Industrial Liquid Mixing Process: What Is It And How Does It Work?

By Published On: December 22, 2022Last Updated: January 2, 2023

The industrial liquid mixing process has many applications. This process involves blending two or more liquids or solids together to form a uniform mixture. This is done to create a homogeneous solution. In this article, we explore the uses of industrial liquid mixing and the key components of the process.

The industrial liquid mixing process is useful for mixing two or more liquid reagents to initiate a chemical reaction. It can also be used to create a slurry, a mixture of two or more solids.

The process can also be used to create a suspension: an immiscible combination solid and a liquid. The versatility of the mixing process can also be used to create a solution, which is a uniform mixture of a solid and a liquid.

The Industrial Liquid Mixing Process

All About Hydrodynamics

Hydrodynamics is the study of the motion of fluids. Fluid motion can be either laminar or turbulent. Turbulence is the most common type of fluid motion in nature. A laminar flow is a uniform and steady flow of fluid that can move in only one direction. A turbulent flow of fluid moves chaotically and unpredictably.

Software like Visimix can utilize both laminar and turbulent modeling to simulate mixing conditions. Hydrodynamics parameters that determine whether the mixing is laminar or turbulent are the viscosity, density characteristic of the vessels and speed of the mixer.

This process is used to mix two liquids of different densities to form a uniform mixture. The process can be used in various industries. The products include paints, pharmaceuticals, and foods.

The process involves the use of centrifugal force and heat. Centrifugal forces are used to separate the lighter liquid from the heavier one. The method uses high-speed centrifuges that spin at 10,000 revolutions per minute.

Heat is used to accelerate the separation process. This is done by passing the hot water through tubes in the center of the centrifuge. This type of process is also known as hot-stage centrifugation.

The Process Flow Chart

The Process Flow Chart shows the different steps needed for the industrial liquid mixing process. There are usually four main steps involved in this process.

1. Solubility: This very first step involves combining the solids and liquids together to make sure that they can dissolve in each other.

2. The Solution Formulation: The next step is to form a homogenous mixture through thorough mixing of the different chemicals.

3. The Final Product: This is a step where the mixture is filtered to remove impurities and other chemicals that did not dissolve in the first step.

4. Process Control: Throughout the steps outlined above, the production line is controlled at all stages to achieve the desired end product.

Seven Key Components of the Industrial Liquid Mixing Process

Different equipment components are used in the industrial liquid mixing process.

1. The Mixer: A mixer is a machine used to thoroughly combine two liquids. It can be any mixer, such as a continuous mixer.

2. The Boiler: A boiler is a device that is used to heat the liquids that are mixed. It can be a steam boiler or a hot water boiler.

3. The Chemical Concentrator: A chemical concentrator is a device that can remove certain unwanted chemicals from the solution. These are generally filters or centrifuges.

4. The Filter: Filters are machines that remove impurities from water. They are devices used in the industrial liquid mixing process. They can be ceramic filters, cartridge filters, sand filters, or fiber filters.

5. The Pump: There are different types of pumps like positive displacement, diaphragm, screw, or turbine pumps.

6. The Tank: A tank is a device that stores and holds liquids. They can be storage tanks, carboys, drums, or barrels.

7. The Heater: The heating system is another crucial ingredient in industrial liquid mixing. There are different types of heaters, including steam, electrical, hot air, and infrared.

Benefits of the Industrial Liquid Mixing Process

The benefits of the industrial liquid mixing process are the following.

High production rates:High production rates are associated with high efficiency. The process requires less energy to produce the same volume of product.

High-quality output: This process  ensures quality and consistency in the production process. This improves the product’s visible appearance and taste.

Low cost: This type of process requires an upfront investment and subsequent maintenance costs. In the long run, however, a lot of money will be saved compared to other methods of obtaining the mixtures.

Low space requirement: The process requires lesser space than other processes. This also makes it possible to control the sizes of batches in production. 

Challenges in Industrial Liquid Mixing

The equipment is expensive.

There are only so many companies that can afford to invest in this process. This is why most small-scale industries have to purchase the chemical mixtures used in making their products, rather than producing their own.

The cost of chemical ingredients can be high.

Since the raw chemical ingredients must be bought in bulk, the upfront cost of raw materials is high in this type of process. Storage of these ingredients may also pose an issue to the manufacturer.

Lack of skilled manpower

There is a lack of skilled individuals to operate the process. To make a good product through industrial liquid mixing, you need to hire a qualified and experienced person.

Should I Use Liquid Mixing For My Products?

The liquid mixing process is very useful in producing liquid products. However, the equipment is expensive and there are very few companies that are willing to invest in the process. This is compounded by the cost of purchasing the bulk chemical ingredients, and the low availability of skilled people to operate the process. It is because of these reasons that most small-scale industries are reluctant to invest in liquid mixing. 

However, industrial liquid mixing is definitely beneficial to the user in the long run, since the quality and rate of production can be altered to suit their needs. Furthermore, the per-unit costs of producing mixtures are often cheaper than purchasing them from suppliers, especially for specialty chemicals.

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