Problem
In an operational in-line mixer for the petrochemical industry, viscous gel formed when 1% surfactant was blended into a low viscosity media. This leads to:

• Frequent mixer blockage
• High pressure drop and hence high running costs
• Poor product quality
• Excessive waste production

Objective
Redesign and scale up an in-line mixer to disperse homogeneously a small amount of surfactant in a continuous stream.

Approach
The following main design parameters were investigated:

• Flow rates of bulk and additive
• Diameter of pipe used
• Mixer type
• Feed strategy, e.g. position, number of feed points, number of tubes
• Turbulent energy required
• Residence time required

Results
A fine mist of droplets must be produced on addition to avoid gel formation. This is a function of mixer type, number of mixers, feed strategy, flow rates of bulk and additive. A mixer arrangement was sized and fully specified for this operation, taking into account the client’s requirements.

Benefits

The retrofit:

• Started up right first time
• Did not give blockage
• Gave consistent product quality
• Required less additive
• Reduced operating costs through lower pressure drop.

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