A Technical Guide by Jongia Mixing Technology
Core Function
High-speed dispersers excel at three critical tasks:
- Fracturing powder agglomerates into fine particles
- Creating uniform powder distribution throughout liquid mediums
- Facilitating complete dissolution of soluble materials
Operating Principles
High-speed dispersers transform rotational energy into mixing power through a specialized mechanism:
The system centers around a disc-mounted blade at the shaft base, rotating at precisely calculated velocities. This rotation creates a measurable tip speed (peripheral velocity = 3.14 × diameter (m) × RPM).
As the disc spins, it generates powerful suction forces, pulling materials toward the mixing zone. The rotation creates dual vortices—above and below the disc—where intense energy transfer occurs upon material contact with the blade.
This energy transfer creates dramatic velocity differentials throughout the mixture, generating shear forces that tear material layers apart.
Disperser Categories
High-Shear Models:
- Operate at maximum blade velocity
- Generate intense mixing energy
Moderate-Shear Models:
- Run at approximately 50% standard blade speed
- Feature enlarged teeth for enhanced fluid movement
- Require only one-third the power input of high-shear variants
- Still demand triple the energy of conventional agitators
Dispersers vs. Agitators: Choosing Wisely
Dispersers generate sufficient shear force to break apart powder structures—a capability standard agitators lack. While agitators effectively maintain already-dispersed mixtures, they cannot overcome the binding forces holding agglomerates together.
The key difference: agitators sustain dispersions but cannot create them.
Performance Boundaries
A disperser’s effectiveness depends on material properties:
- Excessive viscosity prevents material circulation between blade and tank wall
- Insufficient viscosity fails to generate adequate layer separation
- Adhesive materials disrupt proper flow patterns
Optimal performance creates a distinctive toroidal (doughnut-shaped) flow pattern with the blade positioned at the center void.
Engineering Solutions
- Additional agitation mechanisms can improve material delivery to the disperser blade
- Multi-shaft systems combine slow-moving wall scrapers for bulk movement with high-speed disperser elements for shear generation
Sizing Considerations
Power Requirements
- Measured in kilowatts (kW)
- Correlates with blade dimensions and expected material resistance
- Power demand increases exponentially with blade diameter Example: Doubling blade diameter from 30cm to 60cm might increase power requirements fivefold (15kW to 75kW)
- Larger blades significantly increase material throughput
Variables Affecting Power Needs
- Blade and tank dimensions
- Processing volume
- Material flow characteristics
- Viscosity profile
- Material density
Tank Design Essentials
Optimal manufacturing vessels feature:
- Height slightly exceeding width
- Curved or bowl-shaped bottoms preventing material accumulation
- Centered drainage points for complete evacuation
- Flush-mounted discharge valves for efficient emptying and cleaning
Blade Selection Parameters
Blade configuration depends on:
- Material flow behavior
- Required dispersion intensity
Our History
From the moment Jongia was founded in 1937 we have been evolving structurally over the years. Learn more about our company’s history with the summary of most important moments highlighted in a timeline.
Blade-to-Tank Ratio Guidelines
- Dense, flowable pastes: 0.5:1
- Standard materials (like paint): 0.33:1
- Low-viscosity formulations: as low as 0.125:1
Practical application: A 1.8-meter tank using the 0.33:1 ratio requires a 0.6-meter blade
Maintenance Indicators
- Well-formulated batches should achieve maximum dispersion within 20-30 minutes after final ingredient addition
- Extended processing rarely improves dispersion quality and may increase thermal load
- Increasing batch times often indicate blade wear
- Replace sawtooth blades when tips wear to 50% of original height
Performance Optimization
Formulation Strategy
- Material addition sequence dramatically impacts results
- Best practice: Add approximately half of total powders rapidly into the liquid vehicle
- Introduce remaining powders with progressively decreasing speed
- Adjust blade speed from 50% of final tip speed initially, increasing to maximum as batch thickens
Operational Parameters
- Optimal performance indicator: toroidal flow pattern
- Target blade tip speed: approximately 1525 meters/minute for medium viscosity (1,500-5,000 centipoises)
- Reduce tip speeds for higher-viscosity materials
- Increase tip speeds for lower-viscosity materials
- Shear intensity correlates directly with blade-tip speed and material rheology
Performance Optimization Checklist
- Begin with thoroughly cleaned equipment
- Verify correct blade-to-tank proportions
- Follow engineered formulation protocols
- Select appropriate blade design in optimal condition
- Operate at maximum suitable blade-tip velocity
- Ensure tank geometry meets requirements
- Supply sufficient power capacity
- Implement proper material addition techniques
- Maintain appropriate rheological parameters
Critical Safety Protocols
- Review all operational and safety documentation from Jongia Mixing Technology
- Ensure comprehensive operator training on equipment use and hazard awareness
- Operation permitted only with all safety systems functional:
- Mixing shaft protective guards
- Tank holder with integrated limit switch
- Lift limit switches preventing operation when blade/shaft is accessible
Critical Warning: High-speed dispersers combine extreme power with rapid movement. Momentary inattention can result in severe or fatal incidents. Never compromise safety protocols for operational convenience.
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