Pipe and patented mixing vane inserts emerge from 3D printing as a preassembled Static Mixer that is glued inside a PVC pipe and saves customers money and time.
Bristol, RI. January 23, 2018—Westfall Manufacturing Co. has pioneered the manufacture of small size Static Mixers, specifically their Low Headloss Pipe Static Mixer 3050, by 3D printing their patented mixer of durable nylon and gluing it into a PVC pipe.
This innovation comes in response to customers who asked for Low Headloss Mixer 3050 in the 3/8″ to 5″ (0.95cm to 12.7cm) range, which is too small for cost-effective fiberglass or stainless steel custom fabrication.
Westfall engineers knew that whether the materials used were metal, fiberflass or 3D printed nylon, the mixer’s high performance would not change. If the geometry stayed the same, the hydrodynamics would be the same.
The durable nylon inserts withstand steady exposure to harsh chemicals, from caustics to gas and oil. 3D printed inserts can be made of a variety of materials, from Kynar to stainless steel.
The addition of 3D printing to Westfall’s manufacturing ability means that customers can order Static Mixers in small sizes and receive rapid, cost-effective delivery.
Because of K-Values ranging from 0.58 to 1.64, Westfall’s Model 3050 causes 2 to 4 times less headloss than other mixers.
These smaller size versions offer an important solution for municipal and industrial water and wastewater treatment, oil, gas, natural gas, propane and biofuel processors.
Bob Glanville, CEO of Westfall, commented, “For mixing low velocity, low viscosity water and gases, durable 3D printed nylon inserts are the wave of the future. For mixing high velocity and high viscosity fluids. durable 3D printed stainless steel inserts are the wave of the future. Either way, 3D printing makes our high performance Static Mixers more affordable to customers around the world.”
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Westfall Applies 3D Printing To Manufacture Of Low Headloss Pipe Mixer 3050
Bristol, RI. January 23, 2018—Westfall Manufacturing Co. has pioneered the manufacture of small size Static Mixers, specifically their Low Headloss Pipe Static Mixer 3050, by 3D printing their patented mixer of durable nylon and gluing it into a PVC pipe.
This innovation comes in response to customers who asked for Low Headloss Mixer 3050 in the 3/8″ to 5″ (0.95cm to 12.7cm) range, which is too small for cost-effective fiberglass or stainless steel custom fabrication.
Westfall engineers knew that whether the materials used were metal, fiberflass or 3D printed nylon, the mixer’s high performance would not change. If the geometry stayed the same, the hydrodynamics would be the same.
The durable nylon inserts withstand steady exposure to harsh chemicals, from caustics to gas and oil. 3D printed inserts can be made of a variety of materials, from Kynar to stainless steel.
The addition of 3D printing to Westfall’s manufacturing ability means that customers can order Static Mixers in small sizes and receive rapid, cost-effective delivery.
Because of K-Values ranging from 0.58 to 1.64, Westfall’s Model 3050 causes 2 to 4 times less headloss than other mixers.
These smaller size versions offer an important solution for municipal and industrial water and wastewater treatment, oil, gas, natural gas, propane and biofuel processors.
Bob Glanville, CEO of Westfall, commented, “For mixing low velocity, low viscosity water and gases, durable 3D printed nylon inserts are the wave of the future. For mixing high velocity and high viscosity fluids. durable 3D printed stainless steel inserts are the wave of the future. Either way, 3D printing makes our high performance Static Mixers more affordable to customers around the world.”
For Water Utilities, Westfall’s High-Performance Flow Straightener Generates Improved Billing Accuracy And Reassures Customers
17 January, 2017
Flow Straightener Model 3000 Fin-like mixing vanes create vortices to gently blend the incoming flow of water. Then wing-shaped vanes flatten the vortices into a straightened or conditioned outflow for a fully developed velocity profile with minimal headloss in less than 8 pipe diameters.
In parts of the world where water is rationed, savvy customers want to know they’re getting every drop they pay for. If the water utility can’t prove their billing is accurate, they may face volatile public meetings like a customer in the southwestern US did.
The problem was real: if water flowing into the meters was disturbed by swirl or turbulence from pipe bends or uneven pressure, meter readings could be inaccurate. Customers wanted reassurance from their utility company.
The utility took two steps to resolve the problem.
First, they brought Westfall’s CEO, Bob Glanville, to their next planning meeting. By showing graphic illustrations of test results from Alden Laboratories, he proved that the installation of a Flow Straightener would provide the flow meter measurement accuracy these customers sought.
Second, the utility installed Westfall’s Flow Straightener Model 3000. As a result, water flowing into
24″ Flow Conditioner Model 3000 prepared for an installation in Texas. View from the downstream end shows the wing-shaped vanes first, followed by the fin-shaped vanes.
their metering device was free of swirl and turbulence, and had a fully developed velocity profile well before it reached the flow meter.
The water utility now installs Flow Straightener Model 3000 at metering points throughout its distribution network. Customers were reassured that the water for which they were billed actually matched the water they received.
According to Bob Glanville, CEO of Westfall Manufacturing, Inc. “This is an easy infrastructure upgrade for water utilities to install, and a smart one to improve their billing accuracy and customer satisfaction.”
For Poultry Processors, Westfall’s High-Performance Static Mixers Save Space, Energy and Money
December 20, 2016
Operators of poultry processing plants, in both the US and Mexico, are now inserting Westfall’s Static Mixers into their waste treatment piping systems at 3 different stages of the clean up process.
Industrial plants like these generate flows of 1 million to 1.5 million gallons of wastewater every day of operation.
Pollutants range from meat, skin and feathers to fat, blood and grit. Before discharging this wastewater, plants must remove all suspended solids and particles in order to meet three levels of regulation: local, state and federal.
Westfall helps these companies comply by providing affordable, high-performance mixers for three critical treatment phases: Coagulation, Flocculation and Disinfection.
Coagulation
Plate Static Mixer 2800 causes rapid, thorough collision of added coagulant chemicals with the many types of suspended solids and particles. The resulting charge neutralization causes the particles to floc within a short lay length.
Flocculation
Pipe Static Mixer 3050 replaces the need for lengthy serpentine piping in both retrofits and new construction. In less than 10 pipe diameters, added polymers are gently mixed to encourage the formation of increasingly larger flocs. Depending on the desired chemical interactions, the flocs will either float or sink for easy removal.
Disinfection
Plate Static Mixer 2800 is used as part of the tertiary treatment process. Its high-performance aperture effectively and thoroughly mixes selected disinfectants like sodium hypochlorite with the reclaimed wastewater prior to discharge or reuse.
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Bob Glanville, Westfall President, reports: “Our Static Mixers rely on CFD analysis to achieve optimal performance with less energy in a smaller space. They are ideal for both industrial and municipal Wastewater Treatment Plants in regions that face the competing challenges of growing populations and budget restrictions.”
Westfall’s Flow Straightener 3000 Used For Next Generation Rocket Fuels
December 12, 2016
Cryogenic fuels are gases that require extreme low temperatures to be sustained in a liquid state.
They include blends such as the liquid hydrogen and liquid oxygen mixture used to propel NASA’s Space Shuttle.
Accurate mixing and precision metering of cryogenic propellants are critical because their mass flow rate is so much greater than that of traditional fossil fuels.
To insure the precise delivery of these powerful liquid fuels, one US developer of next-generation rocket engines has added Westfall’s Flow Conditioner Model 3000 to its pre-ignition system.
This model is an in-line flow straightener that is proven to provide a (+/- .05%) fully developed velocity profile.
It includes 4 fin-shaped vanes that reduce or eliminate swirl, and adds 4 wing-shaped vanes to suppress excess turbulence and straighten flow. It enables repeatable error-free measurement and delivery of liquids or gases.
This flow conditioner is preferable to a perforated plate conditioner because it significantly limits headloss, avoids fouling and requires little to no maintenance. The interior of Westfall’s Flow Conditioner 3000 can be coated with 3M Scotchkote Fusion-Bonded Epoxy, which effectively resists corrosion and enhances metering for cryogenic propellants in sub-orbital and orbital rocket engines.
Photograph of the downstream end shows the two kinds of low headloss vanes that provide a swirl-free profile for accurate measurement of air, natural gas, water, oil and numerous other liquids and gases.
How Westfall’s Team Made A South African Engineer’s Top Choice Available and Affordable
May 4, 2016 Bristol, RI, USA… When a Water Treatment Plant in South Africa needed to increase their conversion of raw water to potable water by up to 57% (without building new infrastructure) they turned to PCI Africa, specialists in engineering and constructing municipal water systems.
PCI Africa then turned to Westfall because they needed to replace a pair of inline static mixers that had been underperforming: creating excessive headloss and inadequate mixing.
The Westfall units would more than provide the effective mixing needed, and would drop easily into the existing short lay length.
On April 18, PCI Africa placed the order.
The mixers had to be on location by the beginning of June. The cost of airfreight was prohibitive, and ocean freight would take more than 30 days.
This gave the Westfall team a narrow window of 5 working days to custom manufacture two 40″ stainless steel plate mixers with injection ports and flanges, put them through a 3-stage inspection process, then crate for delivery to the U.S seaport.
On April 22, Westfall shipped the order.
Westfall’s sales rep at JLS International reports that PCI Africa is delighted with Westfall’s affordability and speed of production on a custom order of this size. Because of the simple drop-in installation, the new mixers require no new infrastructure and will cause minimal interruption to the customer’s potable water delivery service.
When retrofitting older water treatment installations, engineers often find outdated static mixers, like the one here, that unnecessarily reduce pressure and limit the delivery of potable water.