Pneumatic Lifting 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 pneumatic lifting 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 fixed-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 fixed structure of traditional equipment made it difficult to adjust the stirring height according to material levels, leading to inadequate mixing of materials at the bottom and upper layers. Moreover, 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. The fixed stirring position of conventional equipment easily caused accumulation of solid particles at the bottom, triggering emulsification anomalies. 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. Meanwhile, cleaning after production was cumbersome due to the fixed structure, prolonging the interval between batches.
Solution: Introduction and Application of Pneumatic Lifting Emulsifier Equipment
To solve the above problems, the manufacturer selected a chemical-grade pneumatic lifting emulsifier equipment with customized parameters. This equipment integrates pneumatic lifting adjustment, high-shear homogenization, and sealed stirring functions, with a body constructed of 304 stainless steel to meet the corrosion resistance and cleanliness requirements of chemical production. Its core advantage lies in the pneumatic lifting system, which enables stepless adjustment of the stirring head height within a range of 0-800mm, adapting to different material barrel specifications and material level changes during the emulsification process.
The equipment is equipped with a high-shear stator-rotor structure with an adjustable gap of 0.15mm, capable of generating a linear velocity of up to 26m/s to break material particles into uniform micron-level sizes. The pneumatic lifting system adopts a double-cylinder drive design, ensuring stable lifting and positioning accuracy within ±1mm, avoiding uneven mixing caused by position deviation. 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, lifting frequency, and stirring time. The test results showed that when the stirring speed was set to 7500rpm, the lifting frequency was adjusted to once every 5 minutes, and the temperature was controlled at 38±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 pneumatic lifting 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 adjustable height of the stirring head eliminated material accumulation at the bottom and inadequate mixing of upper-layer materials. The particle size distribution of the emulsified system was significantly optimized, with the D90 value of the product reduced from over 15μm to below 4.8μm, and the particle size uniformity improved by more than 88%. The stable emulsified system formed by high-shear homogenization effectively eliminated product delamination. Storage stability tests showed that the product could be stored at room temperature for 12 months without obvious delamination or precipitation, greatly extending the product shelf life. Meanwhile, the sealed stirring design of the equipment reduced air introduction by 95% compared with traditional open-type equipment, and the bubble removal rate reached over 97%. Coating products produced no longer had surface defects caused by bubbles, and the qualification rate increased from 82% to 97.5%.
In terms of production efficiency, the flexible height adjustment of the pneumatic lifting system shortened the stirring time per batch of materials from 2.5-3 hours to 40 minutes, a reduction of nearly 78%. The equipment's adaptive design for different barrel specifications eliminated the need for material transfer between different devices, saving transfer time by about 20 minutes per batch. The integrated emulsification and mixing functions also eliminated independent post-processing procedures such as standing defoaming. The continuous operation capability of the equipment supports large-scale mass production, and the daily output is increased by 2.3 times compared with the traditional process. Additionally, the pneumatic lifting system simplifies equipment cleaning—after production, the stirring head can be lifted to a fixed height for centralized cleaning, reducing cleaning time by 40%.
In terms of cost control, reduced emulsification and cleaning time lowered unit product energy consumption by 35%. The stable emulsification effect avoided material loss caused by emulsification anomalies, reducing raw material waste by about 16%. The elimination of chemical demulsifiers further reduced auxiliary material costs. The equipment's durable pneumatic components have a long service life, and the modular design facilitates maintenance, reducing maintenance costs by 25% compared with traditional fixed equipment. The sealed structure also reduces the loss of volatile raw materials, further optimizing overall operational costs.
In terms of process stability, the equipment is equipped with an intelligent control system that accurately monitors and adjusts key parameters such as stirring speed, lifting position, and temperature in real time. The parameter fluctuation range is controlled within ±2%, ensuring consistent product quality between batches. The 360° scraping wall auxiliary stirring device cooperates with the lifting function to avoid material residue on the inner wall of the barrel, further ensuring the uniformity of each batch of products.
Long-Term Operation and Experience Summary
As of the current statistical period, the chemical-grade pneumatic lifting emulsifier equipment has been in continuous stable operation for more than 8,000 hours, with a failure rate of less than 1%. The pneumatic system adopts imported components with strong corrosion resistance and wear resistance, adapting to the harsh working environment of chemical production. 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 pneumatic lifting emulsifier equipment, with its flexible height adjustment, high-shear homogenization, and sealed stirring capabilities, can effectively solve common problems in traditional chemical emulsification processes. By optimizing material mixing uniformity 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. The pneumatic lifting function is particularly suitable for production scenarios with multiple barrel specifications and variable material levels. Customized parameter design and strict pre-commissioning tests are 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.
Your message must be between 20-3,000 characters!