and 3 on the rotor, 11kW motor, flange mounted with high flow impeller, no seal. Special hygienic design option included.
Mounting F - flange P - pedestal C - crane hoist B - bottom entry
CODE POSITION 3
DETAILS Cavity rows The number of rows of mixing cavities on the stator and the rotor. A 2-3 configuration gives more pumping (agitation) and less mixing whilst a 3-4 option provides the opposite. Mounting The mixer can be mounted above a vessel on a bridge using a simple flat flange plate (F) or it can be mounted directly onto the top of a lidded vessel using a pedestal (P). A crane hoist mount (C) allows the mixer to be suspended above the vessel for frequent removal whilst a bottom-entry mounting (B) enables the mixer to be fitted into the vessel from underneath using a mechanical seal. High flow option The unique design of the DB mixing head allows an axial flow impeller (F) to be mounted on the upper surface of the rotor. This can provide greatly increased agitation for low viscosity fluids in the vessel where it is impractical or expensive to use a separate impeller/stirrer to improve batch uniformity. Seal A seal can be selected for a pedestal mounted mixer. A lip (dust) seal (L) is suitable for non-critical, non-pressurised applications whereas a single (S) or double (D) mechanical seal is needed for pressurised, hygienic and toxic applications. A bottom entry mounted mixer must be fitted with a single or double mechanical seal. There are many options relating to seals including materials of construction, pressure ratings, hygienic assessment ratings etc. Please contact Maelstrom for advice on seal selection for a particular application. Special options Machines designed specifically for hygienic (H) and flameproof/ATEX (F) applications.
2 row stator 3 row rotor 3 row stator 4 row rotor
Crane hoist
Pedestal
Bridge
Bottom entry
Vented top plate Impeller 3 row rotor
Impeller Types
2 row stator
Lip or V-ring Seal
Single Mech. Seal
Double Mech. Seal
Seal
Filler & level gauge
Quench cup
Flush IN
Flush OUT
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Maelstrom
DC50
LABORATORY FDM INLINE MIXER
For consistent, repeatable
Dispersing Homogenising Rapid blending De-agglomerating Emulsifying Reacting Diluting
mixing results in the laboratory, the DC50 inline high shear mixer is hard to beat. Using high performance FDM high shear technology in a simple, convenient benchtop format, many common laboratory mixing tasks can be performed with the minimum of effort. Whilst batch mixers are very familiar and convenient for small vessels, ensuring that all of the mixture has seen the same stress history and that the process can be reliably scaled up to production levels demands inline mixing. Simple, quick-release pipe couplings and excellent flushing/cleaning performance are critical to ease of use in the lab. Combined with a powerful and flexible electric motor and controller and discrete fluid injection port, the DC50 offers all of these features and many more, making it simply the easiest and most flexible inline high shear mixer to use in the lab environment. Special versions of DC50 are available for hazardous environments and dedicated hygienic food and pharmaceutical applications.
SPECIFICATIONS
Nominal rotor diameter Rotor maximum speed (typical) Typical maximum flowrate Viscosity range
(approx.)
DC50
mm (inch) rpm 50 (2) 6000* 800 (3.5) 0.1 (0.0001) to 30000 (30)
litres/hr (gpm) cP (Pa.s)
Ports Materials of construction Seal Control & Instrumentation (optional) Weight** Motor power Electrical (typical values) Approvals / Certification (standard)
* Using optional frequency inverter/speed controller at 100Hz. ** Excluding control panel
1 diameter inlet and outlet RJT, Triclamp, threaded and ANSI options 316 stainless steel wetted parts with stainless steel baseplate and aluminium bearing housing Single component mechanical seal with carbon/ ceramic faces and Viton o-rings (EPDM option) Power ON/OFF, Mixer START/STOP, speed control pot., LCD control panel, optional PC link kg (lbs) kW (hp) 30 (66) 1.1 (1.5) Motor only: 3 phase 240Vac, 50/60Hz, Optional controller: 1 phase, 240Vac, 50/60Hz CE marking (Europe), UL/ASME components (US) + others
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DC50
LABORATORY FDM INLINE MIXER
DC50-_-_-_ _ _ _
1
Model DC50 Motor Size In kW x 10 Seal S - single mechanical D - double mechanical
5
Special options N - no special options H - hygienic option F - flameproof/ATEX option
DC50-4-4-11SH means a DC50 mixer with 4 cavity rows on the rotor and stator, 1.1kW motor, a single mechanical seal and hygienic design option. CODE POSITION 2 DETAILS
Cavity rows The number of rows of mixing cavities on the stator and the rotor. A 2-3 configuration gives lower stress than the standard 4-4 option for materials that are more sensitive to shear.
2 row stator 3 row rotor
Seal A single mechanical seal (S) is fitted as standard but a double (flushed) mechanical seal (D) can be specified, if required. Special options Machines designed specifically for hygienic (H) and flameproof/ATEX (F) applications.
Note that although the DC50 will provide some centrifugal pumping action for low viscosity fluids, additional upstream pumping is highly recommended to ensure independent control of flowrate and mixing speed for best performance.
RECOMMENDED SYSTEM CONFIGURATIONS

TRUE INLINE MIXING RECIRCULATING BATCH MIXING MULTI-PASS INLINE MIXING
DC50 MIXER PUMP
DC50 MIXER PUMP
DC50 MIXER
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Maelstrom
DC75-200
PRODUCTION FDM INLINE MIXERS
High shear mixing performance combined with robust design and high quality components make the DC range of inline production machines an excellent choice for many processes.
Dispersing Homogenising Rapid blending De-agglomerating Emulsifying Reacting Diluting
The DC range features FDM high shear technology which uses inter-cavity transfer and hydraulic shear to deliver up to five times the mixing energy of conventional high shear mixers. This translates into faster throughputs and better, finer dispersions and emulsions with particle and droplet sizes typically in the 2 to 5 micron range. A wide range of mixing head and flange fitting options mean that the DC range can be easily included in most existing processes, much like a simple centrifugal pump. Special options for hygienic and CIP operation are available for food and pharmaceutical applications and flameproof versions can be provided for hazardous areas. A choice of single or double mechanical seals in various materials is offered to compliment specific applications. Whether you are replacing an existing high shear mixer or moving from batch to inline processing for the first time, the DC range should be your first port of call for simple operation and robust, reliable performance.
MODEL RANGE
Nominal rotor diameter Typical maximum flowrate (water) Viscosity range
(approx.)
DC75
mm litres/hr gals/min Pa.s (cP) 75 2500 10
DC100
100 6000 25
DC125
125 12000 50
DC150
150 20000 90
DC175
175 30000 130
DC200
200 50000 220
0.0001 (0.1) - 30 (30,000)* 1 36 80 2.2 3 6000*** 1.5 65 145 5.5 7.5 1.5 140 310 11 15 2 255 560 18.5 25 3600 CE marking (Europe), UL/ASME components (US) + others 2.5 385 850 30 40 3 440 970 45 60
Ports
(RJT, Triclamp and ANSI options)
inch kg lbs kW hp rpm
Weight**
* For fluids towards that upper end of this viscosity range, the addition of a pump upstream of the mixer is highly recommended. ** Typical for alloy motors. Larger and non-standard motors available on request *** Achievable using optional frequency inverter drive
16
DC75-200
PRODUCTION FDM INLINE MIXERS
DC_ _ _-_-_-_ _ _ _ _
1
Model DC
6
Seal S - single mechanical D - double mechanical Special options N - no special options H - hygienic option F - flameproof/ATEX option
Size _75 100 EXAMPLE DC100-4-4-55SH means a DC100 mixer 125 with 4 rows of cavities in the rotor and 150 175 stator, 5.5kW motor, single mechanical 200 seal and hygienic design option.
Motor Size In kW x 10
CODE POSITION 3
DETAILS Cavity rows The number of rows of mixing cavities on the stator and the rotor. A 2-3 configuration gives lower stress than the standard 4-4 option, for materials that are more sensitive to shear.
Seal A single mechanical seal (S) is fitted as standard but a double (flushed) mechanical seal (D) can be specified, if required. Special options Machines designed specifically for hygienic (H) and flameproof/ATEX (F) applications.
Note that although the DC range will provide some centrifugal pumping action for low viscosity fluids, additional upstream pumping is highly recommended to ensure independent control of flowrate and mixing speed for best performance.

DC MIXER PUMP
DC MIXER PUMP
DC MIXER
17
Maelstrom
DCL100-350
ULTRA-LOW SHEAR FDM INLINE MIXERS
For controlled inline mixing and blending of shear-sensitive ingredients, the DCL range of FDM mixers provides the answer.
Delicate blending Shear-sensitive mixing Texturing Structuring Reacting Diluting
Using the unique FDM cavity geometry incorporating intercavity transfer principles, DCL machines deliver a gentle cutting and folding action to high viscosity fluids in the laminar flow regime. For many high viscosity applications, difficult batch mixing processes can be replaced by a DCL machine operating downstream of a pump or extruder. Low viscosity ingredients can be dosed directly into the mixing head at multiple points using injectors, making the DCL ideal for adding colours, treatment agents and other additives to a high viscosity stream. Rugged design, very low pressure drop and a wide range of options make DCL machines easy to partner with existing equipment and easy to tailor for a specific application. The mixing head is also very cleanable - an important consideration if jacketed heating options are chosen and bake-on is a possibility or if adhesives are being processed. Special options for hygiene and CIP operation are available for food and pharmaceutical applications and flameproof versions can be provided for hazardous areas.
MODEL RANGE
Nominal rotor diameter Typical maximum flowrate (paste) mm litres/hr gals/min litres/hr gals/min Pa.s (cP)
DCL100
100 9000 40 900 4
DCL150
150 20000 90 2000 9
DCL200
200 36000 160 3600 16
DCL250
250 55000 240 5500 24
8
DCL300
300 75000 330 7500 33
DCL350
350 100000 440 10000 44
Typical maximum flowrate (rubber) Viscosity range

(approx.)
1 (1000) - 100,000 (10 )* 1 75 165 1.5 2 15 20 1.5 130 290 3 4 30 40 1000 1.5 270 600 5.5 7.5 45 60 2 550 1200 11 15 75 100 2.5 750 1650 18.5 25 150 200 200 3 960 2100 30 40 250 330
Ports
inch kg lbs kW hp kW hp rpm
Weight**
Motor power range (paste)
Motor power range (rubber) Rotor speed (typical max.) Approvals / Certification (standard)
CE marking (Europe), UL/ASME components (US) + others
* For fluids towards that upper end of this viscosity range, substantially stronger components and higher power drives are used. ** Typical for paste viscosities and alloy motors. Larger and non-standard motors available on request.
18
DCL100-350
ULTRA-LOW SHEAR FDM INLINE MIXER
DCL_ _ _-_-_-_ _ _ _ _
1
EXAMPLE DCL200-4-4DH means a DCL200 mixer with 4 rows of cavities in the rotor and stator, double mechanical seal and hygienic design option. CODE POSITION 3 Model DCL
2
Size 100 150 200 250 300 350
6
Seal S - single mechanical D - double mechanical B - stuffing box R - reverse pumping groove Special options N - no special options H - hygienic option F - flameproof/ATEX option
Motor Size In kW x 10
DETAILS Cavity rows The number of rows of mixing cavities on the stator and the rotor. A 2-3 configuration gives lower stress than the standard 4-4 option, for materials that are more sensitive to shear and which may require very light processing. The 4-4 option is standard. Seal A single mechanical seal (S) is fitted as standard but a double (flushed) mechanical seal (D), stuffing box with gland packing (B) or reverse pumping groove (R) can be specified, if required. The choice of seal depends on how the mixer is used and the lubricating/cooling properties of the process fluid. Special options Machines designed specifically for hygienic (H) and flameproof/ATEX (F) applications.
Note that as the DCL range is designed to provide a pure low shear mixing action and cannot be assumed to provide any pumped pressure. An upstream pump suited to the viscosity of the process fluid is required in all cases.

GEAR PUMP FED DCL (PASTES) EXTRUDER FED DCL (PLASTICS)
DCL MIXER
DCL MIXER
19
Maelstrom
IBV40
LABORATORY IPM BATCH MIXER Emulsifying Homogenising De-agglomerating1 Stabilising
The IBV40 makes it possible to homogenise small volumes of fluids inside the vessel. In a laboratory environment, the ability to perform homogenisation and emulsification in a beaker has traditionally been the domain of rotorstator (high shear) mixers but these cannot produce the results of nozzle homogenisation. Using Maelstroms unique, patented IPM technology, the IBV40 combines to the benchtop. internal pumping with integrated Smaller droplet and particle sizes nozzles to bring new levels of batch mixing performance with narrower size ranges allow finer and more stable emulsions and dispersions to be formed directly in the vessel. The results are easily scalable too, with larger batch and inline IPM mixers able to translate laboratory processes into the factory. IBV40 machines are supplied with a separate controller boasting infinitely variable speed, displays of both speed and load and optional outputs to datalogging software. In terms of both performance and versatility, the IBV40 package is the ideal homogenisation partner in the laboratory.
1 The sliding nature of internal components makes the IBV40 unsuited to the processing of hard or abrasive solids.
SPECIFICATIONS
Nominal rotor diameter Rotor speed (typical max.) Typical minimum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at high viscosity (e.g. thick cream)* Viscosity range
(approx.)
IBV40
mm rpm litres (gals) litres (gals) litres (gals) cP (Pa.s) 40 1500 0.5 (0.13) 5 (1.25) 3 (0.8) 0.1 (0.0001) to 30000 (30) 316 stainless steel wetted parts + PEEK vanes & bearings Power ON/OFF, Mixer START/STOP, speed control pot., LCD displays of power (load) and speed, optional PC link kg (lbs) kW (hp) 31 (68) 1.1 (1.5) 240V/120Vac, fused, 2000W max. CE marking (Europe), UL/ASME components (US) + others
Materials of construction Control & Instrumentation Weight** Motor power Electrical controls Approvals / Certification (standard)
* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required. ** Excluding control panel
20
IBV40
LABORATORY IPM BATCH MIXER
IBV40
IBV40 laboratory batch IPM mixer 1.0mm diameter nozzle rotor 1.1kW 4-pole induction motor Single mechanical shaft seal Stainless steel base and support column Separate control panel with speed control and digital speed and load displays Cables and user manual
OPTIONS AND ACCESSORIES

CODE IBV40-P DETAILS Datalogging port A serial connection port fitted to the IBV40 control panel allowing load and speed data signals (0-10V) to be fed to a PC datalogger. Note that this option must be specified at the time of ordering. USB data interface Multi-channel external data acquisition device with USB connection to a PC to allow logging of load and speed data. Basic Windows datalogging software included. Note that option IBV40-P is required. Datalogging interface cable Serial connection cable linking the IBV40P port to the LAB-USB interface. Excel datalogging upgrade Upgrade to the basic datalogging software of the LAB-USB option to enable data export to Microsoft Excel for detailed analysis.
LAB-USB
LAB-CBL
LAB-XL
SPARES
CODE IBV40-ROT SPARES Rotor (Central Element) The rotor carries the nozzles which provide the extensional stressing action of the IBV machine. Rotors with different nozzle diameters are available to suit particular fluid viscosities. Vane set - PEEK Spare set of 8 vanes in PEEK polymer Thrust bearings - PEEK Spare set of 2 thrust bearings in PEEK polymer Radial bearings - PEEK Spare set of 2 radial bearings in PEEK polymer 0.5mm 1.0mm 2.5mm
IBV40-VSP
VSP
TBP
RBP
IBV40-TBP
IBV40-RBP
21
Maelstrom
IBV60-100
PRODUCTION IPM BATCH MIXERS Emulsifying Homogenising De-agglomerating1 Stabilising
The IBV range of production IPM batch mixers provides multi-nozzle homogenisation of fluids directly in the vessel. Delivering dispersion and shearing performance between that of high pressure homogenisers and rotor-stator high shear mixers, IBV machines offer a unique combination of performance and flexibility at a very competitive price. Improved emulsion stability, shelf-life and texture results from reducing the droplet size of the dispersed phase. IBV mixers can be used to achieve droplet sizes down to 1 micron in typical oil/water systems with a very narrow range of sizes across the sample, compared to the typical 3-5 micron range for a rotor-stator mixer. IPM technology is based on an arrangement of multiple nozzles combined with a vane pumping effect that enables mixers to develop high levels of extensional fluid stress as fluid is pressurised through the nozzles. This stress breaks up droplets in a similar way to high pressure homogenisers which is why IBV mixers are so effective, even without the expensive high pressure pumps that are the key feature of the traditional inline homogeniser. The self-pumping nature of the mixing head is also what makes it suitable for use as a batch machine, meaning that all of the homogenisation benefits are available in batch processes.
1
The sliding nature of internal components makes IBV mixers unsuited to the processing of hard or abrasive solids.
MODEL RANGE
Nominal rotor diameter Typical maximum mixing volume at low viscosity (e.g. water) Typical maximum mixing volume at high viscosity (e.g. thick cream)* Viscosity range
(approx.)
IBV60
mm litres gals litres gals Pa.s (cP) 60 200 50 50 15
IBV100
100 1000 250 250 65
0.0001 (0.1) - 30 (30,000) 33 73 5.5 3 1500 CE marking (Europe), UL/ASME components (US) + others 65 145 25 7.5
Weight**
kg lbs kW hp rpm
* For fluids in this viscosity range, supplementary agitation using some form of impeller may be required . ** Typical for alloy motors. Larger and non-standard motors available on request
22
IBV60-100
PRODUCTION IPM BATCH MIXERS
IBV_ _ _-_ _ _ _ _
1
Model IBV Size _60 100 Motor size In kW x 10 EXAMPLE IBV60-55PF means an IBV60 mixer with 5.5kW motor, pedestal mounted with high flow impeller. Single mechanical seal fitted within mixing head. Mounting F - flange P - pedestal C - crane hoist
5
High flow option N - no high-flow F - high flow impeller
CODE POSITION 4
DETAILS Mounting The mixer can be mounted above a vessel on a bridge using a simple flat flange plate (F) or it can be mounted directly onto the top of a lidded vessel using a pedestal (P). Note that the mechanical seal is mounted inside them mixing head so that only a static seal (o-ring) is needed for the mixer shaft as it passes through the vessel wall or lid. A crane hoist mount (C) allows the mixer to be suspended above the vessel for frequent removal. High flow option The design of the IBV mixing head allows the driveshaft to be extended through the centre of the mixer and a radial impeller (F) to be fitted to it. The impeller can provide greatly increased agitation for low viscosity fluids in the vessel where it is impractical or expensive to use a separate impeller/stirrer to improve batch uniformity. Crane hoist Pedestal Bridge
SPARES
CODE IBVxxx-ROT SPARES Rotor (Central Element) The rotor carries the nozzles which provide the extensional stressing action of the IBV machine. Rotors with different nozzle diameters are available to suit particular fluid viscosities. Vane set - PEEK Spare set of 8 vanes in PEEK polymer Thrust bearings - PEEK Spare set of 2 thrust bearings in PEEK polymer Radial bearings - PEEK Spare set of 2 radial bearings in PEEK polymer 1mm 2.5mm 5mm
IBVxxx-VSP
VSP
TBP
RBP
IBVxxx-TBP
IBVxxx-RBP
23
Maelstrom
ICV40
LABORATORY IPM INLINE MIXER
When rotor-stator high shear mixers cannot deliver the performance needed and a high pressure homogeniser is beyond the budget, an ICV40 inline mixer may be the ideal answer. A benchtop machine based
Emulsifying Homogenising De-agglomerating Stabilising
on Maelstroms unique IPM technology, the ICV40 provides shear, extensional and impact stressing to fluids for efficient mixing energy transfer. This gives finer droplets and particles with the narrow dispersion range normally associated with high pressure homogenisers. Typical droplet sizes down to 1-2 microns are achievable in oil/water systems without emulsifying agents. High performance in a laboratory homogeniser usually means compromised flexibility, cleanability and ease of use. An ICV machine, in contrast, can be used just like a positive displacement vane pump, providing pressures of up to 5 bar at the outlet and strong suction at the inlet. Modular design and the ability to deal with soft solids as well as emulsions, make ICV machines the idea lab partner. Special versions of ICV are available for use in hygienic and hazardous area applications. Please consult Maelstrom for specific information on these options.
SPECIFICATIONS
Nominal rotor diameter Rotor maximum speed (typical) Typical maximum flowrate Viscosity range
(approx.)
ICV40
mm (inch) rpm 40 (1.6) 1750* 200 (0.9) 0.1 (0.0001) to 100000 (100) FLAMEPROOF / ATEX VERSION
litres/hr (gpm) cP (Pa.s)
Ports Materials of construction Seal Control & Instrumentation (optional) Weight** Motor power Electrical (typical values) Approvals / Certification (standard)
* At 60Hz motor supply frequency. ** Excluding control panel
3/4 diameter inlet and outlet RJT, Triclamp, threaded and ANSI options 316 stainless steel wetted parts with stainless steel baseplate and aluminium bearing housing Single component mechanical seal with carbon/ ceramic faces and Viton o-rings (EPDM option) Power ON/OFF, Mixer START/STOP, speed control pot., LCD control panel, optional PC link kg (lbs) kW (hp) 35 (77) 1.5 (2) Motor only: 3 phase 240Vac, 50/60Hz, Optional controller: 1 phase, 240Vac, 50/60Hz CE marking (Europe), UL/ASME components (US) + others
HYGIENIC VERSION
24
ICV40
LABORATORY IPM INLINE MIXER
ICV40-11_ _
1
Model ICV40 EXAMPLE ICV40-11SH means an ICV40 mixer with 1.1kW motor, a single mechanical seal and hygienic design option. CODE POSITION 3 DETAILS Seal A single mechanical seal (S) is fitted as standard but a double (flushed) mechanical seal (D) can be specified, if required. Special options Machines designed specifically for hygienic (H) and flameproof/ATEX (F) applications. SPARES Rotor (Central Element) The rotor carries the nozzles which provide the extensional stressing action of the ICV machine. Rotors with different nozzle diameters are available to suit particular fluid viscosities. Vane set - PEEK Spare set of 8 vanes in PEEK polymer Thrust bearings - PEEK Spare set of 2 thrust bearings in PEEK polymer Radial bearings - PEEK Spare set of 2 radial bearings in PEEK polymer 0.5mm 1.0mm 2.5mm Motor Size In kW x 10 Seal S - single mechanical D - double mechanical
4
Special options N - no special options H - hygienic option F - flameproof/ATEX option
CODE ICVxxx-ROT
ICVxxx-VSP
VSP
TBP
RBP
ICVxxx-TBP
ICVxxx-RBP

ICV40 MIXER
PUMP ICV40 MIXER ICV40 MIXER
PUMP
25
Maelstrom
ICV60-100
PRODUCTION IPM INLINE MIXERS
Bridging the gap between high shear rotor-stator mixers and high pressure nozzle homogenisers, ICV mixers provide exceptional mixing performance at a low price point.
Emulsifying Homogenising De-agglomerating1 Stabilising
High flow rates and efficient mixing energy transfer are key benefits of Maelstroms proprietary IPM mixing technology, making ICV machines ideally suited to a wide range of emulsification and homogenisation tasks. IPM combines shear, extensional flow and impact stress mechanisms with an integral positive displacement pumping action to ensure that all fluid passing through the mixing head experiences the same levels of stress. This results in finer droplets and particles with a narrower dispersion range normally associated with high pressure homogenisers. Typical droplet sizes down to 1-2 microns are achievable in oil/ water systems without emulsifying agents. Simple operation and integrated pumping action make ICV mixers simple to integrate into most production processes and maintenance costs are low due to the user of low-cost polymer wear parts and quick-assembly modular construction. ICV machines are offered with either single or double mechanical seals and a range of options including special hygienic design features for food and pharmaceutical use.
1 The sliding nature of internal components makes ICV mixers unsuited to the processing of hard or abrasive solids.
MODEL RANGE
Nominal rotor diameter Typical maximum flowrate (water) Viscosity range
(approx.)
ICV60
mm litres/hr gals/min Pa.s (cP) 60 4000 20
ICV100
100 10000 45
0.0001 (0.1) - 100 (100,000)* 1 65 145 5.5 7.5 1750 CE marking (Europe), UL/ASME components (US) + others 2 300 660 30 45
Ports
inch kg lbs kW hp rpm
Weight**
* For fluids towards that upper end of this viscosity range, the addition of a pump upstream of the mixer is highly recommended. ** Typical for alloy motors. Larger and non-standard motors available on request *** Achievable using optional frequency inverter drive
Note that although the ICV range will provide good positive displacement vane pumping action for low and medium viscosity fluids, additional upstream pumping is highly recommended to ensure independent control of flowrate and mixing speed for best performance. Care must be taken in specifying pumps that match or exceed the flowrate of the ICV machine to avoid starvation at the ICV inlet.
26
ICV60-100
PRODUCTION IPM INLINE MIXERS
ICV_ _ _-_ _ _ _ _
1
Model ICV EXAMPLE ICV100-300SH means an ICV100 mixer with 30kW motor, single mechanical seal and hygienic design option. CODE POSITION 5
2
Size _60 100
5
Seal S - single mechanical D - double mechanical Special options N - no special options H - hygienic option
Motor size In kW x 10
DETAILS Seal A single mechanical seal (S) is fitted as standard but a double (flushed) mechanical seal (D) can be specified, if required. Special options Machines designed specifically for hygienic (H) applications. SPARES 1mm Rotor (Central Element) The rotor carries the nozzles which provide the extensional stressing action of the ICV machine. Rotors with different nozzle diameters are available to suit particular fluid viscosities. Vane set - PEEK Spare set of 8 vanes in PEEK polymer Thrust bearings - PEEK Spare set of 2 thrust bearings in PEEK polymer Radial bearings - PEEK Spare set of 2 radial bearings in PEEK polymer VSP 2.5mm 5mm
CODE ICVxxx-ROT
ICVxxx-VSP
TBP
RBP
ICVxxx-TBP
ICVxxx-RBP

ICV MIXER
PUMP ICV MIXER ICV MIXER
PUMP
27
Maelstrom
NANO & CUSTOM

SPECIALISED FLUID EQUIPMENT Nano-dispersions Nano-emulsions Encapsulation Fluid structuring High pressure pumps
Please contact us directly to

With its emphasis on solving challenging mixing problems, Maelstrom has developed a range of high performance nanodispersion and nano-emulsification equipment that push the boundaries of what is possible to achieve with mechanical mixing and dispersion devices. Using combinations of crushing, grinding, ultra-high pressures, high speeds and extremely small running clearances, Maelstrom can deliver a machine tailored to your application. Using our own in-house technologies together with specific licenses from Unilever, we have developed machines for nanoscale CDDM (Controllable Deformation Dynamic Mixing). With rotational speeds of up to 50,000 rpm and pumped fluid pressures to 5000 bar, CDDM mixers deliver unparalleled mixing energy to fluids for dispersion and de-agglomeration of nano-scale colloids. Described as the best mixer in the world by a world-leading process company, CDDM is opening up new fluid structuring and formulation opportunities to organisations facing the challenges of innovation with their existing, increasingly obsolete mixing technologies. Maelstrom can provide the design, manufacture, integration, installation, commissioning and certification of complex fluid processing systems including the necessary electrical and hydraulic controls. The CDDM installation at the University of Liverpools Ultra Mixing and Processing Facility (UMPF - pictured above) is an example of this integrated approach with Maelstrom as the prime contractor managing the entire system design, delivery and commissioning phases of the project within both time and budget constraints. Other examples of Maelstroms custom process equipment design include specialised shear pumps for viscous materials, a shear conditioner for a polymer meltstream, a custom IPM machine for batch chocolate processing (pre-conching) and an inline dosing pump skid for the offshore drilling market.
discuss your nano-processing or other custom applications.
28
HEAD OFFICE
Maelstrom Advanced Process Technologies Ltd First Floor 59-61 High Street West Glossop Derbyshire SK13 8AZ United Kingdom Tel: Fax: email: web: +44 (0)1457 867777 +44 (0)1457 862207 sales@maelstrom-apt.com www.maelstrom-apt.com
LICENSEES / DISTRIBUTORS Japan

Satake Chemical Equipment Mfg. Ltd 66 Niizo Toda-shi Saitama 335-0021 Japan Tel: Fax: web: +81 48 433 8711 +81 48 433 8541 www.satake.co.jp
China
Yiyang Rubber & Plastics Machinery Group Co. Ltd (part of ChemChina Group) 64 Huilong Road Yiyang Hunan China Tel: Fax: email: web: +86 737 429 9404 +86 737 429 8888 group@chinamixing.com www.chinamixing.com
India
Chempro Technovation Pvt. Ltd 3 Sukhshine Complex, Sunrise Park Drive-In Road Ahmedabad 380054 Gujarat India Tel: Fax: email: web: +91 079 268 51135 +91 079 268 51154 info@chempro.in www.chempro.in
Copyright 2010 Maelstrom APT Ltd., England. All rights reserved. No reproduction of any part of this publication is permitted without written authorisation of the Company. The information in this literature is provided without prejudice and is subject to alteration without notice. It may not be relied upon in making any purchasing decisions and is not intended to support any contract. For the latest information and pricing on any Maelstrom product, please contact the Company directly.
29

Innovation in Fluid Mixing

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Advanced Process Technologies