What is the relationship between flow rate and pressure of industrial high shear mixer

As a key mixing equipment in modern manufacturing, the performance of industrial high shear mixers directly affects product quality and production efficiency. Among many parameters, the relationship between flow and pressure is particularly important. A deep understanding of this relationship helps to optimize equipment operation, improve process effects, and thus achieve reduced production costs and improved product quality.

Introduction to the working principle of high shear mixers
High shear mixers form strong shear forces between high-speed rotating impellers and stators to quickly disperse, emulsify or homogenize materials. The fluid dynamics characteristics inside the equipment determine the interaction between flow and pressure. The higher the impeller speed, the stronger the shear force on the fluid in the stator gap, resulting in better mixing effects, and also affecting the changes in flow and pressure.

Basic relationship between flow and pressure
Flow refers to the volume of material passing through the mixer per unit time, usually measured in cubic meters per hour (m³/h); pressure refers to the pressure on the material in the mixer, generally expressed in Pascals (Pa) or bar. Flow and pressure show a certain nonlinear relationship.
Under constant speed and equipment structure conditions, as the flow increases, the pressure inside the mixer usually increases. This is because when more material passes through the narrow stator gap, the fluid resistance increases, back pressure is generated, and the pressure rises accordingly. However, the pressure rise is not unlimited, but is limited by factors such as impeller speed, gap size and material viscosity.

Key factors affecting the relationship between flow and pressure
Impeller speed
The higher the impeller speed, the greater the shear force on the fluid, the higher the fluid flow speed, and the higher the flow output. However, high-speed operation will also cause a greater pressure increase due to increased fluid resistance and turbulence.
Stator and impeller gap
The size of the gap determines the space for the fluid to pass through. The smaller the gap, the greater the resistance to fluid flow, the more obvious the pressure rise, and the flow rate decreases accordingly. Adjusting the gap is an effective means to control flow and pressure.
Material viscosity
High-viscosity materials have large flow resistance, limited flow, and significantly increased pressure. Low-viscosity materials flow smoothly and have lower pressure. Viscosity changes have a significant impact on the flow-pressure curve.
System resistance
The resistance of pipelines, valves and other equipment to the fluid also affects the outlet pressure and flow of the mixer. When the system resistance is large, the flow rate decreases and the pressure increases.

The practical significance of the flow-pressure curve
The flow-pressure curve reflects the working performance of the mixer. The curve usually shows a negative correlation trend, that is, the higher the pressure, the lower the flow rate, and vice versa. Understanding this relationship helps to determine the optimal operating point of the equipment and ensure the balance between mixing effect and energy consumption.
By adjusting the speed and gap, the shape of the curve can be adjusted to meet different process requirements. Reasonable flow and pressure configuration can achieve full shearing of materials and avoid heating and material deterioration caused by excessive stirring.

Technical application of flow and pressure regulation
Industrial high shear mixers are often equipped with variable frequency speed regulators and adjustable gap devices. The variable frequency speed regulator adjusts the impeller speed according to the process requirements and dynamically controls the flow and pressure. The adjustable gap device achieves precise control of the shear intensity through mechanical adjustment.
The intelligent control system combines sensor data to monitor pressure and flow in real time, automatically optimizes equipment parameters, and ensures production stability and product consistency. This technology not only improves process accuracy, but also significantly reduces the cost of manual intervention.