Disintegrated Dissolvers
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PHARMACEUTICAL & NUTRACEUTICALS
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FOOD AND BEVERAGES
BITUMEN PROCESSING
CHEMICAL AND AGRO-CHEMICALS
PAINTS, INKS AND COATINGS
The unit is responsible for dis-integrating, dissolving, solubilizing, dispersing and homogenizing the coarse material directly into the material.
FPS Disintegrated Dissolver comprises of a dual stage action:
- Firstly, the coarse material in solid (chips, powder, bales) form is dispersed well into the liquid phase because of the intense high shearing action of the Batch Homogenizer in the dissolving vessel. The solids are ripped off and dispersed well in the mix ensuring the refining of coarse material prior to final refinement in the Inline homogenizer.
- Secondly, the slurry thus prepared in the initial stage is fed into the Inline Homogenizer for final refinement through continuous re-circulation of the material in the Inline Homogenizer, ensuring solids are totally solubilized and suspended in the liquid phase and also homogenize additive fluids to the mix.
Features:
- End Connections: ANSI Flanged/ TC Clamps/ SMS Union
- M. O. C: S. S-304/ S. S-316L/Others Material as per request
- Multiple range of Working Heads
- Drive Unit: TEFC/ Explosion Proof Electric Motor
- Shaft Sealing: Single Mechanical Seal/Double Mechanical Seal
- Temperature control: Double Jacketed Housing for heating/cooling
- Motor Starter: S/D starter (for fixed rpm)/ VFD (for variable rpm)
- Volume range starting from Lab Scale to Commercial Volumes
Blending
Blending refer to mixing of liquids of similar varying viscosities which is achieved easily using a FPS High Shear Homogenizer Mixer
Disintegrating
Disintegration is defined as the process in which particles, majorly in form of chips/bales/agglomerates are disintegrated to fine particles making a consistent slurry, which is achieved easily using a FPS High Shear Homogenizer Mixer
Homogenizing
Homogeneous product is designed as one which shall have equal distribution of particles through the mix which can also be defined as consistency of the mix, which is achieved easily using a FPS High Shear Homogenizer Mixer
Particle Size Reduction
Particle size reduction is a process of preparation of finer suspensions from slurries (semi-solid materials) making it consistent, which is achieved easily using a FPS High Shear Homogenizer Mixer
Emulsifying
Emulsification is defined as the process in which droplets of the mix (majorly liquids of varying viscosities) are dropped down to the range of 0.5 to 5 microns typically, which is achieved easily using a FPS High Shear Homogenizer Mixer
Solubilizing & Gelling
Solubilizing is a process of dispersion of solids into liquids which are not easily dispersed into liquids and usually form agglomerates, this process of breaking of agglomerates into finer particles to form consistent slurries, which is achieved easily using a FPS High Shear Homogenizer Mixer
Shear Force Principle:
FPS Inline High Shear Mixers works on the principle of shear force produced in between the rotor and stator. The high-speed rotation of the rotor sucks the material into the eye of the rotor wherein high amount of centrifugal force throws the material outwards towards the stator wall. The material is sheared off as the high rotational kinetic energy is converted to heat energy because of disruption to the flow of the material in between the rotor and stator further leading to the high amount of shear energy in a small confined space, also known as the tolerance in between the rotor and stator.
Working of Disintegrated Dissolvers:
STEP 1
STEP 2
STEP 3
STEP 4
STEP 1
The liquid phase (either solvent, water, base oil, etc) is fed into the along with the charging of solid phase (either bale/flakes/chunks form) into the dissolution vessel.
STEP 2
The dissolution vessel comprising of a Batch High Shear Dissolver responsible for chipping off the large solids due to the intense continuous shearing action of the rotor-stator tool of the Batch Mixer, where the material is centrifugally forced to the stator walls through the rotor and shearing in between the rotor-stator set.
STEP 3
A rapid fragmentation of the solids takes place in the liquid phase until the solids are broken down to a granular level, which further can be fed to the Inline Homogenizer for final refinement/disintegration.
STEP 4
The material thus formed is pumped and re-circulated in the dissolution vessel though the Inline High Shear Homogenizer (the type of homogenizer is selected on the basis of the coarseness/fineness of the material required). The Inline Homogenizer is responsible for final refinement of the product by efficiently solubilizing and suspending the granular solids in the mix and providing a super fine particle size with consistency.
Configuration of Disintegrated Dissolver in Process:
FPS range of Disintegrated Dissolver is referred to as a combination of a Batch Homogenizer (either Top Mounted or Bottom Mounted) along with an Inline Homogenizer (either Single, Two or Four Stage Homogenizer).
Major Applications of Disintegrated Dissolver:
Processing of VM Lube oils, Adhesives:
Rapid solubilization of Rubbers & Polymers blocks into the lubricating oil, solvent or any other liquid phase.
Processing of Polymer Modified Bitumen:
Efficient dispersion of polymers in to the Bitumen at a higher temperature of about 180 degrees Celsius for the application of road surfacing.
Reclamation of Waste Candy:
Waste candy can be rapidly disintegrated in to the mix without pre-grinding or chopping off the material.
Dispersion of Higher Concentrates of Solids:
A comparatively higher concentration of powders/solids are rapidly dispersed in liquid phase having tendency of wetting out or aeration of the solids.
Efficient Dispersion of Filter Cake:
Filter cake is efficiently dispersed with the FPS Dis-integrated Dissolver unit providing an ease of processing.