Electric submersible mixers are important equipment in the fields of wastewater treatment, chemical industry and food processing. They are designed to be fully immersed in liquids to efficiently mix and stir various fluids. Manufacturing such mixers is a complex and delicate process that requires deep expertise, precise craftsmanship and strict quality control.

There are multiple key links in the entire manufacturing process, and each step will affect the final performance, durability and reliability of the mixer.

Design And Material Selection

The manufacturing journey of electric submersible mixers begins with the crucial design and material selection stage. This basic stage clarifies the functional positioning, performance standards and applicable scenarios of the mixer.

At the beginning of the design, engineers will deeply analyze the intended use of the mixer, covering factors such as fluid type, desired flow pattern, container specifications and mixing objectives. These considerations directly guide the setting of the core parameters of the mixer, such as impeller design, motor power configuration, shaft length and overall size planning.

As the soul of the mixer, the impeller design is particularly critical. Engineers use advanced computer-aided design (CAD) technology and computational fluid dynamics (CFD) simulation to carefully carve the geometry of the impeller, in order to accurately predict fluid movement, shear efficiency and mixing effectiveness before the physical prototype is made, thereby optimizing the development process and saving valuable resources.

In terms of electrical design, engineers focus on the precise matching of motor performance, including power output, speed setting and control system planning, to ensure that the impeller can be driven efficiently to meet the needs of different mixing intensities. Variable speed operation is also one of the key considerations.

The material selection stage should not be underestimated, as it profoundly affects the performance, durability and cost-effectiveness of the mixer. Common materials such as cast iron (often used for motor housing and some impeller designs due to its high strength, cost-effectiveness and good vibration damping), stainless steel (preferred for shaft and impeller structures due to its excellent corrosion resistance and strength, with specific grades such as AISI 316 or AISI 304 depending on corrosion requirements), engineering plastics (such as reinforced polyamide or PEEK, used to reduce weight or enhance chemical resistance) and special alloys (such as Hastelloy or Inconel, suitable for extremely corrosive or high-temperature environments) are all within the scope of material selection.

Material selection requires a comprehensive consideration of chemical compatibility, mechanical strength, weight control and cost budget. At the same time, when different metals are used in the same component, it is also necessary to be vigilant about the risk of galvanic corrosion.

Ultimately, based on detailed design analysis and material selection decisions, engineers will draw precise engineering drawings and specifications as a guide for the manufacturing process, ensuring that each component is accurately manufactured and works seamlessly together during assembly to create an excellent electric submersible mixer.

Manufacturing And Assembly

Once the design and material selection are in place, the manufacturing and assembly phase begins. This is when the design concept is transformed into the physical components that together make up the electric submersible mixer. The entire process consists of several core steps, each of which requires extreme precision and attention to detail to ensure that the product meets the high standards of industrial applications.

The first step in manufacturing is to produce the two key components of the mixer: the motor and the impeller. The motor, the power heart of the mixer, can be manufactured in-house or purchased from a specialized motor manufacturer. The manufacture of the motor involves winding the stator coils, assembling the rotor, and safely enclosing it in a waterproof housing.

The impeller, as a decisive factor in mixing efficiency, has extremely strict manufacturing requirements. Depending on the material, the impeller may be formed by casting (especially metal impellers, which often use lost wax casting to create complex shapes and then precision machining to achieve accurate dimensions and finish), solid raw material machining or molding (for engineering plastic impellers). Computer numerical control (CNC) machining centers play a key role in this process, ensuring that the impellers are produced with precision and consistency.

Other components such as shafts, seals and housings are also carefully manufactured at this stage. The shaft, usually made of high-grade stainless steel, is precisely machined to exacting tolerances to ensure a perfect fit with the bearings and seals. Mechanical seals, which are essential to prevent liquid intrusion into the motor, are often purchased from specialist seal manufacturers but may require custom installation or adjustment for specific agitator designs.

During the manufacturing process, each component undergoes rigorous quality control checks, including dimensional review, material verification and non-destructive testing of key components (such as ultrasonic or X-ray testing) to ensure that all components meet design requirements and are free of defects that may affect performance.

The assembly process is a critical step in bringing all the manufactured and purchased parts together. This is usually done in a clean and controlled environment to prevent any contamination. The specific assembly steps include: the precise assembly of the stator and rotor inside the motor; the careful installation of the shaft, bearings and seals to ensure the waterproofness of the agitator; the solid connection of the impeller to the shaft, while paying attention to balance and alignment; the electrical connection of the motor and the power cord, using a waterproof cable gland to maintain the submersible characteristics; and finally, the assembly of the housing assembly to provide the necessary protection for the internal components.

During assembly, a number of quality checks are strictly carried out, such as electrical continuity tests, seal pressure tests and mechanical function verification, in order to detect any potential problems in advance and ensure that the mixer enters the final testing stage smoothly.

The manufacturing and assembly stages constitute the main construction of the physical form of the mixer. The quality of work at this stage is directly related to the performance, reliability and service life of the final product. Therefore, a skilled technical team, advanced manufacturing facilities and a strict quality control system are the cornerstones of producing high-quality electric submersible mixers that can withstand the rigors of industry.

Testing And Delivery Preparation

The final stage of manufacturing electric submersible mixers focuses on testing and delivery preparation to ensure product quality and safety. Testing includes:

1.Motor efficiency and power factor tests to verify that electrical performance is up to standard.

2.Insulation resistance tests to ensure that the electrical insulation system is intact.

3.Vibration analysis to check mechanical balance to avoid excessive vibration.

After passing the test, delivery preparation begins:

1.Final inspection to confirm that the product meets quality standards and customer specifications.

2.Careful packaging to protect the product from transportation damage.

3.Prepare for shipment, check that components are complete, and organize relevant documents.

This stage promotes customer satisfaction and product reliability.

Electric Submersible Mixer Manufacturers

Tianjin Kairun’s customization process includes the following steps:

1.Requirements Analysis: The engineering team works with customers to understand application details such as fluid type, tank size, flow pattern, and special environmental or operating requirements.

2.Custom Design: Based on the information collected, the agitator design is developed, which may involve special impeller shapes, motor specifications, or corrosion-resistant materials.

3.Prototype Development and Testing: Complex or novel designs require prototype development and performance testing.

4.Manufacturing: Agitator components are produced to precise specifications using advanced facilities.

5.Quality Assurance: Agitators are rigorously tested and quality controlled to ensure that they meet high standards and customer requirements.

Tianjin Kairun provides customization services to ensure that customers get the most suitable electric submersible agitator, improve efficiency, reduce energy consumption, extend life, and bring better return on investment. Welcome to contact Tianjin Kairun at catherine@kairunpump.com for quotes, technical information and customization requirements.

References

1. Cheremisinoff, N. P. (2000). Handbook of Chemical Processing Equipment. Butterworth-Heinemann.

2. Harnby, N., Edwards, M. F., & Nienow, A. W. (2001). Mixing in the Process Industries. Butterworth-Heinemann.

3. Oldshue, J. Y. (1983). Fluid Mixing Technology. McGraw-Hill.

4. Paul, E. L., Atiemo-Obeng, V. A., & Kresta, S. M. (2004). Handbook of Industrial Mixing: Science and Practice. Wiley-Interscience.

5. Tatterson, G. B. (1991). Fluid Mixing and Gas Dispersion in Agitated Tanks. McGraw-Hill.

6. Uhl, V. W., & Gray, J. B. (1986). Mixing: Theory and Practice. Academic Press.

7. American Water Works Association. (2011). Submersible Mixers for Water Storage Tanks. AWWA.