What is a static mixer?

A static mixer is a motionless inline mixing device installed in a pipeline. It uses the flow energy of the process fluid to achieve homogeneous mixing, blending, or dispersion without any moving parts. Static mixers are used in water treatment, oil and gas, chemical processing, polymer production, food and pharmaceutical manufacturing.

What types of static mixers does Primetech manufacture?

Primetech manufactures three series: KE Series (Kenics-equivalent helical element mixer, DN25–DN600, suitable for all Reynolds Number ranges), SX Series (Sulzer SMX-equivalent cross-bar mixer, DN10–DN300, for deep laminar high-viscosity applications), and VN Series (Ross LPD-equivalent radial vane mixer, DN100–DN1200, for large-bore turbulent service).

Which static mixer is best for water treatment?

For water treatment applications such as chlorination, pH control, coagulant flash mixing, fluoridation and ozonation, the KE Series helical element static mixer is the standard choice. For large-bore water mains (DN300 and above) where pressure drop must be minimised, the VN Series LPD vane mixer is preferred with its K-factor of 0.7 per stage.

Which static mixer is best for polymer blending and melt mixing?

For high-viscosity polymer melt blending, colour masterbatch letdown, and two-component adhesive mixing, the SX Series cross-bar static mixer is recommended. It handles viscosity ratios up to 1,000,000:1 and provides exponential striation growth (2^N per element). For lower-viscosity polymer dilution and in-line blending, the KE Series helical element mixer covers all flow regimes.

Which static mixer is best for oil and gas applications?

For crude oil blending, scale and corrosion inhibitor injection, biocide dosing, demulsifier injection and fuel blending in oil and gas pipelines, the KE Series helical element mixer handles the full range of Reynolds Numbers from laminar to turbulent. For large-bore crude blending pipelines, the VN Series LPD vane mixer provides minimal pressure drop.

What mixing performance can I expect from a Primetech static mixer?

All Primetech static mixers are designed to achieve a Coefficient of Variation (CoV) of 0.05 or less at the mixer discharge, indicating 95% or better mixing uniformity. The number of elements or stages required depends on the application — typically 6–12 elements for the KE Series, 8–24 for the SX Series, and 6–8 stages for the VN Series.

What size range do Primetech static mixers cover?

Primetech static mixers cover DN10 (SX Series, laboratory scale) to DN1200 (VN Series, large water mains). The KE Series covers DN25 to DN600, the SX Series DN10 to DN300, and the VN Series DN100 to DN1200.

What materials are available for Primetech static mixers?

Primetech static mixers are available in Carbon Steel, 304 Stainless Steel, 316 Stainless Steel, 316L Stainless Steel, Duplex 2205, Super Duplex 2507, Hastelloy C-276, Titanium Grade 2, FRP Vinyl Ester, Polypropylene, and Rubber-Lined Carbon Steel. Sanitary (3-A/BPE compliant) and ATEX hazardous area options are available.

How is a static mixer different from an agitator or dynamic mixer?

A static mixer has no moving parts — it uses only the kinetic energy of the flowing process fluid. This means zero maintenance, no seals, no power consumption beyond the pipeline pump, and no mechanical failure modes. Dynamic mixers (agitators, impellers) require motors, seals, bearings and regular maintenance. Static mixers are installed permanently in the pipeline and are significantly more cost-effective for continuous flow processes.

Can static mixers handle slurries and fibrous media?

The VN Series LPD vane static mixer is specifically designed for slurry service up to 20% solids content, fibrous media, and two-phase gas-liquid flows. Its open vane geometry avoids the plugging issues that affect helical and cross-bar mixers with particulate-laden fluids. The KE Series can handle low-concentration slurries provided the particle size is small relative to the element gap.

What is a Kenics-type static mixer?

A Kenics-type static mixer uses 180-degree helical twisted elements, alternating between right-hand and left-hand rotation, joined at 90 degrees to each other. This geometry creates radial mixing and flow division — the number of striations doubles with each element. Primetech's KE Series is the Kenics-equivalent design, covering DN25 to DN600 across all Reynolds Number flow regimes.

What is a Sulzer SMX equivalent static mixer?

A Sulzer SMX-equivalent static mixer uses an intersecting cross-bar lattice at plus and minus 45 degrees to the pipe axis, creating a three-dimensional mixing grid. It provides exponential striation growth (2^N per element) and is specifically designed for deep laminar, high-viscosity applications. Primetech's SX Series is the SMX-equivalent design, covering DN10 to DN300 for Reynolds Numbers below 500.

Does Primetech ship static mixers internationally?

Yes, Primetech Static Mixers supplies to customers worldwide including the Middle East, Southeast Asia, Europe, Africa and the Americas. Units are manufactured in Chennai, India and shipped with full documentation including material certificates, dimensional reports and hydrostatic test certificates as required.

What certifications do Primetech static mixers carry?

Primetech Static Mixers is ISO 9001:2015 certified. Products are designed to ASME B31.3 Process Piping and PED 2014/68/EU (Pressure Equipment Directive). NACE MR0175 / ISO 15156 compliance is available for sour service. 3-A and BPE compliant sanitary construction is available for food and pharmaceutical applications.

How do I size a static mixer for my application?

To size a static mixer you need: fluid properties (viscosity, density, flowrate for each stream), pipe diameter, allowable pressure drop, and the required mixing uniformity (target CoV). Submit your data using the Static Mixer Sizing Questionnaire on this website and our engineering team will provide a sized recommendation with pressure drop calculations within one business day.

Applications · Chemicals

STATIC MIXER FOR EMULSIFICATION & LIQUID-LIQUID DISPERSION

Production of stable oil-in-water (O/W) or water-in-oil (W/O) emulsions using the controlled turbulent shear field of the KE mixer. Droplet size is governed by Weber number and interfacial tension.

Immiscible | Weber Number | Droplet Size Control

← Back to Applications

1–100 µm Target D32

Key Parameter 1

We = ρV²D/σ

Key Parameter 2

DN25–DN200

Key Parameter 3

Narrow PSD

Key Parameter 4

Process Scheme

Continuous Phase

→

Pump

→

Dispersed Phase + Surfactant

▼

KE Mixer

→

Emulsion Product

Mixing Criteria

Target Sauter mean diameter D32 set by We number: We = ρV²D/σ. For D32 <10 µm, We >10 required. Surfactant must be present at mixer inlet to stabilise droplets immediately on formation. Dispersed phase volume fraction <30% for O/W emulsion stability.

Typical Viscosity

Continuous phase: 0.5–100 cP (centipoise). Dispersed phase: 0.5–5000 cP

Reynolds Number (Re)

Reynolds Number (Re) 2,000–100,000 (turbulent)

Material & Special Requirements

Preferred MOC: 316SS for general chemical and food emulsions. 316L with Ra ≤0.8 µm for sanitary emulsification. FRP for corrosive emulsion chemistry.

Surfactant injection nozzle immediately upstream of mixer (not downstream). Dispersed phase injection through centreline quill. Multiple injection ports for high dispersed-phase fractions. Temperature control if exothermic.

Recommended Mixer

KE Series — Helical Element

Kenics-equivalent. 180° RH/LH helical elements joined at 90°. Halves striation thickness per element. Works laminar to turbulent. Best general-purpose choice.

KE Series →

Build Model Code → Request Application Quote →