Vacuum Powerful Disperser Mixer – Structure & Working Principle Explained
1. Why Choose Stainless Steel Construction?
Stainless steel (primarily 304 or 316L) is the standard material for this type of equipment for the following reasons:
| Characteristic | Explanation |
|---|---|
| Corrosion Resistance | Resists chemical attack from acidic/alkaline materials and cleaning agents |
| Easy Cleaning | Smooth surface prevents material buildup, compliant with GMP hygiene standards |
| No Contamination | Does not release metal ions that could contaminate materials, ensuring product purity |
| Durability | High mechanical strength provides long service life |
316L stainless steel contains added molybdenum, offering superior resistance to chloride corrosion. It is recommended for applications involving salt or highly corrosive materials.
2. Core Structure Breakdown
The stainless steel vacuum powerful disperser typically features a triple-shaft gantry-type structure, consisting of four main systems:
2.1 Mechanical System – The "Skeleton" of the Equipment
Gantry Frame: Welded from heavy-gauge steel plates, it supports all agitation mechanisms and material weight, ensuring stability without vibration during high-speed operation.
Hydraulic Lifting System: Composed of hydraulic cylinders, pistons, and a hydraulic power unit. The cover can be raised and lowered vertically, facilitating easy charging, cleaning, and tank changes. Lifting height and speed can be adjusted according to process requirements.
2.2 Agitation and Dispersion System – The "Heart" of the Equipment
This is the core part that determines mixing effectiveness, utilizing a "planetary rotation + high-speed rotation" compound motion design:
| Component | Motion Type | Impeller Type | Core Function |
|---|---|---|---|
| Low-speed shaft (center) | Planetary rotation (around tank axis) | "Mountain" scraper blade | Scrapes material from tank wall/bottom, prevents dead zones, pushes material toward high-speed zone |
| High-speed shafts ×2 (sides) | High-speed rotation (around own axis) | Butterfly impeller + disperser disc | Generates high shear force, breaks down powder agglomerates, achieves micron-level dispersion |
Key Specification: The tip speed of the high-speed disperser disc must typically reach 20 m/s or higher to effectively disperse nano-scale powders. Variable frequency drive (VFD) allows stepless speed adjustment.
2.3 Vacuum System – Ensuring Product Density
Vacuum Pump: Rotary vane or liquid ring type, with pumping speed matched to tank volume.
Sealing Device: Double protection with mechanical seal + oil seal, ensuring in-tank vacuum can reach -0.098 MPa (gauge pressure).
Function: Vacuum is applied during agitation to remove air bubbles from the material, preventing voids in the final product and ensuring sealant adhesion strength and surface density.
2.4 Auxiliary Systems – Enhancing Operational Convenience
Movable Tanks: Equipped with casters on the bottom. One machine can be paired with multiple tanks for alternating production.
Jacketed Temperature Control: The tank has an outer jacket for circulating cooling water or steam, allowing precise temperature control. Silicone sealant production typically requires temperature control below 40°C to prevent heat-induced cross-linking.
Hydraulic Extruder: Ancillary equipment used to extrude the finished high-viscosity paste from the disperser tank for subsequent filling.
3. Working Process (Using Silicone Sealant Production as an Example)
Charging → Low-speed Scraping Mixing → High-speed Dispersion → Vacuum Degassing → Discharging
│ │ │ │ │
Liquids + Powders Prevents wall adhesion Breaks agglomerates Removes bubbles Hydraulic extrusion
Detailed Steps:
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Charging: Base material (e.g., 107 gum), powders (calcium carbonate, silica), and additives are loaded into the tank according to the formulation.
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Low-speed Mixing: The scraper blade operates at approximately 20-60 rpm, pushing material toward the center.
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High-speed Dispersion: Disperser discs rotate at 0-1500 rpm, generating high shear to break powder agglomerates down to micron level.
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Vacuum Degassing: Vacuum is applied continuously during dispersion to extract entrained air bubbles from the tank.
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Discharging: After dispersion is complete, the tank is moved to a hydraulic extruder to discharge the finished product.
Conclusion
Through precision engineering including triple-shaft联动, vacuum degassing, and hydraulic lifting, the stainless steel vacuum powerful disperser perfectly solves the industry pain points of difficult uniform dispersion and degassing of high-viscosity materials. Understanding its structure and working principle is the foundation for correct selection and efficient operation.
