Gas-Enhanced Ultra-High Shear Mixing: A Concept and Applications

The processes of mixing, homogenizing, and deagglomeration are of paramount importance in many industries for modifying properties of liquids or liquid-based dispersions at room temperature and treatment of molten or semi-molten alloys at high temperatures, prior to their solidification. To implement treatments, a variety of technologies based on mechanical, electromagnetic, and ultrasonic principles are used commercially or tested at the laboratory scale. In a large number of techniques, especially those tailored toward metallurgical applications, the vital role is played by cavitation, generation of gas bubbles, and their interaction with the melt. This paper describes a novel concept exploring an integration of gas injection into the shear zone with ultra-high shear mixing. As revealed via experiments with a prototype of the cylindrical rotor–stator apparatus and transparent media, gases injected radially through the high-speed rotor generate highly refined bubbles of high concentration directly in the shear zone of the mixer. It is believed that an interaction of large volume of fine gas bubbles with the liquid, superimposed on ultra-high shear, will enhance mixing capabilities and cause superior refining and homogenizing of the liquids or solid–liquid slurries, thus allowing their effective property modification.