SV Type Corrugated Plate Static Mixer

Product Overview

The SV type corrugated plate static mixer is the highest-precision model in the ywmixing product line. Its internal geometry consists of multiple flat plates that have been press-formed into a sinusoidal corrugation, then stacked crosswise inside a cylindrical shell. Adjacent plates are rotated 90° relative to one another, so the flow is forced to split, rotate, and recombine as it passes through each successive layer. This repeated radial-and-axial redistribution is what produces the mixer's signature 1-2 μm dispersion precision — finer than any of the other four models in our range.

The SV type is the model of choice when the process involves clean, low-viscosity fluids where the engineer must hit a tight coefficient of variation, usually σX ≤ 1-5%, in a compact footprint. It is the smallest of our mixers in terms of free channel width (typically 2-5 mm between adjacent corrugations), which is also its main limitation: the unit must not see suspended solids above 0.5 mm, fibers, or viscosities above 100 cP. Used within those limits, the SV delivers the best mixing efficiency per unit length of any inline static mixer on the market, with typical L/D ratios of 5-12 and pressure drops 30-50% lower than equivalent-duty orifice-plate or perforated-element designs.

Across the five-model family (SV, SK, SX, SH, SL), the SV occupies the top end of the dispersion-precision scale and the bottom end of the viscosity scale. Where the SK and SH handle viscosities up to 1,000,000 cP and the SX covers the middle ground, the SV is reserved for clean, low-μ, high-precision work — gas blending, fine chemical dosing, and the production of tight emulsions where droplet size directly controls downstream product quality.

Working Principle

Inside the SV housing, a series of pressed metal plates (typically 0.5-1.0 mm thick for SS316L, up to 3 mm for carbon steel) are stacked with their corrugations rotated 90° to one another. The corrugation pitch is usually 5-15 mm, with a depth of 1.5-4 mm; these dimensions are selected to keep the Reynolds number inside the plates within the desired mixing regime while maintaining a free cross-section of 60-75% of the pipe bore.

As the two (or more) feed streams enter the mixer, the first corrugated plate splits each stream into two sub-streams along the corrugation valleys. The 90° rotation of the next plate then turns each sub-stream 90°, forcing it to cross the channels of the previous plate. This is repeated 4-8 times along the housing length. The net effect over the full mixer length is several hundred split-and-recombine events — by the time the fluid exits the last plate, the residence-time distribution has narrowed to within σX ≤ 1-5% of the theoretical ideal.

Two operating regimes are relevant. In the turbulent regime (Re > 10,000), the dominant mixing mechanism is eddy breakup of the laminar sub-layers, giving droplet sizes in the 1-2 μm range. In the laminar regime (Re < 2,300), mixing is driven by the repeated folding of stream tubes, which produces somewhat coarser dispersions (3-5 μm) but still acceptable for most low-μ applications such as polymer solution make-up or acid-base neutralization. For Re between 2,300 and 10,000 (transitional), the SV still performs well but the residence time should be increased by selecting a housing with 1-2 additional elements.

Technical Specifications

Parameter	Value
Internal Structure	Multi-layer corrugated plates stacked crosswise (90° rotated) in cylindrical housing
Dispersion Precision	1-2 μm (turbulent regime) / 3-5 μm (laminar)
Viscosity Range	≤ 100 cP (kinematic)
Pressure Drop	Low to moderate; typically 0.1-0.5 bar across 8 elements at 2 m/s
Non-Uniformity Coefficient	σX ≤ 1-5% depending on L/D and element count
Material Options	SS304, SS316L, Carbon Steel, PVC, PP, Hastelloy C-276
Connection Types	Flange (ANSI / DIN / JIS), Threaded (NPT / BSP), Welded, Tri-Clamp
Temperature Range	-50°C to +300°C (metallic) / -10°C to +80°C (PVC/PP)
Pipe Diameter Range	DN15 to DN1000
Flow Rate Range	0.1 to 2,500 m³/h (model and pipe-size dependent)
Clogging Risk	High — channel width 2-5 mm; particulate must be < 0.5 mm

Material Options

The SV corrugated plate element is available in six standard material grades, and the housing follows the same selection. SS304 is the default for potable water, dilute chemicals, and food-grade service up to 80°C. It handles chloride concentrations below 200 ppm without pitting risk. SS316L is the workhorse for chemical processing — chloride resistance is improved to roughly 1,000 ppm continuous, and the low-carbon formulation eliminates sensitization at welds, which is critical for plate-to-housing welded assemblies in pharmaceutical and fine-chemical plants.

Carbon steel (typically A516 Gr.70 or SA-106) is used where the process fluid is non-corrosive but the pipe is large (above DN300) and the cost of stainless becomes prohibitive. Carbon steel plates are usually PTFE- or rubber-lined for chemical resistance. PVC and PP are reserved for aggressive media such as 30% HCl, sodium hypochlorite, or HF below 5%; the operating envelope is restricted to 60-80°C and pressures below 6 bar. Hastelloy C-276 is specified for hot concentrated acids, wet chlorine gas, and any service where SS316L would fail within 12 months — it carries a 4-6× cost premium but is the only practical choice for some of the aggressive chemistries in our water-treatment reference projects.

Gasket material is selected independently of the plate material. EPDM is standard for water and dilute bases; FKM (Viton) for hydrocarbons and oils; PTFE for solvent service above 150°C; and graphite-clad stainless for steam and high-temperature hydrocarbons above 200°C.

Installation Methods

SV mixers are installed in-line in the process pipe. The four standard connection types each suit a different service environment. Flanged connections (ANSI B16.5 Class 150, DIN PN16, or JIS 10K) are the most common — they allow the mixer to be removed for plate inspection without cutting the pipe, and they tolerate the thermal expansion of long housings when the process sees more than 80°C differential. Specify flanges for DN50 and above, or whenever the mixer will see periodic maintenance.

Threaded connections (NPT or BSP) are used for small-diameter mixers (DN15 to DN50) in low-pressure service — typically instrument-air lines, water-treatment skid packages, and lab-pilot installations. They are quick to install and disassemble, but limited to about 16 bar at DN50 and 40 bar at DN15. Welded connections are specified for high-pressure or high-temperature service where threaded joints would be a leak risk, and for permanent installations where the mixer is not expected to be removed. Welds must be post-weld stress-relieved when the housing material is carbon steel and the service is above 200°C to prevent sensitization cracking at the heat-affected zone.

Tri-clamp (sanitary) connections (ISO 2852 or DIN 32676) are mandatory for pharmaceutical, biotech, and food-service installations where the line must be CIP-cleaned. The mixer housing carries polished ferrules and a surface finish of Ra ≤ 0.8 μm. The clamp design allows the entire unit to be removed in under five minutes for plate inspection between batches — a significant advantage in validated multi-product facilities.

Regardless of connection type, install the mixer with a minimum straight-pipe run of 3D upstream and 3D downstream. The upstream straight section is required for the feed streams to develop a uniform velocity profile before they enter the first plate; the downstream section lets the mixed stream relax before it meets the next fitting or instrument.

Typical Applications

Water treatment chemical dosing. Municipal water-treatment plants dose polymeric coagulants (polyaluminum chloride at 5-15 mg/L and anionic polyacrylamide at 0.1-1.0 mg/L) into raw-water streams. An SV mixer installed immediately downstream of the injection point achieves > 95% distribution uniformity within 0.3 seconds, eliminating the streak floc formation that occurs with static mixers that have wider channels. The fine dispersion directly translates to a 15-25% reduction in polymer consumption and a measurable improvement in settled-water turbidity.

Gas–gas blending. In nitric acid plants, ammonia and air are blended upstream of the converter gauze. An SV mixer operating in the turbulent regime (Re ≈ 50,000) achieves σX ≤ 0.5% at the converter inlet — a level of homogeneity that is critical for safe operation, because any ammonia-rich pocket contacting the platinum-rhodium gauze can cause a temperature excursion that destroys the catalyst. Similar configurations are used for SO₂/air blending in sulfuric acid contact plants.

Liquid–liquid emulsification. For oil-in-water emulsions with droplet size targets of 1-3 μm, the SV produces finer dispersions than any of the other models in our range. A DN100 SV housing processing 30 m³/h of a 5% oil-in-water stream at 1.5 m/s will yield a mean droplet size of 1.8 μm with a coefficient of variation of 8% — sufficient for cutting fluids, metalworking coolants, and certain cosmetic intermediates.

Acid–base neutralization. Continuous pH adjustment in industrial wastewater streams requires intense, rapid mixing to prevent localized pH excursions that would corrode downstream piping. The SV's fine dispersion eliminates pH swings greater than ±0.2 units, allowing the operator to control the neutralization reaction by a single pH probe downstream of the mixer.

NOx flue-gas treatment. In selective catalytic reduction (SCR) systems, aqueous ammonia or urea is injected into the flue gas. The SV mixer, sized for the gas-side flow and installed vertically with a 30° inclination, achieves NH₃/NOx distribution within σX ≤ 5% across the duct cross-section, meeting the catalyst supplier's homogeneity requirement without an upstream flow-distribution grid.

Model Comparison

Parameter	SV	SK	SX	SH	SL
Internal Structure	Corrugated plates	Helical twist	Crossed bars	Dual-channel helical	Single-X bars
Dispersion Precision	1-2 μm	≤ 10 μm	2-5 μm	1-2 mm	Medium
Max Viscosity (cP)	100	1,000,000	10,000	1,000,000	10 (or polymer)
Pipe Diameter	DN15-DN1000	DN15-DN500	DN25-DN800	DN15-DN200	DN15-DN600
Clogging Risk	High	Lowest	Moderate	Moderate	Low
Best For	Fine dispersion	High-viscosity	Mid-range	High-viscosity clean	Heat transfer

Frequently Asked Questions

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