Statiflo Static Mixers, Channel Mixers and Motionless Mixing Technology

The UK’s first major desalination plant came on stream at the beginning of June with the assistance of Statiflo static mixers. The Beckton plant in east London draws brackish water from the Thames estuary on the outgoing tide, reducing the salt content with resulting lower energy to treat it.  However the plant designers were aware of the importance of good pre treatment to minimise the load on the four stage RO units and selected Statiflo static mixers for coagulation of the raw water with PAC where very fast mixing mixing is crucial . The Series 550 GRP mixers with Statiflo STM mixing elements offers rapid mixing with the best mixture quality (measured as CoV) at the lowest head loss  making it a popular choice for all water treatment applications and for the process industries.

Statiflo Series 550 GRP mixer with STM elements.

A Statiflo Gas Dispersion System was chosen to disperse carbon dioxide into the treated water for remineralisation. The GDS is recognised as the most efficient gas dispersion system for a range of gases: ozone, oxygen, carbon dioxide and air, commonly used in water treatment processes.  The success of the system is founded in the generation of very small but of uniform diameter bubbles in a side stream that is driven by a small pump, giving a very cost effective KG gas/ KWH.  A contactor mixer in the main pipeline ensures high mass transfer efficiencies by uniformly dispersing the gas/ liquid side stream into the main flow and in the case of carbon dioxide transfer efficiency, would be typically greater than 95%.

Statiflo has a worldwide reference list for desalination applications.

Always at the forefront of innovative solutions to the many problems facing the wastewater industry, Statiflo has now developed a totally new concept in Static Mixing that enables, for the first time, efficient mixing of chemicals into raw sewage without the risk of ragging.
The Statiflo NRC is a channel mixing device, developed from our successful NR pipeline mixer used for additive dosing into sludge and wastewaters. The NRC is a non-ragging device designed primarily for P removal applications, and can be used for any chemical dosing on WWTPs.

One of the main features of the NRC is the unique variable angle control vane for optimising the mixing performance within tight headloss constraints. The control vanes can also be raised clear of the TWL, either manually or automatically, for operational or maintenance purposes. Fixed subsurface vanes create critical flow regimes at all liquid levels - another factor in the success of the NRC.

The design allows customization to a wide range of channel sizes, aspect ratios, water depths and flow rates and comes complete with accessible internal sparger for chemical injection - all for easy installation into live open channels.
Statiflo NRC mixers have been thoroughly tested and have now been successfully operating and saving chemicals since 2008 at various sites in the UK.

Click here for the full story and more information on the Statiflo NRC Mixer.

In the near future, the award-winning Statiflo exhibition stand will be appearing at several relevant conferences and exhibitions throughout the world, staffed by experts in their fields.

If we're near to you, why not come and say hello, and see how we can help you improve performance, cost savings, and profits.

For more information on this year's exhibitions where you can visit a Statiflo stand and discuss your mixing requirements, click here.

As reported on the 25th January news item, two STMC Channel Mixers have been installed at Vancouver's Annacis Island wastewater treatment plant.  The larger mixer, approximately 7m wide (23 feet) was installed under live conditions in a matter of minutes.

The mixers are undergoing initial testing and dosed chemicals will be on stream late spring 2010.

For further information on Statiflo Channel Mixers click here or contact Statiflo International

A convoy of four trucks is delivering two STMC Channel Mixers to Vancouver's Annacis Island treatment plant for installation during February 2010.

Both mixers are approximately 7m wide (23 feet) and are believed to be the largest of their type in North America, one of which will be installed under live conditions as the plant cannot be shut down.

Once the STMC Channel Mixers are installed they will be used for chlorinating and de-chlorinating effluent before final discharge into the Fraser river.

For further information on Statiflo Channel Mixers click here or contact Statiflo International

Teknologisk Institutt a/s in Norway has selected Statiflo International Ltd to work in collaboration with other SMEs throughout Europe to develop a novel system to control marine growth in water chests and heat exchangers on ships. Statiflo’s expertise and proven record on previous EU funded projects for static mixing technology and in particular gas dispersion knowledge will be put to good use on the new project named BioFoul Control. The project will run for two years and in that period the new system will be developed and tested at laboratory and a full scale installation on a supply vessel is planned.

The project is funded and administered under the European Seventh Framework Programme

Statiflo has supplied two GDS packages to the City of Frankfort to augment the existing ozonation system on its waste water treatment facility. Statiflo equipment was chosen for its simple operation, low power draw, low headloss and high mass transfer efficiency.

The ozonation system was updated with oxygen based generators supplied by Ozonia. The existing dome diffuser system in parallel contact chambers could not meet future ozone demand and flow conditions. To meet the new operating conditions, two 36” (900mm) diameter Statiflo Mixer/Contactors were installed, each complete with a single proprietary side loop for ozone injection, comprising pump, eductor and predispersing static mixer.

The parallel train systems are designed to handle up to a combined maximum waste water flow of 38 MGD (6000 m3/h). At low flow conditions, the dome diffusers are capable of supplying the required ozone, however, at higher flows ozone demand exceeds the mass transfer capability of the dome diffusers. The Statiflo GDS packages are then operated ahead of the contact chambers to provide the extra ozone required to meet the disinfection requirement.

The system has been in successful operation since 2008 and has achieved transfer efficiencies of 95% or better.

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As part of Statiflo’s framework agreement with Scottish Water, for the supply of static in line mixers, we are regularly monitored by Scottish Water contractors under a number of headings including quality of service and quality of product. Once again we are delighted that we have appeared in the top five companies that supply equipment or services to Scottish Water, but, more importantly for Statiflo, we are the highest placed company in the category of ‘static in-line mixers’.

For more information on this story please contact Mr Ron Cordon our Sales Manager for Scotland. Tel 01625 433100 or e-mail roncordon@statiflo.co.uk

A leading producer of bottled mineral water was experiencing problems using a conventional glass bead carbonator for dispersing and dissolving carbon dioxide gas in water. Consistent gas bubble sizes were impossible to achieve without frequent maintenance and lost production.

A further problem with the conventional equipment, which was designed without any particular attention to mixing, was that flavours were periodically accumulating in the carbonator and were then released in slugs resulting in very high flavour concentration in the carbonated water and customer dissatisfaction. Regular cleaning was necessary to minimise this problem.

The company required an answer to both process problems to reduce maintenance and the considerable amount of lost production.

The tank and agitator used for mixing the flavours into water and the glass bead carbonator were both removed and replaced with a Statiflo Series 200 Sanitary Motionless Mixer. This Mixer was fitted with removable elements, RJT couplings and integral injectors for both carbon dioxide gas and flavour.

The Statiflo equipment ensured that total and efficient distribution of flavours and gas was achieved. Gas bubble size and bubble size distribution were predictable due to its almost ideal plug flow characteristic.

The previously complex piping arrangement to the filling machine was greatly simplified as the Statiflo Motionless Mixer is an inline device requiring no direct power supply.

The installation of the Statiflo Motionless Mixer was an instant success. It was soon apparent there was no accumulation of flavour - the Statiflo Mixer is a self cleaning device due to its intense mixing action. Downtime and lost production resulting from the old carbonator was eliminated.

Consistent gas bubble sizes were ensured for efficient mass transfer into solution. Complete and uniform mixing of the flavours was guaranteed. The company had earlier suspected that overdosing was occurring to compensate for lack of mixing. It now had the satisfaction that the efficient operation had eliminated the possibility of wasting flavour.

There were still more benefits - the Statiflo Motionless Mixer operates without moving parts, without spare parts and with virtually no maintenance. The high running costs of the agitator and carbonator were concerns of the past!

The company immediately installed Statiflo Motionless Mixers on all its production lines, after which no more customer complaints were received.

To read the full case study on 'Carbonating Mineral Water' please go to the download area of our website.

A lube oil blending plant in the north west of England was experiencing a whole host of problems with its existing tank mixing system, ranging from excessive energy consumption to poor product quality control.

The company was using large 1500 tonne tanks, approximately 10m diameter x 10m high, to blend various proprietary additives into base oil in the manufacture of engine oils. Preweighed amounts of additive were manually dumped into the top of the tank and mixed by compressed air from a sparge system above the tank floor. This arrangement had many drawbacks

• Long mixing time – 3 to 4 days

• High energy consumption, compressed air is expensive and causing starving of other plant where air was essential

• Oxidation of base oil

• Overdosing of expensive additives due to poor mixing

• Frequent tank cleaning and sludge removal due to overdosing

The solution Statiflo recommended that the dedicated transfer pump should be used to provide the energy for mixing using a Statiflo Motionless Mixer installed in a recycle line. Additives should be injected at the Mixer for optimum effect.

The result being batch mixing times were reduced from several days to approximately 16 hours. Compressed air was no longer required for mixing and oxidation of the base oil eliminated. The air sparge system was removed from the tank, and equipment elsewhere on the plant was no longer starved of compressed air. The sludge buildup was stopped because of improved mixing and lack of overdosing. This was also helped by pumping the recycle stream from the tank bottom.

Following its immediate success, a further nine tanks were converted and each provided with a dedicated Statiflo Motionless Mixer.

To read the full case study on 'Improved Tank Blending' please go to the download area of our website.