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Difference between revisions of "High Pressure Homogenizers"
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High Pressure Homogenizers (view source)
Revision as of 06:15, 25 February 2022
, 06:15, 25 February 2022no edit summary
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===Electric=== | ===Electric=== | ||
[[File:High_Pressure_Homogenizers_electric.jpg|thumb| | [[File:High_Pressure_Homogenizers_electric.jpg|thumb|250px|right|Electric high pressure homogenizer with intensifier]] | ||
Electric homogenizers are powered by an electric motor. This category of homogenizer can be further subdivided into two types: direct-drive and intensifier. | Electric homogenizers are powered by an electric motor. This category of homogenizer can be further subdivided into two types: direct-drive and intensifier. | ||
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===Intensifier type=== | ===Intensifier type=== | ||
In intensifier-type high pressure homogenizers, the motor drives the intensifier to pressurize the material through the interaction chamber. The intensifier system can provide higher pressure, thereby improving the performance of the homogenization process. The flow rate of the homogenizer with an intensifier is lower than it is for the homogenizer with a crankshaft, smaller amounts of materials are required, and the pressure is higher. It can be used for laboratory applications with small amounts sample, and for production applications with high pressure. When equipped with the diamond interaction chamber, the electric high pressure homogenizer with an intensifier falls into the category of high-end homogenizers. This type is widely used in biology, pharmaceutical, and nanotechnology laboratories. The traditional intensifier is hydraulic, and the new type of electric cylinder by linear actuator is emerged with more performance. | In intensifier-type high pressure homogenizers, the motor drives the intensifier to pressurize the material through the interaction chamber. The intensifier system can provide higher pressure, thereby improving the performance of the homogenization process. The flow rate of the homogenizer with an intensifier is lower than it is for the homogenizer with a crankshaft, smaller amounts of materials are required, and the pressure is higher. | ||
It can be used for laboratory applications with small amounts sample, and for production applications with high pressure. When equipped with the diamond interaction chamber, the electric high pressure homogenizer with an intensifier falls into the category of high-end homogenizers. This type is widely used in biology, pharmaceutical, and nanotechnology laboratories. The traditional intensifier is hydraulic, and the new type of electric cylinder by linear actuator is emerged with more performance. | |||
===Hand Driven=== | ===Hand Driven=== | ||
[[File:High_Pressure_Homogenizers_handdriven.png|thumb| | [[File:High_Pressure_Homogenizers_handdriven.png|thumb|250px|right|Hand-driven high pressure homogenizer]] | ||
Hand driven homogenizers pressurize the material by manual power. The flow rate of a hand homogenizer is small, but it is portable and easy to assemble and disassemble. It requires very small amounts of materials, making it suitable for small-scale experiments. This type of device is capable of supporting biopharmaceutical laboratories’ research and development needs. The manual high-pressure homogenizer is also called the Handgenizer.1 | Hand driven homogenizers pressurize the material by manual power. The flow rate of a hand homogenizer is small, but it is portable and easy to assemble and disassemble. It requires very small amounts of materials, making it suitable for small-scale experiments. This type of device is capable of supporting biopharmaceutical laboratories’ research and development needs. The manual high-pressure homogenizer is also called the Handgenizer.1 | ||
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==By principle and structure of the interaction chamber== | ==By principle and structure of the interaction chamber== | ||
[[File:High_Pressure_Homogenizers_principle.png|thumb| | [[File:High_Pressure_Homogenizers_principle.png|thumb|250px|right|The three-type principle of high pressure homogenization]] | ||
===First Generation: Impact Type=== | ===First Generation: Impact Type=== | ||
'''Cavitation nozzles:''' The main function of this nozzle is cavitation, which leads to the separation of the emulsion and thereby increases the particle size. Under the pressure of the homogenizer, the materials flow into the cavitation nozzle with a very small aperture at several times the speed of sound. Meanwhile, intense friction and collision take place between the particles and the metal valve parts. This friction reduces the service life of the equipment, and the collisions cause metallic particles to fall into the final products. | '''Cavitation nozzles:''' The main function of this nozzle is cavitation, which leads to the separation of the emulsion and thereby increases the particle size. Under the pressure of the homogenizer, the materials flow into the cavitation nozzle with a very small aperture at several times the speed of sound. Meanwhile, intense friction and collision take place between the particles and the metal valve parts. This friction reduces the service life of the equipment, and the collisions cause metallic particles to fall into the final products. | ||
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===Second Generation: Interaction Type=== | ===Second Generation: Interaction Type=== | ||
[[File:High_Pressure_Homogenizers_Interaction_chamber.png|thumb| | [[File:High_Pressure_Homogenizers_Interaction_chamber.png|thumb|250px|right|Interaction chamber with cooling jacket]] | ||
'''Y-type interaction chamber:''' The Y-type interaction chamber, regarded as one of the most powerful homogenization chambers to date, has been used by several manufacturers in the USA. In these systems, the flow stream is split into two channels that are redirected over the same plane at right angles and propelled into a single flow stream. High pressure promotes a high speed at the crossover of the two flows, which results in high shear, turbulence, and cavitation over the single outbound flow stream. With the unique Y-type structure, the high-speed moving materials in the high-pressure solution collide with each other, in a process that greatly improves the service life of the chamber over those with more conventional designs. The use of diamond material prevents the formation of metal particle residue. | '''Y-type interaction chamber:''' The Y-type interaction chamber, regarded as one of the most powerful homogenization chambers to date, has been used by several manufacturers in the USA. In these systems, the flow stream is split into two channels that are redirected over the same plane at right angles and propelled into a single flow stream. High pressure promotes a high speed at the crossover of the two flows, which results in high shear, turbulence, and cavitation over the single outbound flow stream. | ||
With the unique Y-type structure, the high-speed moving materials in the high-pressure solution collide with each other, in a process that greatly improves the service life of the chamber over those with more conventional designs. The use of diamond material prevents the formation of metal particle residue. | |||
The Y-type interaction chamber is widely used in the preparation of pharmaceutical emulsions because it minimizes cavitation and produces exquisite, stable particle size and PDI (poly dispersity index) control ability. Genizer and Microfluidics Corp. are the main manufacturers of the diamond interaction chamber. At present, the Y-type diamond interaction chamber is mainly used in high-end nanotechnology, and it occupies more than 90% of the US pharmaceutical industry. Genizer’s temperature-controlled interaction chamber avoids temperature surges and enables working pressure of up to 60,000 psi. | The Y-type interaction chamber is widely used in the preparation of pharmaceutical emulsions because it minimizes cavitation and produces exquisite, stable particle size and PDI (poly dispersity index) control ability. Genizer and Microfluidics Corp. are the main manufacturers of the diamond interaction chamber. At present, the Y-type diamond interaction chamber is mainly used in high-end nanotechnology, and it occupies more than 90% of the US pharmaceutical industry. Genizer’s temperature-controlled interaction chamber avoids temperature surges and enables working pressure of up to 60,000 psi. | ||
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===Direct-drive type=== | ===Direct-drive type=== | ||
[[File:High_Pressure_Homogenizers_direct-drive.jpg|thumb| | [[File:High_Pressure_Homogenizers_direct-drive.jpg|thumb|250px|right|Internal structure diagram of direct-drive type homogenizer]] | ||
The motor drives the crankshaft to move the plunger back and forth and directly pressurize the material. Multiple sets of plungers provide constant pressure, and the flow rate is high for this type of homogenizer. However, the minimum material requirements are also high, as is the amount of residual produced. The crankshaft driven by the motor needs a multi-stage gear reduction mechanism, which limits these homogenizers to only moderate efficiency and requires large unit dimensions. This homogenizer type is suitable for the food and chemical industries, as well as other applications that do not have high pressure requirements. | The motor drives the crankshaft to move the plunger back and forth and directly pressurize the material. Multiple sets of plungers provide constant pressure, and the flow rate is high for this type of homogenizer. However, the minimum material requirements are also high, as is the amount of residual produced. | ||
The crankshaft driven by the motor needs a multi-stage gear reduction mechanism, which limits these homogenizers to only moderate efficiency and requires large unit dimensions. This homogenizer type is suitable for the food and chemical industries, as well as other applications that do not have high pressure requirements. | |||
===Intensifier type=== | ===Intensifier type=== | ||
[[File:High_Pressure_Homogenizers_hydraulic_type-quad_pump.jpg|thumb| | [[File:High_Pressure_Homogenizers_hydraulic_type-quad_pump.jpg|thumb|250px|right|Structural diagram of hydraulic type-quad pump with constant pressure]] | ||
The intensifier-type homogenizer is the result of the development of ultra-high pressure technology in recent years. One of its mechanisms involves the motor driving the oil pump to pressurize the material through the hydraulic system. The pressure provided by the hydraulic system is higher than in direct-drive homogenizers, while the volume and the minimum material requirement is smaller. The intensifier-type homogenizer can be applied to both laboratory and production homogenizers with high pressure. Hydraulic homogenizers are expensive, but the hydraulic intensifier can achieve low-frequency and high-thrust piston movement, which increases the machine’s service life and reduces its maintenance costs. Using parallel four-cylinder technology, stable pressure can be obtained without an accumulator, achieving ultra-high pressure of up to 45,000 psi. | The intensifier-type homogenizer is the result of the development of ultra-high pressure technology in recent years. One of its mechanisms involves the motor driving the oil pump to pressurize the material through the hydraulic system. The pressure provided by the hydraulic system is higher than in direct-drive homogenizers, while the volume and the minimum material requirement is smaller. The intensifier-type homogenizer can be applied to both laboratory and production homogenizers with high pressure. | ||
Hydraulic homogenizers are expensive, but the hydraulic intensifier can achieve low-frequency and high-thrust piston movement, which increases the machine’s service life and reduces its maintenance costs. Using parallel four-cylinder technology, stable pressure can be obtained without an accumulator, achieving ultra-high pressure of up to 45,000 psi. | |||
In the past, most high pressure homogenizers were the direct-drive type, but this type’s disadvantage is obvious. Its service life is short, and its wearing parts need frequent maintenance, especially those pressure-bearing parts when the pressure is above 100 MPa. Hydraulic homogenizers have a high manufacturing cost, but they also offer a long service life and lower maintenance costs for wearing parts. | In the past, most high pressure homogenizers were the direct-drive type, but this type’s disadvantage is obvious. Its service life is short, and its wearing parts need frequent maintenance, especially those pressure-bearing parts when the pressure is above 100 MPa. Hydraulic homogenizers have a high manufacturing cost, but they also offer a long service life and lower maintenance costs for wearing parts. | ||
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=How to select a high pressure homogenizer= | =How to select a high pressure homogenizer= | ||
==Selecting a high pressure generator== | ==Selecting a high pressure generator== | ||
[[File:High_Pressure_Homogenizers_Ceramic_piston.png|thumb| | [[File:High_Pressure_Homogenizers_Ceramic_piston.png|thumb|250px|right|Ceramic piston]] | ||
Overall, a cylinder with an intensifier is superior to a direct-drive one. | Overall, a cylinder with an intensifier is superior to a direct-drive one. | ||
Under the same flow rate, higher pressure produces lower frequency, fewer pressure fluctuations, better product quality, and greater equipment durability. At 30,000 psi, a laboratory high pressure homogenizer, can reach fluctuation levels of less than 10 Hz, as opposed to 60 Hz from a normal homogenizer. | Under the same flow rate, higher pressure produces lower frequency, fewer pressure fluctuations, better product quality, and greater equipment durability. At 30,000 psi, a laboratory high pressure homogenizer, can reach fluctuation levels of less than 10 Hz, as opposed to 60 Hz from a normal homogenizer. | ||
High pressure piston materials can be divided into ceramics, tungsten carbide, and hardened stainless steel, with ceramics as the costliest option and hardened stainless steel as the most affordable. Quality and durability align with cost: Ceramic materials offer the highest quality, followed by hard tungsten alloy, with hardened stainless steel as a lower-quality option. | High pressure piston materials can be divided into ceramics, tungsten carbide, and hardened stainless steel, with ceramics as the costliest option and hardened stainless steel as the most affordable. Quality and durability align with cost: Ceramic materials offer the highest quality, followed by hard tungsten alloy, with hardened stainless steel as a lower-quality option. | ||