How to optimize Dispersion Kettle process parameters

Jun 16, 2025

To optimize Dispersion Kettle process parameters, material characteristics, equipment parameters, and process control need to be coordinated and adjusted. The specific measures are as follows:
1. Mixing system matching
Linear speed: adjusted according to material viscosity, 20-25m/s for low viscosity (<5000cP) and 15-20m/s for high viscosity (>10000cP).
Dispersion disk diameter: 1/3-1/2 of the kettle diameter, such as φ300-500mm dispersion disk for a 1m diameter kettle.
Blade combination: double-layer paddle (upper serrated disk + lower anchor paddle) improves circulation efficiency and reduces dead corners.
2. Temperature and pressure control
Heating rate: heat-sensitive materials ≤2℃/min, ordinary materials ≤5℃/min, jacket temperature difference ≤20℃.
Vacuum degree: Pump to -0.08MPa in the later stage of dispersion, maintain degassing for 10-15min, and solvent-based systems require higher vacuum.
Pressure dispersion: Apply 0.3-0.5MPa pressure to nanomaterials to inhibit agglomeration.
3. Optimization of feeding strategy
Powder addition: Negative pressure inhalation is performed 2-3 times, with an interval of 5min each time to avoid agglomeration.
Premixing process: High-solid content materials are first made into 50-60% premixed slurry, and then diluted and dispersed.
Dispersant: Add 0.5-2% to reduce surface energy and shorten dispersion time by 30%.
4. Process monitoring and energy efficiency
Power curve: The end point is judged by the motor current fluctuation (<3%) to avoid over-dispersion.
Intelligent control: The PID algorithm automatically adjusts the speed and temperature, reducing energy consumption by 15%.
Segmented speed regulation: high-speed dispersion for 15-20 minutes, then low-speed homogenization for 10 minutes, saving 20% energy
If you are interested in learning more about HDispersion Kettle, please visit www.mixerbeadmill.com! We have industry-leading technology and professional customer service, and we look forward to working with you to create a better future together!