- [Introduction] Static mixing stations go beyond simple material blending; they are engineered to precisely premix crucial components—such as cyclopentane, catalysts, and 245fa—to the exact uniformity required for advanced processing. By delivering highly consistent mixtures directly into the production cycle, they ensure a seamless, efficient, and reliable manufacturing flow across demanding industrial applications.
- [Capacity] 0.5-1 t/h
- [Improvement] Haifeng can customize the polymer premixing station according to the actual working conditions and customer requirements.
ADVANTAGES
- Intelligent Remote Monitoring System - The station is equipped with an advanced remote monitoring system that allows operators and engineers to track real-time operational status, process parameters, and data logs. This transparency facilitates quick fault diagnosis and enables remote technical support, maximizing machine uptime and ensuring continuous production.
- Strict Anti-Leakage Control - Engineered specifically for the handling of polyurethane chemicals, the static mixing station features high-standard sealing and anti-leakage control designs. From pipeline connections and valves to the pumping system, it comprehensively eliminates material dripping. This ensures a clean, eco-friendly production environment while preventing the waste of expensive raw materials.
- Reliable Nitrogen Protection - A comprehensive nitrogen protection mechanism is integrated into the material mixing and storage process. By displacing air within the pipelines and storage tanks, it prevents oxygen and moisture from reacting with and degrading the raw materials. This maintains optimal chemical activity and significantly enhances the explosion-proof safety of the entire system.
- Cyclopentane Gas Monitoring and Alarm System - Safety is the absolute priority in cyclopentane foaming applications. The system features a highly sensitive gas concentration monitoring matrix. If cyclopentane gas in the working area approaches safety thresholds, it instantly triggers audio-visual alarms and automatically activates emergency ventilation and system shut-off protocols, providing the highest level of operational safety.
- Industrial-Grade Explosion-Proof Electrical Appliances - To meet strict safety compliance in flammable and explosive environments (such as pentane premixing workshops), all critical electrical components, sensors, motors, and control cabinets feature a fully explosion-proof design. This ensures the equipment operates safely and reliably within high-risk classified zones, meeting international industrial safety standards.
- Precision Carbon Dioxide Gas Filling Unit(Optional) - The station includes a high-accuracy CO2 gas filling unit capable of stably injecting liquid or gas carbon dioxide into the system at exact ratios. This unit not only optimizes the eco-friendly profile of the foaming process but also significantly improves the cell structure and thermal insulation properties of the final polyurethane foam.
- Polyether Component Gas Filling Unit(Optional) - A dedicated gas nucleation and filling system for the polyether (polyol) component ensures precise control over the gas content within the raw material. This specialized unit enhances the mixing uniformity inside the static mixer, guaranteeing consistent density and superior physical properties in the final foamed products, such as home appliance insulation and automotive interiors.
PRODUCT STRUCTURE
PRODUCT PARAMETERS
Model | Size | Number of tanks | Volume of tanks (L) | Power(kVA) | Feeding output(kg/min) | Temperature Control(℃) | Application |
HF-SMS-2X10-P&I-I | 3600 x 2000 x 3600 mm | 2 | 1000 | 10 | 5-20 | ±2 | cyclopentane, catalyst or 245FA |
HF-SMS-2X10-P&I-II | 3600 x 2000 x 3600 mm | 2 | 1000 | 15 | 10-25 | ±2 | cyclopentane, catalyst or 245FA |
HF-SMS-2X10-P&I-III | 3600 x 2000 x 3600 mm | 2 | 1000 | 20 | 15-30 | ±2 | cyclopentane, catalyst or 245FA |
Technical Highlights
High-Efficiency Static Mixer Core
The core of the station utilizes precisely engineered internal geometric elements to continuously divide, recombine, and shear the material flow. This continuous in-line process ensures a perfectly homogenous blend of polyol with blowing agents (such as cyclopentane or 245fa) and catalysts. Because it achieves this without relying on moving mechanical parts, it significantly minimizes maintenance requirements while maximizing mixing consistency.
High-Precision Closed-Loop Dosing
The system integrates advanced mass flow meters and VFD-controlled dosing pumps to form an intelligent closed-loop control network. This setup continuously monitors and adjusts the flow rates in real-time, guaranteeing exact stoichiometric ratios of the main raw materials and trace additives. This level of precision drastically reduces formulation errors and prevents the waste of expensive chemical components.
Dynamic Temperature and Pressure Regulation
To handle sensitive and volatile blowing agents safely, the station features integrated heat exchangers and automated pressure-sustaining valves. These components work together to maintain optimal thermodynamic conditions throughout the entire premixing process. This dynamic regulation is crucial for preventing gas cavitation, stabilizing the chemical blend, and ensuring consistent cell nucleation in the final polyurethane foam structure.
Micro-Precision Gas and Trace Dosing
To maximize the efficiency of the integrated CO2 and polyether gas filling units, the station employs high-resolution mass flow meters combined with specialized micro-dosing valves. This ultra-precise metering architecture allows for the exact, continuous injection of trace catalysts and gaseous blowing agents under incredibly strict tolerances. By guaranteeing that these critical micro-components are metered with flawless accuracy prior to entering the static mixer, the system ensures perfectly uniform cell nucleation, leading to exceptional density consistency and thermal insulation performance in the final polyurethane product.
