Our company has been manufacturing the USB fast mixing unit for 20 years. There is nothing really new or supernatural in our units, which is based on a 200 year old process, however, they are still in high demand today.
Mixing units found widespread use during the Second World War, with the sharp increase in demand for high octane airplane fuel. Such fuel was made by adding lead containing additive, which had been used by oil refineries up to 1995. It was such units that were employed for aircraft fuel production due to unparalleled reliability and simplicity of service. So what is the secret of such longevity? Why is it important today? And why us?
The USB mixing unit: key benefits
The first thing to note is the simplicity of design, which directly translates into reliability of operation.
Here is a brief description of the design: the unit consists of a pump, which creates approximately 7-18 bar pressure, and a vacuum ejector. The vacuum created in the ejector sucks in a certain amount of an additive (ingredient). Mechanical or electromechanical flowmeters are used for precise portioning, along with needle valves.
The unit’s high applicability is due to simplicity of use and, of course, the need to mix and blend various components. The USB units are most commonly used:
- at chemical production facilities;
- in petrochemical processes;
- in food production;
- at waste oil product recycling facilities;
- in the energy industry etc.
The unit found a new use with the development of biofuels (biodiesel and bioethanol).
Why us?
First, we are the developer and manufacturer of the unit. I.e. we can make all necessary calculations for a specific system. Second, we can manufacture a specific model, accompanied with the corresponding document package. Third, we:
- are responsible for warranty;
- offer technology consulting;
- provide installation assistance and commissioning, with training for your personnel;
- offer all kinds of information and technology support for the duration of equipment life cycle;
- provide post warranty service.
The client may specify the system to be manufactured with manual controls or with various degrees of automation.
Design features
We don’t just use a vacuum ejector. There are finer points, such as: the ejector is supplemented with a hydrodynamic cavitator, which also improves the quality of mixing to obtain highly dispersed liquids. Since the velocities of mixing exceed the speed of sound, our cavitators are ultrasonic.
All company products are tested according a strict test procedure for compliance with specified parameters before being shipped to the client.
Ingredient ratios and amounts
The principle of operation implies, that the ingredient supplied to the mixer by the pump, creates vacuum, which means that the amount of the other ingredient cannot exceed the amount of the basic ingredient. The ideal mixing ratio is 50% of the basic ingredient and a total of 50% of other components; however, in practice the ratio is close to 60/40%. The question is, what do you do when there is no single ingredient for 60% of the flow, or, for instance, more than 40% of the flow must be supplied through the vacuum channel? We have found a simple solution. We install several flow meters at the pump inlet and can combine several streams into the primary ingredient. For instance, the product formula may call for 35%+30%+35% ratio. Two components (35%+30% or 35%+35%) can be supplied to the pump, while the remaining components can be added through the vacuum channel. There are other possibilities as well, such as an auxiliary portioning pump. Our specialists will suggest a solution that works best for you.
The number of ingredient streams
The amount of additives supplied through the vacuum channel can be from one to … let’s say, ten. In practice, we have manufactured units with 8 additive streams coming in through the vacuum channel. When extremely fine portioning of small amounts of additives is required, it is possible to use portioning pumps and other external systems.
If the viscosity of the liquid stream is low, we install suitable pumps, such as multistage centrifugal pumps. If the ingredients are highly viscous, we install gear pumps, or even heating systems for the unit.
In the basic stock version of the unit, the mixers are made of stainless steel. For food production and for heavy duty use, we make the mixers of suitable steel alloys. On occasion, the mixers have been made from plastic. These issues are discussed with the sales manager and listed in the questionnaire filled out before the order.
Why can we not tell you the prices outright?
The problem is that mixing units are usually highly customized: there are various pump m construction material, temperature range options etc, the need for ex-proof design, processed liquid characteristics and many other factors.
To accelerate the calculation of unit prices, contact our specialists and fill out the product questionnaire on the website.