Custom Gasification Plates for Injecting Gas into Liquid Systems

Some mixes need gas in the liquid, not just solids or a second liquid. Air, nitrogen, carbon dioxide, or process gas may be added to aerate a batch, strip a solvent, change density, support a reaction, or keep a slurry from settling. Dumping gas through an open pipe rarely works. Large bubbles rise, the liquid stays lean, and the mixer wastes energy chasing foam.

Kady International designs custom gasification plates for injecting gas into liquid systems. The plates work with the same high-speed rotor-stator mills used for dispersion, emulsion, cooking, aeration, and deaeration. Gas is introduced where the liquid is already moving at high velocity, so the mill can break the gas into small bubbles and fold them into the batch.

Why Gas Injection Needs a Plate, Not Just a Sparger

A Kady mill pumps liquid through slotted rotor openings and drives it into a closely fitted stator at tip speeds up to 9,000 feet per minute. Head plates sit against the stator and keep flow in the slots instead of spilling over the edges. That geometry is already built to concentrate energy.

A custom gasification plate uses that same idea for liquid/gas work. Gas is metered to the head so it meets the liquid in the high-shear zone. The rotor then shears bubbles the way it shears droplets or agglomerates. The result is finer gas distribution than a tank-bottom sparger or a simple dip tube can give.

Kady equipment is specified for liquid/liquid, liquid/solid, and liquid/gas systems. Batch sizes run from lab pints to large production tanks. Continuous-flow mills handle roughly 3 to 500 gallons per minute when the line needs a steady stream.

What Custom Design Controls

Gas feed is not one size. Viscosity, solids loading, gas rate, and whether the plant wants aeration or tight bubble size all change the plate. Kady engineers the plate and head around the process, including:

• Gas inlet location and passage size so flow is even across the head
• Head-plate and stator arrangement that keeps liquid and gas in the working slots
• Rotor-stator clearance and slot pattern for the target bubble or emulsion size
• Materials chosen for corrosion, abrasion, or sanitary duty
• Top-entry or bottom-entry mounting to match the tank and keep gas in the circulation loop
• Seals and vessel options for pressure, vacuum, or inert gas service

Bottom-entry mills help when the liquid is heavy and gas must be pulled through a dense zone. Top-entry units fit many existing tanks. Jacketed vessels add heating or cooling when gas uptake or reaction heat matters.

Where Gas-in-Liquid Mixing Is Used

Custom gasification plates are useful anywhere a Kady mill already runs and the formula also needs a gas phase:

• Aeration of coatings, foods, or chemical slurries
• Inerting or nitrogen blanketing while solids are dispersed
• Carbonation or CO2 contacting in liquid systems
• Gas-assisted flotation, stripping, or mass transfer in process tanks
• Fuel and pipeline slurries, including coal-water and coal-oil-water mixes used as gasification feedstocks, where a stable liquid/solid or liquid/oil mix is the first requirement
• Reactions that need gas distributed through a viscous or high-solids batch

The mill can also run the other direction. Enclosed shafts and vacuum options support deaeration when trapped air is the problem instead of the goal.

How the Mill Finishes the Job

Injecting gas is only half the process. The liquid still has to wet powders, emulsify oils, and stay uniform. Kady’s rotor-stator head does that work in the same vessel:

1. Liquid and solids are drawn into the head from above and below.
2. Gas enters through the custom plate at a controlled rate.
3. High-velocity flow through the rotor-stator slots shears bubbles and particles together.
4. Auxiliary propellers keep the tank turning so new liquid and gas keep feeding the head.
5. The batch leaves as a finer dispersion, emulsion, or aerated mix, often without a second machine.

Short, high-energy residence time limits the long soak that creates foam caps or heat damage. Variable-speed drives let operators change tip speed as viscosity or gas hold-up changes.

From Trial Head to Production Plate

Because Kady lab and production mills share the same rotor-stator approach, a small trial can show whether the gas rate, plate layout, and tip speed will work before a full tank is committed. Free testing is available. Refurbished mills can also be fitted with custom heads and plates when a plant needs a faster path to equipment.

To specify a gasification plate, Kady needs the liquid, the gas, the target hold-up or bubble size, tank geometry, and whether the duty is batch or continuous. From that, the team can recommend a head, plate, drive, and vessel package.

Kady International 30 Parkway Drive Scarborough, ME 04074 Phone: 207.883.4141 Email: This email address is being protected from spambots. You need JavaScript enabled to view it. Hours: Monday–Friday, 8 AM–5 PM

Custom gasification plates turn a Kady mill into a liquid/gas mixer: gas is injected where shear is highest, then dispersed with the same head that already handles solids and emulsions.