Emulsifiers are essential in industrial mixing systems, especially in solid-liquid blending, liquid-liquid mixing, oil-water emulsification, dispersion, homogenization, and shear grinding. Their main function is to achieve emulsification, which refers to the process of combining two immiscible liquids into a stable mixture. However, their applications go far beyond just emulsifying.
Thanks to their powerful shearing action, emulsifiers can break down solid particles in a liquid, reducing them to the desired particle size. This allows for a more uniform and stable suspension, also known as "dispersion." In some cases, dispersing agents are added to further enhance the stability of the suspension. When solids dissolve in a liquid, the smaller particles created by shearing increase the surface area, enabling faster dissolution.
As people become accustomed to using high-pressure homogenizers, the term "fine" often equates to "homogeneous." Thus, the role of an emulsifier in refining and thoroughly blending materials is considered "homogeneous." Therefore, emulsifiers are sometimes referred to as homogenizers. To differentiate between types, they are often categorized as high-speed or high-shear homogenizers, leading to various designs such as high-shear emulsifiers, high-shear cutting homogenizers, and high-shear dispersing emulsifiers.
The effectiveness of an emulsifier largely depends on the intensity of its shearing action. Several factors influence this, including blade sharpness, hardness, stator gap, relative movement speed between the rotor and stator, and the maximum allowable particle size. While blade sharpness, hardness, and stator gap are usually fixed, the relative movement speed—expressed as the rotor’s circumferential speed—has the most significant impact. A higher linear velocity means more frequent collisions and better refinement. However, increasing the speed too much can lead to flow barriers, reduced efficiency, and excessive heat, which may cause material aggregation and reduce performance.
It's important to understand that the "speed" mentioned in emulsifiers typically refers to linear velocity, not angular velocity. Linear velocity is calculated as angular velocity multiplied by diameter and π. Industrial emulsifiers often operate at 3000 or 1500 rpm, while lab models might run at 10,000 or 280 rpm. This difference accounts for the diameter, ensuring similar shear speeds and comparable results. Lab devices tend to be smaller, so they use higher rotational speeds to compensate for the smaller diameter and maintain effective shearing.
In production settings, the choice of emulsifier speed depends on processing capacity and cost-effectiveness. For example, 2-pole motors below 18.5 kW typically run at 8.5 rpm, while 4-pole motors between 22 kW and 55 kW operate at 1500 rpm. Above 75 kW, 6-pole motors may exceed 1000 rpm. Choosing a reputable brand like Nanjing Shunliu ensures reliable quality, precise engineering, durable materials, and long-lasting performance. Their key components are designed for wear resistance and efficiency, resulting in low maintenance costs and excellent service, making them a trusted name in the industry.
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