Online citations, reference lists, and bibliographies.
Please confirm you are human
(Sign Up for free to never see this)
← Back to Search

Rotor-Stator Mixers: From Batch To Continuous Mode Of Operation—A Review

Andreas Håkansson
Published 2018 · Materials Science

Save to my Library
Download PDF
Analyze on Scholarcy
Share
Although continuous production processes are often desired, many processing industries still work in batch mode due to technical limitations. Transitioning to continuous production requires an in-depth understanding of how each unit operation is affected by the shift. This contribution reviews the scientific understanding of similarities and differences between emulsification in turbulent rotor-stator mixers (also known as high-speed mixers) operated in batch and continuous mode. Rotor-stator mixers are found in many chemical processing industries, and are considered the standard tool for mixing and emulsification of high viscosity products. Since the same rotor-stator heads are often used in both modes of operation, it is sometimes assumed that transitioning from batch to continuous rotor-stator mixers is straight-forward. However, this is not always the case, as has been shown in comparative experimental studies. This review summarizes and critically compares the current understanding of differences between these two operating modes, focusing on shaft power draw, pumping power, efficiency in producing a narrow region of high intensity turbulence, and implications for product quality differences when transitioning from batch to continuous rotor-stator mixers.
This paper references
10.1007/978-94-011-3030-1_50
On the Breakage of Drops in a Turbulent Flow
V. Tikhomirov (1991)
Fluid Mechanics, 4th ed.; McGraw-Hill
F. White (1998)
10.1016/J.CES.2018.02.021
Single droplet breakup in a rotor-stator mixer
Mohamed Ashar (2018)
10.1016/0255-2701(92)87002-X
Fast reactions in rotor-stator mixers of different size
J. Bourne (1992)
10.1016/0255-2701(94)04005-2
Developments in the continuous mechanical production of oil-in-water macro-emulsions
H. Karbstein (1995)
10.1016/J.CES.2017.06.042
Experimental investigations of turbulent fragmenting stresses in a rotor-stator mixer. Part 1. Estimation of turbulent stresses and comparison to breakup visualizations
Andreas Håkansson (2017)
10.1016/J.CHERD.2008.07.012
Flow pattern, periodicity and energy dissipation in a batch rotor–stator mixer
A. Utomo (2008)
Study on a homogenization effect and a scale-up of batch rotor-stator mixers
T. Kamiya (2010)
10.1016/J.CHERD.2013.04.021
The effect of scale and interfacial tension on liquid–liquid dispersion in in-line Silverson rotor–stator mixers☆
Steven Hall (2013)
10.1016/J.CHERD.2018.01.028
Flow studies in an in-line Silverson 150/250 high shear mixer using PIV
C. Espinoza (2018)
10.1002/CJCE.22718
Hydrodynamic difference between inline and batch operation of a rotor-stator mixer head - A CFD approach
A. Håkansson (2017)
10.1021/I260008A011
Examination of Some Geometric Parameters of Impeller Power
R. Bates (1963)
10.1016/J.CEP.2008.04.002
An expression for the power consumption of in-line rotor-stator devices
A. Kowalski (2009)
Fluid mixing in rotor/stator mixers
T. Sparks (1996)
Measurement and Comparison of Power Draw in Batch Rotor-Stator Mixers
G. A. Padron (2001)
10.1002/AIC.12703
Power consumption characteristics of an in-line silverson high shear mixer
M. Cooke (2012)
10.1016/J.CEP.2014.02.008
Dispersion of oil droplets in rotor–stator mixers: Experimental investigations and modeling
M. Jasinska (2014)
10.1016/J.CEP.2015.03.015
Power characteristics of in-line rotor stator mixers
M. Jasinska (2014)
10.1016/J.CHERD.2013.05.018
Dispersion of water into oil in a rotor–stator mixer. Part 1: Drop breakup in dilute systems
Paul E. Rueger (2013)
10.1021/IE3023274
Pump Capacity and Power Consumption of Two Commercial In-line High Shear Mixers
Qin Cheng (2012)
Studies in agitation vs. the correlation of power data
A. M. White (1934)
10.1002/CJCE.20587
Characteristics of batch rotor–stator mixer performance elucidated by shaft torque and angle resolved PIV measurements
Hans Henrik Mortensen (2011)
10.1205/02638760151095917
Research Needs and Opportunities in Fluid Mixing Technology
R. Calabrese (2001)
Power Characteristics of Mixing Impellers part 1
J. Rushton (1950)
10.1016/J.CEP.2017.01.007
The dissipation rate of turbulent kinetic energy and its relation to pumping power in inline rotor-stator mixers
A. Håkansson (2017)
10.1002/CJCE.20556
Scaling up of silverson rotor–stator mixers
Steven Hall (2011)
10.1002/AIC.690010303
Fundamentals of the hydrodynamic mechanism of splitting in dispersion processes
J. Hinze (1955)
10.1016/J.CHERD.2008.12.011
The effect of stator geometry on the flow pattern and energy dissipation rate in a rotor-stator mixer
A. Utomo (2009)
10.1016/J.CES.2017.04.020
Continuous, Recycle and Batch Emulsification Kinetics using a High-Shear Mixer
S. C. D. Hert (2017)
10.1299/JSMEMAG.59.446_235
Power Characteristics of Mixing Impellers
S. Nagata (1956)
10.1002/CJCE.5450790114
Power draw of a high‐Shear homogenizer
K. Myers (2001)
10.1016/J.CES.2010.10.010
Expression for turbulent power draw of an in-line Silverson high shear mixer
A. Kowalski (2011)
10.1016/J.CHERD.2017.12.006
Local levels of dissipation rate of turbulent kinetic energy in a rotor–stator mixer with different stator slot widths—An experimental investigation
Hans Henrik Mortensen (2018)
10.1016/J.CHERD.2017.06.020
Scale-up of batch rotor–stator mixers. Part 1—power constants
J. James (2017)
10.1016/J.CHERD.2017.03.016
The effect of stator design on flowrate and velocity fields in a rotor-stator mixer—An experimental investigation
Hans Henrik Mortensen (2017)
10.1016/J.CES.2011.01.054
Droplet break-up by in-line Silverson rotor–stator mixer
Steven Hall (2011)
10.1016/0009-2509(85)85036-3
Drop sizes of emulsions related to turbulent energy dissipation rates
J. T. Davies (1985)
10.1016/J.CHERD.2011.07.018
Rotor-Stator Devices: The Role of Shear and the Stator
T. Rodgers (2012)
Characterisation of flow pattern in a rotor stator high shear mixer
A. Pacek (2007)
Investigations of micromixing in a rotor-stator mixer
Bałdyga (2007)
Fundamentals of Interface and Colloid Science
J. Lyklema (1991)
10.1136/bmj.1.4337.269-a
Emulsions
P. B. Mumford (1944)
10.1016/J.FBP.2016.01.011
Model emulsions to study the mechanism of industrial mayonnaise emulsification
A. Håkansson (2016)
10.1016/S0009-2509(97)00072-9
On impeller circulation and mixing effectiveness in the turbulent flow regime
A. Nienow (1997)
10.1016/S0009-2509(97)00438-7
Correlation of mean drop size and minimum drop size with the turbulence energy dissipation and the flow in an agitated tank
G. Zhou (1998)
Rotor-stator mixing devices. In Advances in Industrial Mixing; Kresta
V. A. Atiemo-Obeng (2016)
10.1016/J.CEP.2012.04.004
High shear mixers: A review of typical applications and studies on power draw, flow pattern, energy dissipation and transfer properties
J. Zhang (2012)
Fluid Dynamics of Rotor Stator Mixers
Andreas Lindahl (2013)
10.1016/J.CES.2017.11.037
A validation of commonly used CFD methods applied to rotor stator mixers using PIV measurements of fluid velocity and turbulence
Hans Henrik Mortensen (2018)
10.1016/J.APPLTHERMALENG.2012.06.036
Application of test reactions to study micromixing in the rotor-stator mixer (test reactions for rotor-stator mixer)
M. Jasinska (2013)
10.1002/AIC.14315
LDA measurements and CFD simulations of an in‐line high shear mixer with ultrafine teeth
Shuangqing Xu (2014)
10.1098/rspl.1880.0007
IV. On the friction of water against solid surfaces of different degrees of roughness
W. Unwin (1881)
10.1016/J.CES.2011.01.026
High resolution experimental measurement of turbulent flow field in a high pressure homogenizer model and its implications on turbulent drop fragmentation
A. Håkansson (2011)
10.1002/CEAT.200406111
High‐Pressure Homogenization as a Process for Emulsion Formation
S. Schultz (2004)
10.1002/0471451452.CH8
Rotor–Stator Mixing Devices
V. Atiemo‐Obeng (2004)
10.1016/J.JCIS.2007.03.059
Emulsification in turbulent flow 1. Mean and maximum drop diameters in inertial and viscous regimes.
N. Vankova (2007)
10.1016/J.CHERD.2014.04.004
Scale-up of the power draw of inline-rotor–stator mixers with high throughput
B. Schönstedt (2015)
10.1002/CJCE.20553
Power and flow characteristics of three rotor-stator heads
G. Özcan-Taşkin (2011)



This paper is referenced by
Semantic Scholar Logo Some data provided by SemanticScholar