Definition
Homogeneous emulsification disperser is a mechanical equipment used to efficiently mix two or more immiscible liquids (such as oil and water), and make the solid particles or droplets in them refine and disperse evenly to form a stable and homogeneous system. Its core function is to achieve emulsification, dispersion, homogenization and mixing of materials by applying high-strength mechanical force, and finally obtain products with a narrow particle size distribution range and high stability.
Principle
The working principle of the device is mainly based on high-speed shear, impact and hole effect. The motor drives the rotor to rotate at high speed in the stator cavity, creating a strong mechanical shear force. After the material is sucked into the working chamber, it is subjected to severe shear in the narrow gap between the rotor and the stator. At the same time, the high-speed flowing material collides with the stator wall or each other. In the local low-pressure area, there will also be a hole effect in the fluid, forming tiny bubbles that collapse instantly, generating a strong shock wave. The synergy of these physical effects can effectively break the agglomeration of droplets or particles, so that their particle size can be rapidly reduced and evenly dispersed in the continuous phase, forming a stable emulsification or dispersion system.
Key measurement methods and evaluation indicators
The core index to evaluate the dispersion effect of homogeneous emulsification is the particle size and distribution of the dispersed phase. Laser particle size analyzers are usually used for measurement, and the results are expressed in characteristic particle sizes such as D50 and D90. The stability of the system can be quantified by standing observation of stratification time, centrifugal stability testing, or using multiple light scatterometers. For emulsified systems, their viscosity, conductivity, or microstructure (e.g., by light microscopy or scanning electron microscopy) are also measured.
Main influencing factors
The final treatment effect is affected by multiple factors. In terms of equipment parameters, the linear speed of the rotor, the geometry of the stator rotor gap, and the length of the shear time are the key. In the process conditions, the initial ratio of materials, the processing temperature, the feed flow rate and method, and whether the multi-stage processing process is used all play a role. The characteristics of the material itself, such as the interfacial tension between the two phases, the viscosity of the continuous phase, and the concentration and hardness of the dispersed phase, are also the basic factors that determine the difficulty and effect of treatment. These parameters need to be systematically optimized according to the specific material system.
Applications
Homogeneous emulsification disperser is widely used. In the food industry, it is used in the production of sauces, dairy products, beverages and condiments to improve taste and shelf life. In the field of cosmetics and daily chemicals, it is the core equipment for the manufacture of creams, lotions, shampoos and toothpastes to ensure the delicate and stable texture of the products. In the chemical industry, it is used to prepare coatings, inks, adhesives, pesticide emulsions and nanomaterial suspensions, which directly affects product performance. In the field of biotechnology, it can be used for cell disruption or homogeneous mixing of media components. In addition, it also plays a role in the preparation process of slurry in the fields of new energy and new materials.
Key points to consider in selection
Equipment selection is a process of comprehensive trade-offs. The properties of the material being handled are given primary consideration, including viscosity range, solids content, particle hardness and sensitivity to shear heat. The target particle size is determined according to the pilot or process requirements, which is directly related to the shear strength and energy input of the required equipment. Choose the right working volume and flow rate based on the scale of production (batch or continuous) and the expected capacity. The structural material of the equipment needs to be compatible with the material to meet the requirements of corrosion resistance and no pollution. The durability of wearing parts, whether the equipment is easy to clean and maintain, and whether the speed and processing time can be easily adjusted are also important aspects to ensure long-term stable operation and process flexibility. It is recommended to verify the suitability of the selection through material process tests.