EUROPEAN ROADMAP OF PROCESS INTENSIFICATION

- TECHNOLOGY REPORT -

TECHNOLOGY:
Static mixer reactors for continuous reactions

TECHNOLOGY CODE: 1.2.5

AUTHOR: Mark Dickson, Foster Wheeler Energy Limited

Table of contents

1. Technology
1.1 Description of technology / working principle
1.2 Types and “versions”
1.3 Potency for Process Intensification: possible benefits
1.4 Stage of development
2. Applications
2.1 Existing technology (currently used)
2.2 Known commercial applications
2.3 Known demonstration projects
2.4 Potential applications discussed in literature
3. What are the development and application issues?
3.1 Technology development issues
3.2 Challenges in developing processes based on the
technology
4. Where can information be found?
4.1 Key publications
4.2 Relevant patents and patent holders
4.3 Institutes/companies working on the technology
5. Stakeholders
5.1 Suppliers/developers
5.2 End-users
6. Expert’s brief final judgment on the technology

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1. Technology
1.1 Description of technology / working principle
(Feel free to modify/extend the short technology description below)

Static mixers as mixing devices

The science and technology behind the use of static mixers as mixing and micro-
mixing devices has been reported in a number of sources and it has been assumed
that these principles are covered in TR report 1.1.4. This report is therefore covering
the extension of the theory only applicable to the use of static mixers as reactors to
avoid any overlap with other areas of the TR reports.

Introduction to static mixers as reactors

Static mixer reactors provide excellent heat and mass transfer. The mass transfer is
provided by the insertion of static mixers designed to improved plug-flow and micro-
mixing at high (turbulent mixers) or low (laminar mixers) Reynolds numbers. The
excellent heat transfer comes from the detailed design of heat/cool coils and jackets
around the static mixers.

The use of static mixers as reactors has been recognised by certain industries for
many years. As an example, highly viscous polymerisation reactions are carried out
in static mixer reactors, giving higher product quality and consistency over other
reactor types.

Classification of mixer types

The static mixers available on the market can be classified into groups as follows:
helical-type, bar-type, hole-type (Ross ISG), wafer-type (SMV) and baffle-type (HEV).
The most commonly used are the helical-type (e.g. Kenics) and bar-type (e.g. Sulzer
SMXL) mixers. The helical mixer splits the flow and turns both halves through 90o,
the next element then splits each half again, and so on. The bar-type units tend to
split flow into many segments very early and continue to split and recombine the flow
through each element and onto the next. The bar-type units are considered to be
higher intensity than the helical units, however this comes with a higher pressure
drop.

The emerging area of micro-mixers as static mixer reactors, e.g. the caterpillar mixer,
will not be covered in this report as it is expected to be covered in TR reports 1.1.5
and 1.2.2.

Mixing uniformity of reagents

The key to a good reaction is getting the mixing time of reagents equal to or better
than the inherent reaction time, thereby allowing reactions to proceed at their natural
reaction rate. For homogeneous systems this is typically achieved by a large degree
of micro-mixing between the reagents at the inlet to the reactor, and can be achieved
by using a high-intensity mixing device. The science to explain how efficient mixers
are at blending two streams has been reported previously, e.g. coefficient of variation
(CoV). The pitch and intensity of a static mixer determines how quickly the streams
can be well-mixed, for example the SMX units will achieve better mixed systems in
less distance than the helical type units.

Degree of plug-flow & residence time distribution (RTD)

When using static mixers as reactors a key requirement is often to ensure good plug-
flow. This prevents back-mixing of products with reagents, which may cause side-
reactions, for example in the simple reaction A+B→C+D and C+B→ waste, where C
is the desired product, it would be desirable to prevent C and B mixing. Typically B is
in high concentration at the start of the reactor and C at the end, so less back-mixing

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would result in more of the preferred product. In an ideal plug-flow environment each
element of fluid experiences the same conditions as it passes through each stage of
the reactor irrespective of time.

An approximation of how close a system is to plug-flow can be given by the Reynolds

number correlation. A system Reynolds number will determine whether flow is in
laminar (low Reynolds), transition or turbulent (high Reynolds) regime. A higher
Reynolds number would be required for plug-flow. The dimensionless Reynolds
number is a product of channel diameter, fluid density and fluid velocity divided by
the viscosity. Therefore highly viscous and low flowrate systems are typically laminar
even in small diameter channels, whereas in other systems higher Reynolds
numbers can be achieved by using smaller diameter pipes (although this has a
pressure drop impact). In laminar flow the fluid in the centre of the channel travels
much quicker than the fluid at the wall, and thus a significant level of back-mixing
occurs. In fully developed turbulent flow this effect is reduced and the velocity of fluid
across the channel is more uniform, however boundary layers on the pipe walls are
still observed.

For turbulent flow systems a static mixer will provide additional micro-mixing capacity
and prevent/minimise boundary layer effects. In laminar flow a static mixer will break
the velocity profile and simulate a plug-flow regime. The performance of the static
mixer is still dependent on the bulk fluid velocity, density, viscosity and pipe diameter,
as well as dependent on the mixer type. A more intense mixer will provide a better
approach to plug-flow than a less intense device.

The residence time distribution models presented by Danckwerts (1953) are a good
method of expressing the variation in residence time experienced by various
elements of a fluid in a reactor system. To determine the residence time variation a
tracer is injected at time zero into the start of the reactor and the concentration of
tracer is measured at the outlet over time. The result is a normal distribution curve
with the width directly related to the degree of plug-flow seen in the reactor. For
example a fully laminar regime would provide a very wide normal distribution curve
(significant back-mixing spreads the tracer), whereas a true plug-flow system would
see the same tracer spike that was injected at the start. The models can be displayed
in exit concentration form, E(t), or in cumulative form F(t).

Residence time distribution is often further quantified using the Bodenstein (Bo)
number (sometimes referred to as the Peclet mass-transfer number). The Bodenstein
number is a measure of the width of the residence time distribution in accordance
with the Danckwerts dispersion model, and can be summarised as the ratio of bulk
transport through the reactor to the axial dispersion coefficient. For an ideal CSTR
(continuous stirred tank reactor) Bo=0 and for an ideal plug-flow system Bo=infinity.
In practice, a Bo>100 would be considered a plug-flow system, equivalent to 50
CSTR’s in series.

Heat transfer design

For many chemical reactions an accurate control of reaction temperature is essential
in forming the correct products and minimising side reactions. For static mixer
reactors this can be especially important, as changes in localised conditions can
quickly lead to undesired reactions and potential safety concerns. The high intensity
mixing means observed reaction rates are typically quicker as it is not mixing limited,
this can result in high heat generation. The static mixer reactor must be able to
dissipate this heat quickly to avoid local hotspots.

The rate of heat release in a reactor is often highest in the most intense mixing
sections, typically at the start of the reactor when the streams are first mixed

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together. Heat transfer requirements at intense mixing inlet may be critical and
require separate heat transfer systems than the remainder of the reactor. For
example, use of lower temperature coolant removes heat intensely in this area,
whereas it would overcool and slow the reaction down later, and therefore a different
temperature coolant may be used for the remaining part of the reactor. Alternatively
separate equipment with higher heat transfer intensity may be required just to
remove initial heat of reaction, however consideration must then be given to the
separation distances between one reactor and the next to ensure the reaction is
under control.

Multi-phase systems and droplet size

Many static mixer designs perform well in homogeneous systems whilst others have
been designed specifically for use with two immiscible fluids. In this case
characterisation of performance is dependent on the droplet size produced,
particularly as mass transfer across the droplet surface often controls the reaction
rate. In this case small droplets are preferred (more surface area) to keep the
reaction rate high.

There is limited information and research on the use of static mixer reactors for gas-
liquid and solid-liquid reactions. In the case of gas-liquid systems the mixing
performance has been documented, however this has not been extended to reacting
systems.

In the case of solid-liquid systems a further sub-classification is required, systems

where solids are fed into the reactor (where feeding equipment to provide a
consistent stream is not available) and systems where solids are generated in the
reactor. When solids are generated by a reaction the design of the static mixer can
be very important, as increased surface area can act as a filter for the solids, causing
blockage. In this case the static mixer type may be different in the early part of the
reactor, when less solids are present but intense mixing is required, than towards the
end of the reactor.

Fluid flow and pressure drop considerations

In addition to the fluid flow profile mentioned above consideration should be given to
the affect the static mixer has on the pressure drop in the system. Choosing different
static mixer elements for the reactor may improve the RTD profile, but it will likely
cause an increased pressure drop across the reactor increasing the size of feed
systems. The optimum design of a static mixer reactor should be considered in terms
of the full system and not just an optimised reactor design.

Instrumentation and measurement

Continuous static mixer reactors will often require a high level of process monitoring
and control. This reflects the level of precision control required during the reaction.
Characterisation of temperature profiles and product profiles required throughout the
reactor may result in instruments being incorporated into the design. This is an area
that requires significant development, particularly for small-diameter systems where
the presence of instrumentation and sensors can disrupt the process.

Understanding chemistry to choose structure & whole process design

There are various levels of structure that must be considered in equipment selection
and design. Below are a series of typical reactions and how these reaction conditions
affect the choice and design of the reactor:

1. Some processes need very precise conditions to achieve the optimum reaction, for
example the rate of competing side reactions will increase substantially if the
temperature moves out of defined narrow bands. In this case a reactor must be

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chosen that is capable of very precise control, e.g. micro-reactors, specially designed
static mixer reactors, etc, and the specific reactor should be designed to maximise its
effectiveness at precise control. However if there are no competing side reactions
under operating conditions then a simplified static mixer reactor may be more
appropriate.

2. Some reactions are sensitive to products further reacting to unwanted materials,

unless they are removed or isolated quickly. In this case it is more important to
prevent back-mixing and a high mixing-intensity static mixer could be used. It is
important to recognise the relative rates of preferred and unwanted reactions before
making the decision to invest in more intense static mixer technology.

3. Some reactions may also be inhibited from by-products of the main reaction. In
this case the presence of the by-product may be reducing the reaction rate
significantly and therefore extending the size of the reactor exponentially to achieve a
set yield. Intermediate or continuous removal of the by-product may be desirable, or
alternatively the reactor can be reduced in size to accept a lower yield, with a
separation and recycle provided. This will reduce the yield through each pass of the
reactor but when you consider the full reactor system (inc. recycle) the yield is high
and the equipment much smaller. This is often cost effective as it keeps the reaction
rate high in the reactor. A similar approach of restricting reaction time can also be
useful in preventing formation of by-products that may cause downstream issues.

Information similar to that described above is required when choosing the right
reactor technology and assists the designer in specifying the details of the specific
equipment within that technology.

Theoretical models applicable to static mixer reactors

Levenspiel’s (1998 3rd edit) text on ‘Chemical Reaction Engineering’ provides a
series of models to explain and predict the behaviour of reactor systems. Particular
attention is drawn to the tank-in-series and dispersion modelling sections as they
provide an excellent overview of how to select and design appropriate reactor
systems.

1.2 Types and “versions”

(Describe the most important forms/versions of technology under consideration, including
their characteristic features, differences and similarities)

Sulzer Chemtech market the SMR reactor in which the static mixer elements are
actually the heat transfer coils. This design is very useful for high viscosity systems
where excellent mixing, low pressure drop and good heat transfer are primary
considerations.

A number of static mixer suppliers also market multi-tube heat exchanger reactors.
These designs use a traditional shell-and-tube heat exchanger with static mixers
inserted into the tubes. These tubes can then be used in parallel or series depending
on the design of headplates or external piping.

Static mixer suppliers also offer mono-tube reactor arrangements, where a single
jacketed tube has static mixer elements inserted. Multiple mono-tube arrangements
of various lengths can then be added to increase the available residence time.

Static mixer reactors typically contain an intense mixing section, to promote the
reaction, followed by a less intense section of mixer, to ensure plug-flow is
maintained.

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1.3 Potency for Process Intensification: possible benefits
(In Table 1 describe the most important documented and expected benefits offered by the
technology under consideration, focusing primarily on energy; CO2 emission and costs,
providing quantitative data, wherever possible. Add other benefits, if needed).

Table 1: Documented and expected benefits resulting from technology application

Benefit Magnitude Remarks

Approach to plug- The reasons why plug-flow are important is covered in

flow for low section 1.1, and static mixer reactors can achieve
Reynolds number acceptable plug-flow conditions for high viscosity and low
systems flowrate systems
Orders of magnitude Less floor space, lower energy consumption, shorter
Compact smaller than batch residence time (less material at reaction conditions),
mixers better control
Virtually no
No moving parts
maintenance
Fixed size can operate across a wide flow range, giving
Flexible operating
user flexibility to turn plant up or down to meet product
flow range
demand
Less material to manufacture the equivalent of a batch
vessel, quicker to produce and significantly cheaper.
Need to quantify the cost against other PI technologies,
Lower capital cost but typically this is the most cost effective for reactions
seconds to minutes reaction time. Cost is directly related
to length and therefore very long residence times
become more expensive (over other PI technology)
Higher pressures and temperatures are possible in static
Enhanced reaction
mixer reactors versus batch vessels and some other PI
conditions (temp &
reactors. Operating conditions are available to ten’s bars
pres) o
and hundreds of C
Continuous operations offer energy savings over
traditional batch processes. In addition static mixer
Energy saving
reactors are low energy consumption devices as the
mixing energy is generated by the feed pump system
Plug-flow conditions maximise the preferred reaction
Increased yield and
route, thereby reducing impurity generation. This results
selectivity
in a better product quality

1.4 Stage of development

Static mixer reactors have been used in a variety of applications since the 1970’s,
typically for mixing streams prior to reaction.

The use of static mixers for polymerisation reactions is reasonably well developed
(typically using mixers of 25mm and above).

The use of static mixer reactors for pharmaceutical and fine chemical small-scale
continuous processes is much less developed but has received significant research
and development attention in the last few years. However, many companies and
universities are focussed on the use of static mixer reactors for improving specific
processes, without addressing the need for improvements in the design of the static
mixer equipment being used.

Heat transfer design

Maintaining the reaction in a temperature controlled zone (the main issue with
multiple mono-tube and external flow direction piping systems) is an issue for static
mixer reactor design. Therefore further development effort in this area is required.

RTD and yield considerations

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Choosing the right static mixer design for a reactor is not particularly well understood.
There is literature reporting the similarities between mixers for mixing duties and this
is often confused with the use of mixers for reaction duties. For example, the
difference between the required length of helical and bar-type mixers to achieve the
same CoV may be small (the mixing duty), but the difference between these two
mixers for maintaining plug-flow in a long reactor can be significant (the reaction
duty). Many suppliers and users do not appreciate this difference in the available
information and can therefore be selecting a mixer based on the wrong information.

Cost/benefit of static mixer reactors over other PI technologies

Static mixer reactors appear favourable over other PI technologies for short
residence time (seconds to minutes) and medium exotherm reactions. This is due to
the relatively low investment cost. Also many static mixer element designs are
commercially available and further development reactor systems should make this an
attractive technology. However an assessment of industry processes is needed to
confirm what percentage of reactions could be carried out in static mixer reactors.

2. Applications
2.1 Existing technology (currently used)
(Describe technology (-ies) that are conventionally used to perform the same or similar
operations as the PI-technology under consideration)

Tubular reactors (empty pipes) are often used at high flowrates in the turbulent
regime. These could benefit from the higher mixing and heat transfer intensity that
static mixers provide.

For small-scale applications, that would typically be in the laminar flow regime in ¼”
to 1” lines, there is no single continuous reactor design currently in widespread use.
At this scale many reactions are conducted in stirred batch vessels with
heating/cooling jackets or coils with limited heat and mass transfer capability. There
are a number of options for reactor technologies that may replace batch vessels; this
includes micro-channel devices, macro-channel devices, static mixers, oscillating
flow reactors, spinning discs and cones, spinning tube-in-tube, etc.

The advantages of static mixer based systems are:

• Easy to inspect/clean
• Can be very cost-competitive for the correct processes
• Can meet a range of reaction times (seconds to minutes) – where many industry
reactions would fit
• Fit into current industry standards, e.g. PED
• Established technology in larger volume process industries – perceived as lower
risk
• Variety of mixer types available for fine tuning reactors to process requirements
• Larger number of suppliers available ensures competitive pricing
• No moving parts, resulting in lower maintenance and higher energy efficient in
comparison to other technologies

2.2 Known commercial applications

(Is the technology broadly applied on commercial scale? In which process industry sectors is
the technology most often applied: large volume chemicals – specialty chemicals & pharma –
consumer products – ingredients based on agro feedstocks? What is the estimated number
of existing applications? In Table 2 provide the most prominent examples of realized
applications and provide their short characteristics)

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Historically static mixers have been used for their mixing ability but more applications
of static mixer reactors have emerged in the last 5years.

The commercial use of static mixer reactors in the polymer industry is well
documented and other specialist applications have been reported. However the
emerging interest into the use of static mixer reactors has been during small-scale
trials (laboratory and pilot-plant) and it is expected that many more commercial
applications will be utilised in the next 5-10years.

Table 2. Industrial-scale applications of the Technology (existing and under

realisation)
Company - Producti
Short Year of
Process/ on
Sector characteristic applica Reported effects
Product capacity/
of application tion
name/type Plant size
Major area of use
with multiple users
1980s
Polymerisations who have seen
onward
improved control
and quality
Opening up new
chemical routes
Specialty not previously
Confidential Last
chemicals and accessible in batch
(various) 3yrs
Pharmaceuticals equipment.
Improved control of
reactions

2.3 Known demonstration projects

(Are there any demonstration projects known related to the technology under consideration?
In which process industry sectors are those projects carried out: large volume chemicals –
specialty chemicals & pharma – consumer products – ingredients based on agro feedstocks?
In Table 3 provide the short characteristics of those projects.)

Table 3. Demonstration projects related to the technology (existing and under

realisation)
Short characteristic
Aimed
Who is of application
year of
Sector carrying out investigated, Reported effects
applicati
the project including product
on
name/type

2.4 Potential applications discussed in literature

(Provide a short review, including, wherever possible, the types/examples of products that
can be manufactured with this technology)

There are a variety of reactions currently carried out in a range of industries that
could benefit from the use of static mixers. Below are a series of specific examples
drawn from the literature;

1. The use of ionic liquids and static mixer reactors for isobutane alkylation to
produce high quality trimethylpentanes has been reported in Oil & Gas journal, 2006.
This is one example of many where static mixer reactors have the potential to be
used in large petrochemical and refining operations. Static mixer reactors in this area
tend to be in the turbulent regime and the mixer is used as a mass transfer
improvement device.

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2. A number of publications in the last 5years have referenced the use of continuous
and static mixer based reactors for significant improvements in pharmaceuticals and
fine chemicals production. Given the pressure to reduce cost of manufacture in this
industry the static mixer reactors future looks promising. These reactors are typically
characterised by low flowrate and low viscosity systems (laminar) where static mixers
are used to contact reagents and then maintain plug-flow. One example of this is the
use of jacketed static mixers for oxidation reactions reported at the AIChE 2006
technical program.

3. The characterisation of static mixer reactors for the production of biodiesel has
been reported (ASABE 2007). This is an example of static mixer reactors being used
for emerging technologies and access to reactions that may not be feasible or
possible in conventional equipment.

Static mixer reactors can be applied to a range of chemical reactions across many of
the process industries, and are receiving increase attention and focus in new areas.

3. What are the development and application issues?

Technology development issues
(In Table 4 list and characterize the essential development issues, both technical and non-
technical, of the technology under consideration. Pay also attention to “boundary” issues,
such as instrumentation and control equipment, models, etc.) Also, provide your opinion on
how and by whom these issues should be addressed)

Table 4. Technology development issues

How and by whom
Issue Description
should be addressed?
Static mixer designs range in the mixing
intensity they provide under different flow Ideally an industry
regimes. Users are often concerned that the collaboration or university
Cost/Benefit
increased cost of more intense mixers may not would be better suited to
analysis of
provide an equal benefit in performance. completing this
various static
Suppliers are reluctant to invest in comparison. A standard
mixer designs
performance testing for residence time experimental set-up could
distribution (RTD) without knowing the market be used.
potential
Suppliers must focus on
manufacturing methods or
Manufacturing techniques make some static
Matching industry must identify
mixer elements only available at ½” or 1”
performance at alternative products which
diameter and above. This is too large to see
laboratory and match a static mixers
the benefits for typical development flowrates
plant scale performance at smaller
(especially for high value chemicals).
scale, e.g. caterpillar
micromixers etc.
This survey can be carried
out by the EU or similar
How applicable industry body where
is the An assessment of industry processes is confidentiality of specific
technology to needed to characterise and classify reactions results can be maintained
industry into groups. This analysis can then indicate the and only generalised
requirements potential market for static mixer reactors over reports made available.
(appropriate other competing technologies, as each The key is to get the
level of technology might be more appropriate for a survey questions correct to
structure for specific set of industry reactions understand the base
industry) chemistry and not just the
observed practices (i.e.
some reaction times are

9
 shorter than carried out in
traditional equipment).
The science behind which static mixers may University and industry
Multi-phase
be applicable to different ratios of multiple collaborations could
systems
phases has not been reported determine this science
Collaboration between
Often reactions need continuous monitoring
instrument suppliers and
Availability of inside the reactor and the instrumentation and
equipment suppliers is
appropriate sensors to achieve this and how they are
needed in this area, with
instrumentation integrated into equipment needs further
input from users on the
development
actual requirements.
Suppliers need to be
Process intensification often results in more aware of number of
Availability of
arduous process conditions and the applications requiring
‘exotic’
requirement for exotic materials, e.g. hastelloy, these materials to invest in
materials
tantalum, PTFE, etc the development of this
product range.

Challenges in developing processes based on the technology

(In Table 5 list and characterize the essential challenges, both technical and non-technical, in
developing commercial processes based on the technology under consideration. Also,
provide your opinion on how and by whom these challenges should be addressed)

There have been numerous publications and presentations in the last 5 years where
people have used static mixer reactors for significant processes improvements. On
this basis the challenges in moving into this area appear small. However, more
emphasis should be placed on using the optimum mixer and reactor design
(compared to other static mixer reactors) rather than just reporting the benefits of
static mixer reactors over conventional equipment.

Table 5. Challenges in developing processes based on the technology

How and by whom
Challenge Description should the challenge be
addressed?
Lack of
Static mixers have been designed for intense An industry overview of
investment by
mixing of two streams and not necessarily for the potential for static
suppliers to
optimum RTD performance. They need to be mixer reactors may
understand
convinced of the potential market demand for convince people to
background
them to invest in further characterisation invest.
science
End users of static mixer reactors are
Information gained from
Confidentiality developing novel solutions to gain competitive
University research can
of research advantage and will be reluctant to make the
be published with
companies data and designs available outside their
governing body support
organisations
There are numerous competing technologies in
Published science, with
the area of process intensification. Companies
appropriate review and
developing novel solutions for a specific
Commercial & approval, enable final
application will look for a wider use (even
academic users to make
though other technologies may be more
influences independent judgments
applicable). This can also occur when the
on which technology is
developer is unaware that other technologies
more appropriate.
are more appropriate to the end user.

4. Where can information be found?

Key publications

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(Provide the list of key publications in Table 6)

Table 6. Key publications on the technology

Publication type
(research
Publication Remarks
paper/review/book/
report)
Numerous models
Levenspiel, O. 1998, ‘Chemical Reaction are presented for
rd Book
Engineering’, 3 Edit, Wiley-Interscience the design of
reactor systems
Thakur, R.K. et al., 2003, ‘Static mixers in the Thorough analysis
Process Industries – A Review’, Trans IChemE, Review Paper of static mixer
Vol 81 (part A), August, 787-826 applications
Good overview of
Streiff, F.A. and Rogers, J.A, 1994, ‘Don’t
static mixer reactor
overlook static mixer reactors’, Chemical Feature report
use in many
Engineering, June, 76-82
industries
Bayer, T., Himmler, K. & Hessel, V., 2003, ‘Don’t
Good overview of
be baffled by static mixers’, Chemical Feature report
static mixer design
Engineering, May, 50-57
Brechtelsbauer, C. and Ricard, F., 2001,
Excellent report on
‘Reaction engineering evaluation and utilization
static mixers in
of static mixer technology for the synthesis of Research paper
small-scale Pharma
pharmaceuticals’, Organic process research &
production
development, 5, 646-651
Good overview of
static mixer
Tauscher, W., 1996, ‘Static mixing and reaction
applications in bulk
technology’, Chemical and Petroleum Review paper
chemicals and
Engineering, Vol 32 (3), 224-237
petroleum
industries
Paul, E.L, Atiemo-Obeng, V.A., and Kresta S.M.
Multiple references
ed., 2004, ‘Handbook of Industrial Mixing: Book
to static mixers
Science and Practice’, Wiley Interscience
Green, A., 2004, ‘Inline and High-Intensity
Mainly focused on
Mixers’, In: Reengineering the chemical plant –
initial mixing and
Process Intensification, edited by Stankiewicz, A. Chapter in book
not maintaining
and Moulijn, J.A., New York – Basel: Marcel
plug flow
Dekker
Meyer, T., David, R., Renken, A and Villermaux, Good overview of
J., 1988, ‘Micromixing in a static mixer and an static mixers and
Research paper
empty tube by chemical method’, Chem. Eng. use of Bodenstein
Sci., Vol 43 (8), 1955-1960 correlation
Liu, Z., Zhang, R., Xu, C., and Xia, R., 2006, Use of static mixer
‘Ionic liquid alkylation process produces high- Report reactors in gasoline
quality gasoline’, Oil & Gas Journal, October industry
Characterisation of
Thompson, J.C., and He, B. B., 2007, ‘Biodiesel static mixer
production using static mixers’, Trans. of the Research paper reactors for
ASABE, 50 (1), 161-165 Biodiesel
production

4.2 Relevant patents and patent holders

(Provide the list of relevant patents in Table 7. Under “remarks” provide, where applicable,
the names/types of products targeted by the given patent.)

There are multiple patents related to the use of static mixer reactors in developing
continuous synthesis routes for various chemicals, however these are related to a

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specific use of static mixers and are therefore excluded from this patent list below.
This list refers to the holders of specific designs of static mixer reactor.

In addition the specific design of static mixer elements are subject to patents,
however these should be covered in the TR report sections associated with static
mixers and have therefore been excluded from this list.

Table 7. Relevant patents

Remarks, including
names/types of
Patent Patent holder
products targeted by
the patent
WO02072254: Reactor apparatus and
BHR group Flexreactor
mixing inlet and methods
WO2004/130551: Reactor enabling Variable residence time
Phoenix Chemicals Ltd
residence time regulation reactor

4.3 Institutes/companies working on the technology

(Provide the list of most important research centers and companies in Table 8)

Major suppliers of static mixers are conducting limited research into the use of static
mixers as reactors (limited investment due to the need to see the potential market).

Operating organisations in the fine chemical and pharmaceutical industries consider

the use of static mixer reactors as a way of lower manufacturing costs and are
currently involved in confidential research.

Organisations in biodiesel and gasoline production are investigating the use of static
mixer reactors for major improvements to emerging processes.

In summary many process industry companies have planned or active research into
the use of static mixer reactors.

Table 8. Institutes and companies working on the technology

Institute/Company Country Remarks

5. Stakeholders
5.1 Suppliers and developers
(Provide the list of key suppliers/developers in Table 9)

The list of suppliers provided will all provide static mixer elements and some will
extend this to mono-tube and multi-tube devices.

Table 9. Supplier and developers

Institute/Company Country Remarks
SMXS, SMXL monotube and multitube
Sulzer Chemtech Switzerland
reactors, SMR
Chemineer - Kenics USA & UK Kenics KM and KMX
Koflo USA Series 246, 250, 275, 330
Fluitec Switzerland CSE-W and CSE-X
Statiflo UK Series 100 to 800
Charles Ross & Son Co USA ISG and LPD/LLPD
Admix USA SAN

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Komax USA A and M Series
Verder Netherlands VMV, VML, VMS, VMD
EMI/Cleveland Eastern USA Sanitary helical
Dr. B. Pittaluga Italy XP, VP, X, XL, H
Eesimix Singapore
JLS International USA, UK, Germany Helical and high shear

Additional stakeholders in the development of static mixer reactors would include the
manufacturers of traditional equipment (shell-and-tube heat exchanger suppliers can
fabricate the reactor and fit in sub-contract supplied elements). Major design
companies/consultancies are interested in understanding the basic technology
required to design static mixer reactors to ensure equipment configurations can
match their customers and the industries needs.

5.2 End users

(Describe the existing and potential end-users, other than those already listed in Table 2)
The petrochemical and refining industries have used static mixers as mixing devices
for many years. The polymerisation industry has been using static mixer based
reactors for accurate control of main reactions for many years.

Potential future end users include the fine chemicals and pharmaceutical
manufacturing companies as this technology is useful for many reaction stages
currently carried out in these industries. The biofuels market may also benefit from
the use of static mixer reactors. In addition, the refining and petrochemical industries
can benefit from the more intense heat and mass transfer provided by turbulent static
mixers to reduce the size of process plant and reduce fouling issues due to poor
mixing. This is a particularly favourable to static mixers as they are commercially
available at the larger diameters needed for these industries.

6. Expert’s brief final judgment on the technology

(maximum 5 sentences)
Static mixers have historically been used as mixing devices. However the use of
these devices for chemical reactions is gaining momentum based on the benefits
observed in trial work.

Static mixer reactors offer a low cost intense reactor system when compared with
other process intensification technologies. They are particularly cost-effective
solution for small-scale processing of reactions with residence times from seconds to
minutes, for highly viscous systems and where boundary layers can be formed
affecting flow (e.g. fouling from agro products). Static mixer reactors can exist
alongside other novel PI technologies. Specifically high intensity micro and macro
channel reactors to cover shorter residence time and highly exothermic reactions and
less intense oscillating flow reactors, etc for longer residence time reactions.

Choosing the appropriately structured reactor depends on understanding process

requirements. Static mixer reactors can be improved and used in a wider range of
applications with further development, i.e. improved heat transfer, etc. However they
will also be relevant for many chemical reactions even at the current stage of
development.

The key development areas of understanding the RTD profiles and mixing
performance of different mixer types, improving the science behind multi-phase
system behaviour and improved heat transfer designs will contribute to making this
technology easier to access for all industries.

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