Mixing Systems, Inc.  

MIXING SYSTEMS, INC.

7058 Corporate Way, Dayton, Ohio 45459, USA
Phone: 937-435-7227     Fax: 937-435-9200     E-mail: mixing@mixing.com


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MECHANICAL BENEFITS OF JET AERATORS

  Proven technology
  Quality manufacturing
  Corrosion resistant
  Low maintenance
  Increased reliability
  No moving parts
  No small passages
  Optional backflush
  Reliable pumps and blowers
  Fast, easy installation
  Flexible operation
  Custom designs


Proven Technology

The technology of jet aeration and jet mixing involves combining two fluid streams in a common mixing chamber. One stream is typically liquid and the second stream is usually a gas. With jet mixing, the second stream is another liquid, often entrained from the tank itself. The basic components of the jet aeration system are:

  • Dual concentric nozzles
  • Piping for two fluid streams
  • Pumps to create fine bubbles and circulate the tank
  • Blowers (for jet aeration systems) to supply pressurized air flow

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Quality Manufacturing

Mixing Systems, Inc. typically uses fiberglass reinforced plastic (FRP) for its jet aerators and jet mixers because it is durable, lightweight, corrosion resistant, and easily assembled in the field. FRP has an expected service life of twenty years. Mixing Systems prefers to use 100 PSI pipe so the jet aerators will have a 10:1 safety factor.

The company's commitment to quality is furthered through the use of clear FRP piping so any flaws or imperfections can be seen and corrected before the system is shipped. Jet aerators can also be manufactured in stainless steel or with special resins for extremely corrosive environments.

Mixing Systems, Inc. designs and tests its own molds before any parts are fabricated, ensuring tolerances and superior quality. In addition, Mixing Systems directs the entire fabrication process to make certain that every component is manufactured to its own high standards and specifications. All contact molded components are built to exacting tolerances.

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Layers of construction of FRP piping.Corrosion Resistant

Corrosion resistant FRP piping, used in the construction of most Mixing Systems, Inc. jet aerators and jet mixers, is composed of several layers.

  1. Primary corrosion barrier (gold) - C-veil or Nexus layer with 90% resin and 10% reinforcement.
  2. Secondary corrosion barrier (green) - 100 mil chopped strand mat with resin content of approximately 60% resin and 40% glass.
  3. Structural layer (purple) - 1/4'' to 1/2'' thick continuous glass roving, consisting of 60% glass and 40% resin, for structural integrity.
  4. Exterior corrosion barrier (gold) - C-veil or Nexus layer with 90% resin and 10% reinforcement.
  5. Final layer (blue) - 100% resin and ultraviolet inhibitor. FRP may be painted, but Mixing Systems prefers to leave FRP unpainted so imperfections may be seen.

Mixing Systems, Inc. jet nozzles are manufactured by the hand lay-up process with a 10 to 20 mil abrasion resistant layer consisting of woven roving, chopped strand mat, and resin. The outer surface of the nozzle is finished with a corrosion resistant layer and ultraviolet protection. Standard wall thickness of these nozzles is 0.375-inch (9.5 mm). To further enhance corrosion resistance, the FRP nozzles can be manufactured with an optional layer of silicon carbide bonded to the interior surfaces.

Mixing Systems, Inc. jet aerators and jet mixers can also be manufactured in stainless steel or with special resins for extremely corrosive environments and for specialized applications. Because all units are custom designed, aerators and mixers can be tailored to accommodate unusual requirements.

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Low Maintenance

A jet aeration or jet mixing system by Mixing Systems, Inc. consists of quality components with an established reputation for reliability.

  • Materials of construction are durable and resistant to abrasion, corrosion, and ultraviolet light.
  • Jet nozzles have no moving parts to wear out or small passages to clog.
  • Pumps and blowers are normally placed outside the tank where they can be easily serviced.

In addition, the system is designed and manufactured to minimize field installation labor. Jet assemblies and piping are usually fiberglass that is lightweight, adaptable, and easily installed. The pneumatic backflush system minimizes in-basin maintenance by cleaning the jet nozzles of accumulation of debris that may impair operating efficiency.

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Increased Reliability

Mixing Systems, Inc. jet aeration and jet mixing systems are not hindered by the problems that affect other systems. They are not affected by detergents, like diffused air systems, and there are no small passages to clog. In addition, the pneumatic backflush system assures high efficiency and less maintenance that other systems.

Increased Reliability Over Mechanical Aerators:

High-speed and low-speed surface aerators have a history of needing substantial annual outlay for routine maintenance and replacement parts. Increased problems are associated with the greater sizes of high-speed units. Major problems and failures occur with the motor seals and bearings due to close proximity to the waste. Debris often plugs the impeller and chamber due to close clearances. In colder climates, frequent winter shut down time is common due to freezing.

Increased Reliability over Fine Bubble Diffusers:

Fine bubble diffused air systems are also adversely affected by wastewater conditions. Actual oxygen transfer rates are significantly reduced due to the presence of detergents in wastewater. Carbonate build up in the diffuser element results in progressive deterioration in the performance. Periodic system shut down is required for system cleaning and repair. In addition, electrostatic precipitators and/or extra filter media are required for the air filtering system.

Mixing Systems, Inc. jet aeration and jet mixing systems are not affected by detergents and there are not small passages or orifices to clog. In addition, the pneumatic backflush system assures high efficiency.

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No Moving Parts or Small Passages

Mixing Systems, Inc. jet aerators and jet mixers have no in-basin moving parts. The aeration and mixing equipment is stationary. All mixing momentum comes from the recirculation pump and the air blower, which are typically located outside the tank for easy maintenance. In addition, jet aerators and jet mixers have no small passages that can clog easily. Depending upon the model used, jet nozzles can pass solids up to 2-1/2 inches (6.4 cm) diameter. Jet aerators are often combined with a backflush system to ensure the system is completely efficient.

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Optional Backflush

Mixing Systems can supply an optional backflush system that can virtually eliminate all in-basin maintenance and manual cleaning of the jet aerators. This will help maintain high oxygen transfer rates and efficiencies.

BackflushBy simply shutting off the pump, opening the backflush valve, continuing to supply air to the system, the unit's aerodynamic design converts the submerged aeration system into a pneumatic air lift pump. In the backflush mode, air flow blows backward through the system, displacing the liquid in the liquid distribution line and pumping the surrounding liquid in the reverse direction through the jets and the liquid lines. This cleans the jet nozzles and the entire submerged aeration system of any fouling materials and debris. Most plants backflush their aeration tank once each month to maintain maximum efficiency.

Click here to see the backflush system in operation.

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Reliable Pumps and Blowers

Mixing Systems, Inc. is able to supply a variety of recirculation pumps and air blowers, often at a lesser cost than if the customer purchased these items directly from the manufacturer. Typically, recirculation pumps are placed outside of the tank. This makes them easier to maintain. On request, Mixing Systems can supply submersible recirculation pumps.

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Fast, Easy Installation

Mixing Systems, Inc. designs and manufactures each aerator individually to minimize field installation labor. The equipment is shipped in prefabricated sections that are joined in the tank by flanged connections or field joints. Supports and support hardware are provided to further the rapid, simple installation.

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Flexible Operation

Jet aerators are extremely versatile. Mixing Systems uses recirculation pumps to maintain mixing action. Then, by varying the airflow to the jets, oxygen transfer rates can match process conditions without compromising solids suspension and homogeneity of the basin contents. During non-peak periods, with the pumps running at normal power, airflow rates can be decreased by shutting off the blowers. Substantial power savings are achieved.

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Custom Designs

Mixing Systems, Inc. provides cost-effective jet aeration solutions for many different applications. Since all units are custom designed, the jet aerators and jet mixers can be tailored to accommodate unusual requirements. Mixing Systems supplies complete systems consisting of jet aerators, recirculation pumps, air blowers (compressors), control systems, supports, and hardware.

Typical working capacities of currently installed systems range from 10,000 gallons to 50 million gallons per day. These installations have tank volumes ranging from 5,000 to 240 million gallons and can handle Biochemical Oxygen Demand (BOD5) loads of 1,000 to 150,000 lb/day (450 to 68,000 kg/day).

Designed and engineered to accommodate increased capacity loads, typical jet aeration systems can process up to a 100% increase in flow rates and a 55% increase in organic loads.

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Copyright © 2000 -
Mixing Systems, Inc.
7058 Corporate Way, Dayton, Ohio 45459, USA
Phone: 937-435-7227, Fax: 937-435-9200
E-mail: mixing@mixing.com