ystral information Conti-TDS · Mixer, TDS-DISPERMIX) or for Inline operation outside of the vessel...

Ystral TDS-TechnologyYstral TDS-Technology

ystral gmbhmaschinenbau + processtechnik

Wettelbrunner Straße 7D-79282 Ballrechten-Dottingen

Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99

e-mail: [email protected]

TDS-machines may be used for all processingsteps, from the barrel emptying, powdertransportation, wetting and dispersing up to acomplete desagglomeration. This offers a very highpotential in rationalisationThe main advantages of the TDS-Technology are:q Dust- and loss-free operation,

no transfuse, no exhaust systemsq Direct induction from bags,, BigBag, silo or

any powder containerq Immediate and complete wetting below

liquid level resp. directly into a liquid streamno forming of crusts on the wall of the vesselor on the mixing shaft

q Higher degree of dispersion compared toconventional mixing principles.

q After the induction the machine may be usedfor additional dispersing or as a transferpump to pump the product to a storage tank.

q Even liquids and gases can be inducted

TDS – Technology for a clean andagglomerate-free powder treatment

If you have to mix powder into a liquid you arefamiliar with the following problems:q Dustq Spillageq Unhealthy working conditionsq Expensive exhaust and filter systemsq Loss of powder (during filling, in the exhaust

system, residues in the bags)q Partially wetted powder spots and crusts on

the wall of the vessel, mixing shaft and coverq Agglomerates in the productq For solvent containing liquids:

Powder + Oxygen in Ex-Zone-0

The system that eliminates these problems, becameknown under the name TDS (Transport- andDissolving System).These problems can be avoided by inducting thepowder or the granulate with a strong vacuumdirectly into the liquid and becomes completelywetted and dispersed during the first contact withthe liquid.Neither a vacuum vessel nor an additional vacuumpump air ventilation or filter are required. Theinduction vacuum is produced in the highlyaccelerated liquid stream. It inducts the powder,fluidises it and brings it finely distributed into theliquid. During the wetting process the product isalready dispersed, no lumps or particleagglomerates can form. Powdery substances canbe inducted dust- and loss-free from any type ofcontainer.



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


The TDS-DISPERMIX disperses the liquidproduct during the wetting and the followingmixing process. This is a big advantage whenmixing products that are difficult to wet or whichtend to re-agglomerate. The Conti-TDS offers thewidest range of applications.. The machine isinstalled outside the vessel and inducts the powderinto the flow of liquid, created by the machineitself..

General review of TDS machines

TDS-machines are manufactured in three versions,either to be installed in a vessel (TDS-InductionMixer, TDS-DISPERMIX) or for Inline operationoutside of the vessel (Conti-TDS).

The TDS-Induction Mixer combines theadvantages of a complete and homogeneous mixingeffect of a Jetstream Mixer with the possibility toinduct powder directly into a liquid. It is mainlyused to induct powders into a low viscosity liquid.

Machine TypeTDS-

Induction mixerTDS-

DispermixConti-TDS

Operation Batch System Batch SystemIn-Line-operation

Semi-Batch-operationBatch operation

ApplicationInstalled into a vessel

Lift systemInstalled into a vessel

Lift systemoutside of vesselpiping installation

Power 2,2 to 16 kW 3 to 25 kW 5,5 to 200 kW

additional function MixingMixing

DispersingIn-Line-Dispersing and

Homogenising



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Conti-TDS

The ystral Conti-TDS is a machine to be used fordust-free induction and dispersing of powder into aliquid. The main advantages are:

q Installation outside of the vessel

q Connections through pipe or hose

q Liquid is circulated

q An induction vacuum is created in aspecially designed dispersing zone

q Dust- and loss-free induction and dispersingof the powders

q Induction directly from bags, hopper, barrel,container, BigBag or silo possible

q additional circulation and dispersing untilthe required particle size, homogeneity orconsistence is reached

q Pumping to a storage vessel with the samemachine possible



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Principle of the Conti-TDS

q Powder and liquid come into the dispersingand wetting chamber from different sides

q Only in the dispersing and wetting zone thetwo components come into contact wit eachother

q Through the dispersing energy in themoment of the contact, the surface of theliquid is enormously increased (milliontimes)

q The vacuum is created in the liquidq Under the vacuum, the powder is completely

inducted into the dispersed liquid

q The induction vacuum offers two effects:under vacuum the distance between theparticles is enlarged due to the air in thepowder and the speed of the particles isincreased tremendously

q This facilitates the penetration of the liquidinto the powder and results in anagglomerate-free dispersion

Powder

Liquid

Dispersion

Stator Rotor Rotor

Powder

Liquid



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Conti-TDS - Set-up and Installation

q The machine may be set-up either in verticalor horizontal position.

q It is set-up next to a vessel, recirculating theliquid, but may also be used inline inductingpowder during filling of the vessel.

q The liquid must have a static pressure at theinlet of the machine. This is easy to realiseby selecting the place of the installation insuch a way that the filling level of the tank isabove the mixing head of the dispersingchamber.

q The angle of product inlet and outlet isvariable. The machine can be integrated intoany existing system very easily.

q It may be connected to one or several vessels

q For the use in different working areas themachine can be delivered on casters and theswitchboard assembled to the main frame



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Operation of the Conti-TDS

product supply discontinuousfurther treatment continuousprinciples

directly from bag two vessels inline, with deaeration

from hopper, BigBag working- / buffertank directly inlinecontainer or Silo

min-max-principle bypass

dosing no problem, weighing is sufficient each componentgravimetric

more than only no problem, together or one after another powderpremix or dosingone powder in optimum sequence, swelling times, of all powders together

mixing times, cooling etc. no problem swelling times impossibleWhat about air? escapes in the vessel deaeration requireddispersing with the same machine separate machine

after powderinduction requiredpumping with the same machine separate pumpeproduct change low expense very complicate

C

C

C

C

max

min

C

C

C

C

product supply discontinuousfurther treatment continuousprinciples

directly from bag two vessels inline, with deaeration

from hopper, BigBag working- / buffertank directly inlinecontainer or Silo

min-max-principle bypass

dosing no problem, weighing is sufficient each componentgravimetric

more than only no problem, together or one after another powderpremix or dosingone powder in optimum sequence, swelling times, of all powders together

mixing times, cooling etc. no problem swelling times impossibleWhat about air? escapes in the vessel deaeration requireddispersing with the same machine separate machine

after powderinduction requiredpumping with the same machine separate pumpeproduct change low expense very complicate

C

C

C

C

max

min

C

C

C

C



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Conti-TDS - available options

Conti-TDS - Technical Data

Conti-TDS-2 Conti-TDS-3 Conti-TDS-4 Conti-TDS-5 Conti-TDS-6

Power in kW 7 - 9 11 - 30 25 - 45 55 bis 75 110-150

max. speed in rpm 6.000 3.000 (3.600) 3.000 (3.600) 3.000 (3.600) 3.000 (3.600)

Induction rate in kg/min - from paper bag 1 - 4 2 bis 20 3 bis 50 4 bis 50 4 bis 50 - from BigBag, container hopper or silo 4 - 12 6 bis 200 10 bis 400 10 bis 500 10 bis 500

maximum concentrationnon soluble powder 60 % 70 % 75 % 80 % 80 %

maximum viscosity in mPas - normaloperaton 2.000 4.000 4.000 6.000 8.000 - with additional pump 10.000 50.000 100.000 100.000 100.000

Inlet pressure in bar 0,05 bis 0,2 0,1 bis 0,4 0,1 bis 0,6 0,1 bis 0,9 0,1 bis 0,9

max. counter pressure in bar - during powder induction 0,2 0,4 0,6 0,9 - dispersion, pumping 2,5 (4,0) 3,0 (4,5) 3,5 (5,0) 5 (8,0)

Pumping rate in m³/h - maximum (water) 16 48 84 90 - during powder induction 6-10 20-30 30-50 30-50

working temperature max. 70°C for water as a basic liquidfor liquid with higher boiling point please ask the manufacturer

Basic version Options

parts in contact with product 1.4571 + 1.4404 14539

Surface quality electropolished Ra<1,2µm Ra<0,8µm

Elastomeres FPM (Viton) EPDM, PTFE, FFKM (Kalrez)

Type of sealing Mechanical seal Double Mechanical seal

Powder inlet Induction hose or pipe Funnel, Big-Bag-adapter, Drum-,

Silo- or Container connectionProduct connections Milk thread DIN 11851 Flange, Clamp etc.

Accessory Switch board, pneumatic valves, monitor for seals etc.



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


The results speak for themselves:

q Reduction of the production time for a WhiteLacquer down to about 5% of the originaltime with an increase of product quality

q Reduction of the dissolving time for asynthetic resin granulate to about 19% of theoriginal production time. Induction timeapprox. 6 sec per bag

q Extremely good results when treating starch,absolutely agglomerate-free product, eachparticle can be seen under the microscope

q Reduction of the grinding time for a pigmentto about 60% of the original time

q Increase of the colour brightness andreduction in the grinding time for a woodprotection paint

q Controlled and gentle induction of microballoons into Polyol without destruction ofthe balloons

q Some user consider the system to be the bestfor the induction of powder into Polyol

q Saving complete processing steps in theproduction of foils, fibres and film coating

q Higher solid concentrations in theproduction of paper coating paint

q Relevant shortening in time for Pectin,Alginate, CMC, Guar, Xanthan a.o.

q Homogeneous induction and dispersing ofan extremely high viscosity liquid into a lowviscosity liquid

q Controlled induction of a powdery chemicalcatalyst

q Controlled saponification

q Dust-free handling of high conductive blackcarbon with a specific surface of 900 m² pergram

q Dust-free treatment of harmful powders suchas herbicides, lead pigments, diatomite earthheavy metals, corrosive powders...

Advantages of the Conti-TDS

q Dust- and loss-free operationno transfuse, no exhaust systems, no filter

q Direct induction from bags, BigBag, barrel,silo or powder container

q Immediate and complete wetting directlyinto the liquid stream, no crusts are formedon the wall of the vessel or the mixing shaft

q Higher degree of dispersion compared toconventional mixing principles

q Even liquids and gases may be inducted

q CIP-Cleaning without disassembly

q Universal use and adaptation to existingvessels,also to several vessels,also into existing processing systems,on casters for different working areas

q Powder induction without opening thevessel or the system

q When inducting into solvents, powder maybe covered with a layer of Nitrogen into avessel with a layer of Nitrogen

q The function, independent from size ofvessel and filling level in the vessel

q The possibility, to induct powder intoextremely high concentrated or highviscosity dispersions and wet themcompletely

q The possibility to induct powder directly intoa liquid stream(e.g. when filling the vessel)

q After the induction the same machinedisperses the product Inline until therequired particle size, homogeneity andconsistence.



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Trials in the ystral Pilot Plant

ystral offers a well equipped pilot plant area whereall the required tests can be carried out with allystral trial machines

The main advantage of this possibility is, thatvessels, mixers, piping etc. are available in any size.It also enables the user to test his product withdifferent types of machines to find his best solution.

Trials on site

ystral also leases testing machines for tests directlyin your production facility. In this case our machinescan be tested under production conditions.

The installation of the machine is important. Trialswith wrong piping diameters or a too low initialliquid level in the vessel are questionable.

Conti-TDS - Trial machines

ystral offers a range of trial machines fromlaboratory size to production scale.

With these machines, ystral offers the possibility totest the application with the original product onone side and to learn about the new effects of theystral-machines on the material treated.

As the Conti-TDS operates inline independent fromthe volume the trial is always carried out with theoriginal sized machine.The results (induction timeand dispersing time) can be directly upgraded tothe required production volume, they are 100%reproducible.

Filli

ng lev

el/

stat

ic p

ress

ure



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Field of applications:

q Knifing fillerq Offset printing inkq Filler into Polyolq Treatment of extremely light fillersq high viscosity glueq PUR-productsq soft foam compoundsq structured pastesq Anti-foam for Siliconeq High-Solidsq Pigment pastes with highest concentrations

ystral-Systems for Powder Wetting inhigh viscosity liquids

The data sheets for the ystral Conti-TDS show therange of viscosity in which the machines may beused.Especially when high viscosity products aretreated, a pump is installed to increase the flowrate for the liquid and the induction speed for thepowder.ystral uses only volumetric pumping systems thattransport the medium independent from theviscosity. The transportation of the product iscompletely handled by the pump. The ystral Conti-TDS only inducts and disperses the powder into theliquid stream.With this set-up, in principle, powder may beinducted and dispersed with the ystral Conti-TDSinto any flowing and pumpable productIn case of big variations of the viscosity in theproduct automatic flow control for the liquid maybe installed. After induction the product can becontinuously dispersed until it reaches the requiredparticle size.The powder is inducted with an induction pipedirectly from bags or barrels. When largerquantities have to be treated (e.g. Carbon black fornewspaper ink) the powder may be inducted from aBigBag or a powder container



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


TDS-Induction mixer

The principle of the TDS-Induction Mixer is basedon the Jetstream mixer in combination with theVenturi principle to induct powder. A fast rotatingrotor is placed into an aerodynamic formed pipe.During mixing a vacuum is created in the centre ofthe rotor, which is used to induct the powder.A special induction fitting is welded to the statortube to take the induction hose with the inductionpipe. This device is used to induct the powderduring mixing into the fast rotating rotor.The combination of inducting and mixing is veryeffective as sedimentation is avoided and the entireproduct is homogenised during the operation of themachine.



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Diatomite Earth

Diatomite is a filtering aid which is used in thefiltration of drinks with a very high contents ofturbidity. Diatomite is dangerous. When it gets intothe respiratory system, it may result in silicosis orsilicosis tuberculosis.

Dangerous concentrations are possible when thediatomite is brought into a dosing system or avessel manually..

With the ystral-TDS-machines the diatomite isinducted dust-free directly from a bag into theliquid and wetted completely. There is no dustcoming out of the surface of the liquid.

Tests in the laboratories of Forschungs- undMaterialprüfanstalt Baden-Württemberg inStuttgart showed that no particle reduction occurswhile inducting it with a ystral TDS InductionMixer.

Some employer‘s liability insurance companiesrecommend the use of the ystral TDS InductionMixer.

Reduction of the Oxygen Contents ofFiltering Aid Suspension

The contents of oxygen of filtering aid suspensionsis close to its saturation.

The reason for this is the high contents of oxygen inthe water and the additional air in the powder.Depending on the temperature of the water, thisvalue may be in the range of 20.4 to 10.8 mgoxygen per litre.This quantity of oxygen may be reduced by dosingCO2 through an additional fitting in the inlet of theTDS Induction Mixer.The achievable concentration in this case varieswithin a range of 4 and 5 mg per litre ofsuspension. This equals in a reduction of more than50%

Samples of application for the TDSInduction Mixer:

Highly dispersed Silica

The treatment of highly dispersed Silica e.g..Aerosil, Cab-O-Sil, HDK, Gasil o.s. is an ideal taskfor the TDS machines.

The powder is fluidised very easily. It is inductedinto the liquid directly from the bag. Duringinduction and wetting, no dust is created. Thisresults in a reasonably short wetting andsuspending time..

The degree of dispersion with a TDS-InductionMixer is good enough to avoid additionaldispersing with a shear dispersing machine. If thesuspension has to be stored for a long time orrequires an intensive degree of mixing, our TDSDispermix or the Conti-TDS may be used.

Activated CarbonActivated carbon is used in filter systems in theproduction of drinking water as well as in sewageplants. This causes a strong pollution of theworking environment and a high dust concentrationin the air.

Using a ystral TDS Induction Mixer,reduces thisproblem almost down to zero.

Activated carbon does not tend to clog inside of themachine and is therefore ideal for the treatmentwith the ystral TDS system. After the induction, thespeed of the machine is reduced to keep the mixturein suspension during emptying of the vessel.



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


With this machine products may be treated that

q tend to re-agglomerate after wetting

q need a higher degree of dispersing energy todisintegrate the powder

q have to be dispersed very intensive duringthe induction or after the induction processto reach the required particle size

q are very difficult to wet

Besides the general advantages of the TDSprinciple the following additional effects areachieved with the TDS Dispermix:

q no need for additional rotor-statordispersing process

q reducing the working time for powders thatare difficult to wet during the process

q agglomerate-fee dispersion when treatingpowders that tend to re-agglomerate orwhich are difficult to disagglomerate

q lump free solutions within shortestprocessing time

As the Dispermix (ystral-machine withoutadditional induction feature) may also be used toproduce emulsions, it is obvious that the TDSDispermix may be used for any other processwhere liquids have to be emulsified and powderymaterials to be dispersed.

As the Dispermix as a mixer and a dispersingsystem mixes the total contents of the vessel it maybe used for:

q fast and homogeneous distribution ofstabilisators and emulsifying agents

q narrow droplet spectrum of the emulsion inthe whole vessel

q Rarely the possibility is being used to inductliquids and gases besides powders and todisperse them

TDS - Dispermix

The TDS-Dispermix is also a machine for the dust-free induction of powder into a liquid.

Similar to the TDS Induction Mixer, the powder isinducted through the concentric stator tube into theliquid and wetted and dispersed immediately.

Different to the TDS-Induction-Mixer the TDS-Dispermix offers a combination of a mixing and adispersing head.

The liquid that streams through the mixing head is- same as for the Jetstream Mixer - accelerated andtakes up the inducted powder. The liquid thatpasses through the area of the wall of the mixinghead is forced by the patented Dispermixconstruction to leave the head through thedispersing slots in the mixing head.. The liquid isvery intensively dispersed. Beside the wetting andhomogeneous mixing a partial stream is alwaysdispersed..



Tel: (0)7634 - 5603 - 0 Fax: (0)7634 - 5603 – 99


Are you interested in a concrete quotation for your application?Please fill in this form and send it back to ystral..

Request No.: .......................Customer: ........................................................

........................................................

Application: Induction, Wetting and Dispersing of

...............................................................in ............................................................

End Product: ...........................................................Total Volume l or kgViscosity: mPasDensity: kg/dm³

Basic liquid: ...........................................................Quantity: kg or lViscosity: mPasDensity: kg/dm³

Powder: ...........................................................Quantity: kgBulk density: kg/dm³Particle size: µm

Inlet pressure: ............ barWorking temperature: ........... °CRequired lifting hight: max. ......... mVoltage / Frequency: ............../....... V/HzProtection class: ............. ..............

Further Information:(How does the powder flow? Is it sticky? Does it swell? Is it hazardous? ....)

Questionnaire Conti-TDS

ystral information Conti-TDS · Mixer, TDS-DISPERMIX) or for Inline operation outside of the vessel...

Documents

Transcript of ystral information Conti-TDS · Mixer, TDS-DISPERMIX) or for Inline operation outside of the vessel...