Chemical-Grade Emulsifier Equipment Application Case Study
In the field of fine chemical production, the stability and uniformity of emulsified systems directly determine product performance, production efficiency, and overall operational costs. A manufacturer engaged in the production of industrial coatings and chemical intermediates once faced persistent challenges in its emulsification process, which restricted the optimization of its production line. The introduction of chemical-grade high-shear vacuum emulsifier equipment effectively addressed these pain points, achieving a comprehensive upgrade in production quality and efficiency.
Background: Process Dilemmas in Emulsification Production
The manufacturer's core products include water-based industrial coatings and oil-water mixed chemical intermediates. In the traditional production process, the emulsification stage relied on conventional stirring equipment, which led to multiple technical bottlenecks. Firstly, the shear force provided by the traditional equipment was insufficient, resulting in incomplete dispersion of material particles. The particle size of the emulsified system was uneven, with the D90 value remaining above 15μm. This directly caused problems such as poor stability of the final product, easy delamination during storage, and inconsistent performance indicators between batches.
Secondly, the open-type stirring process introduced a large amount of air into the material, forming numerous micro-bubbles. For coating products, these bubbles would cause surface defects such as pinholes and orange peel after film formation, reducing product qualification rates. For chemical intermediates, bubble residues affected the accuracy of subsequent reaction processes, increasing the difficulty of process control. Additionally, the traditional emulsification process required long stirring time—each batch of materials took 2.5 to 3 hours to complete emulsification, and post-processing procedures such as standing defoaming were needed, resulting in low production efficiency and high energy consumption.
Moreover, the raw materials used in the production process contained trace amounts of surfactants and solid particles, which easily triggered emulsification anomalies under the action of conventional stirring. The formation of stable emulsified layers not only increased material loss but also required additional chemical demulsifiers, which increased production costs and brought potential risks to product purity.
Solution: Introduction and Application of Chemical-Grade Emulsifier Equipment
To solve the above problems, the manufacturer selected a chemical-grade high-shear vacuum emulsifier equipment with customized parameters. This equipment integrates high-shear homogenization, vacuum deaeration, and intelligent temperature control functions, and is constructed with 304 stainless steel to meet the corrosion resistance and cleanliness requirements of chemical production. Its core design highlights include a double-layer stator-rotor structure with an adjustable gap of 0.1mm, which can generate a linear velocity of up to 28m/s, forming strong shear force to break material particles into micron-level even nanometer-level sizes.
Before formal commissioning, the equipment supplier conducted three rounds of process simulation tests using the manufacturer's actual raw materials, optimizing key parameters such as stirring speed, vacuum degree, and temperature. The test results showed that when the vacuum degree was maintained at -0.092MPa to -0.095MPa, the stirring speed was set to 8000rpm for high-shear homogenization, and the temperature was controlled at 35±2℃, the emulsification effect was optimal. Based on these test data, the equipment was officially put into production after on-site installation and commissioning by professional engineers.
Results: Comprehensive Improvement in Production Performance
After the new emulsifier equipment was put into operation, the manufacturer's production process achieved significant improvements in multiple dimensions, with measurable data verifying the application effect.
In terms of product quality, the particle size distribution of the emulsified system was significantly optimized. The D90 value of the product was reduced from over 15μm to below 5μm, and the particle size uniformity was improved by more than 85%. The stable emulsified system formed by high-shear homogenization effectively eliminated the problem of product delamination. The storage stability test showed that the product could be stored at room temperature for 12 months without obvious delamination or precipitation, which greatly extended the product shelf life. At the same time, the vacuum environment during the emulsification process completely avoided air introduction, and the bubble removal rate reached over 98%. The coating products produced no longer had surface defects caused by bubbles, and the qualification rate increased from 82% to 97%.
In terms of production efficiency, the emulsification time per batch of materials was shortened from 2.5-3 hours to 45 minutes, a reduction of nearly 75%. The equipment integrates emulsification, deaeration, and homogenization functions, eliminating the need for independent post-processing procedures such as standing defoaming. This not only saves production time but also reduces labor input in the post-processing stage. The continuous operation capability of the equipment also supports large-scale mass production, and the daily output is increased by 2.2 times compared with the traditional process.
In terms of cost control, the reduction in emulsification time and the optimization of process flow have reduced energy consumption by 32% per unit product. The stable emulsification effect avoids material loss caused by emulsification anomalies, reducing raw material waste by about 15%. In addition, the need for chemical demulsifiers is eliminated, further reducing auxiliary material costs. The equipment's sealed structure and easy-to-clean design also reduce the time and labor cost of equipment cleaning, lowering overall operational costs.
In terms of process stability, the equipment is equipped with an intelligent control system that can accurately monitor and adjust key parameters such as temperature, vacuum degree, and stirring speed in real time. The parameter fluctuation range is controlled within ±2%, ensuring consistent product quality between batches. The 360° scraping wall stirring device avoids material residue on the inner wall of the equipment, further ensuring the uniformity of each batch of products.
Long-Term Operation and Experience Summary
As of the current statistical period, the chemical-grade emulsifier equipment has been in continuous stable operation for more than 8,000 hours, with a failure rate of less than 1%. The equipment's modular design facilitates maintenance and replacement of wearing parts, and the supplier's 24-hour remote technical support and 48-hour on-site troubleshooting service ensure the continuity of production.
The application practice shows that chemical-grade emulsifier equipment with high shear force, vacuum deaeration, and intelligent control capabilities can effectively solve the common problems in traditional chemical emulsification processes. By optimizing the particle size distribution of the emulsified system and eliminating bubble residues, it improves product quality and stability. At the same time, it shortens production cycles, reduces energy consumption and material loss, and realizes the dual improvement of production efficiency and economic benefits.
For chemical manufacturers, the selection of emulsifier equipment should be closely combined with product characteristics, raw material properties, and production scale. Customized parameter design and strict pre-commissioning tests are the key to ensuring the matching between equipment and production processes. The stable operation of this equipment not only provides a reliable guarantee for the manufacturer's product quality but also lays a solid foundation for its subsequent process upgrading and product expansion.
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