Definition
The pilot high-speed disperser is a hybrid dispersion equipment used in laboratories and small and medium-scale production stages. It shears, impacts, and breaks solid particles in liquid media through a high-speed rotating dispersion disc, thereby achieving uniform dispersion, mixing, dissolution, or emulsification of materials.
Principle
The core working principle of the pilot high-speed disperser is based on shear and turbulence effects in fluid mechanics. The motor drives the shaft and rotates the dispersion disc mounted at the end of the shaft at high speed. Dispersion discs usually have a serrated or open-hole structure, and when they rotate at high speed, they generate a strong radial force that sucks the material from the bottom of the container along the axial direction and then throws it at high speed along the radial direction to the container wall. In this process, the material is subjected to strong mechanical and hydraulic shear forces, and the agglomerated solid particles are effectively broken up and fully mixed with the liquid medium. The shear rate produced by it is directly related to the linear velocity of the dispersion disk, which v can be calculated by the formula v = π × D × n, where D is the diameter of the dispersion disk and n is the rotation speed of the shaft.
Measurement and evaluation methods
Measurement and evaluation of dispersion effect is the key to verifying the feasibility of the process. Common measurement methods include particle size analysis, which uses a laser particle size meter to monitor changes in particle size distribution, with D50 or D90 values as quantification indicators for dispersion. For emulsion systems, the dispersion stability can be evaluated by observing the stratification or sedimentation rate with a stability analyzer. In addition, the viscosity of the system before and after dispersion can be measured by a viscometer, or the microscopic dispersion state of particles can be directly observed through a microscope. All measurements should follow relevant industry standards and be repeatedly tested under fixed process parameters to ensure data reliability.
Influencing factors
The dispersion effect is affected by multiple factors. In terms of equipment parameters, the diameter, shape, tooth structure and linear velocity of the dispersion disc are the main factors that determine the shear strength. In the process parameters, the processing time, material temperature control, and feeding sequence and speed all have a significant impact on the final result. Material properties are also critical, including the viscosity and density of the continuous phase (solvent), as well as the concentration, initial particle size, hardness, and surface properties of the dispersed phase (particles or droplets). The geometry of the vessel, the design of the baffle and the amount of material filled can affect the flow field morphology, which can change the mixing efficiency.
Applications
The pilot high-speed disperser plays an important role in many industrial R&D and trial production fields. In the coatings and inks industry, it is used for the verification of pre-dispersion and toning processes of pigment slurries. In the field of new energy, it is used for the uniform mixing of battery cathode and anode paste and the dispersion of conductive agents. In the fine chemical industry, it is used to prepare nanomaterial dispersions, adhesives, or sealants. In the food industry, it can be used for the development of emulsification and homogenization processes for sauces and condiments. Its core value is to provide reliable experimental data and process models for formulation research, process parameter optimization and scale-up production in the above fields.
Equipment selection considerations
The selection process needs to be systematically evaluated based on specific process objectives and material characteristics. First of all, it is necessary to clarify the properties of the treated material, such as viscosity range, corrosiveness, whether it contains volatile solvents or flammable components, which is related to the selection of equipment material, sealing method and explosion-proof grade. Second, determine the effective volume of the vessel and the motor power range based on the expected throughput. Third, consider the flexibility of the process, such as whether speed regulation, lifting, vacuum or pressurization, and temperature control interfaces are required. Finally, the cleanability of the equipment, ease of maintenance, and connection to existing production lines are also important practical considerations. It is recommended to use material trials to verify that critical performance meets expectations.