浅析影响分散机分散效果的主要因素
发布日期：2023-11-06
阅读量：1053
分散机（乳化机、均质机）在现代工业设备搅拌体系和混合中占有重要的作用，特别是在固液混合、液液混合、油水乳化、分散均质、剪切研磨方面有着极其重要的应用。不同行业有不同的叫法，例如化妆品通常以液液混合、油水乳化为主要目的，习惯称为乳化机或均质机；涂料行业经常要用于粉末分散、固液混合比较多，习惯称为分散机。医药行业、精细化工等则根据用途不一而叫法不一，但最终用途都是通过高速搅拌、研磨、剪切达到均匀混合，形成均一稳定体系的目的。
现在分散机的应用不单单局限于“分散”，由于其独特的高剪切作用，在分散的同时粉体颗粒在定、转子狭窄的间隙中受到强烈的机械及液力剪切、离心挤压、液层摩擦、撞击撕裂和湍流等综合作用，从而使固体颗粒进一步细化并充分混合到液体中形成相对稳定的悬浮液，即高剪切分散机。
要分析分散机的性能和特点，先需要了解影响物料分散效果的几个因素：
1分散头的形式（批次式和连续式）（连续式比批次好）
2分散头的剪切速率（剪切速度越大，效果越好）
3分散头的齿形结构（分为初齿，中齿，细齿，超细齿，齿越细效果越好）
4物料在分散腔体内的停留时间，即分散时间（同等电机，流量越小，时间越长，效果越好）
5循环次数（越多，效果越好，直到设备的极限）
关于线速度的计算公式：
剪切速率的定义是两表面之间液体层的相对速率。
剪切速率(s-1)=v速率/g定-转子间距
由上可知，剪切速率取决于以下因素：
转子的线速率
这种请况下两表面间的距离为转子-定子间距。
高剪切分散机定-转子的间距范围为0.2~0.3 mm
速率V=3.14 X D（转子直径）X转速RPM/60
在实验室中试生产、工业生产中的应用：
分散机（10000rpm--30000rpm）应用于实验室，分散机应用于工业化生产；
怎样有效的将二者有机结合起来？是许多工艺工程师经常遇到的一个问题，往往一个产品在实验研发的时候效果很好，配方也没有问题，但在中试和正式投产的时候需要重新对设备进行选型，需要不断调整工艺参数，甚至有时候需要推倒重来，费时费力，影响产品生产进程，对于时间就是金钱，领先就意味着利润的市场，经常是得不偿失。
怎样解决这个问题？高剪切分散机采用现今国际流行的立式结构，实验设备和工业设备使用同一机型，放大型号，保持剪切速率不变，分散效果一致；这样一来，在实验室用高剪切分散机研发出来的产品，在中试和工业生产的时候，不再需要为设备选型，改变工艺条件来适用设备而烦恼。
专栏：技术交流
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