Mixer-Settler Working Principle

Inefficient separation in solvent extraction can lead to low recovery rates, contamination, and increased operational costs—TYIC NEW ENERGY’s advanced MixerSettler solutions provide an efficient and scalable answer.

Mixer-Settlers by TYIC NEW ENERGY are engineered for highefficiency liquidliquid extraction, ensuring consistent separation, chemical stability, and long-term performance in hydrometallurgy and environmental treatment processes.

Explore how TYIC NEW ENERGY’s mixer-settler technology empowers industries to achieve reliable and high-purity separation results.

What Is A Mixer-Settler?

A Mixer-Settler is an essential piece of liquid-liquid extraction equipment designed for selective mass transfer between immiscible liquid phases. Common in non-ferrous metallurgy, especially in lithium, cobalt, nickel, and rare earth extraction, it ensures efficient separation of valuable metal ions using chemical solvents.

TYIC NEW ENERGY, a leading manufacturer in China specializing in extraction equipment, provides fully customized mixer-settler systems. Their units are widely adopted in lithium battery recycling, cobalt-nickel extraction, and wastewater treatment, offering process stability, material compatibility, and seamless integration into broader production lines.

Various Sections In Mixer-Settlers

Each TYIC NEW ENERGY MixerSettler system is structured into key zones:

Inlet and Pre-Mix Chamber – This section ensures feed and solvent streams are evenly introduced under controlled conditions, avoiding premature emulsification.

Mixing Chamber – Equipped with an optimized impeller for thorough dispersion of droplets. TYIC’s design minimizes solvent loss while maximizing contact surface area for rapid ion exchange.

Settling Chamber – Here, emulsions separate via gravity. The settler is fitted with lamella coalescers and phase weirs for precise layer control, supported by TYIC’s proprietary micro-interface control technology, originally developed for oil-removal systems.

TYIC’s design incorporates automated flow balancing, online monitoring, and advanced anti-emulsification mechanisms—ensuring high phase separation efficiency even in fluctuating process conditions.

Working Of The Mixer-Settler Equipment

In a TYIC mixer-settler, feed (usually aqueous) and organic solvent enter the mixer, where vigorous agitation forms a dispersion. Target metal ions transfer to the organic phase through chemical affinity. Once mixed, the two-phase fluid passes into the settler.

The settler provides calm conditions to allow the less dense organic phase to rise and the denser aqueous raffinate to fall. The separated phases are collected and sent either for further processing or returned for another stage. TYIC’s control systems ensure real-time phase interface monitoring and maintain solvent-to-feed ratio consistency.

Advantages Of Mixer-Settlers

TYIC NEW ENERGY’s mixer-settler units are built with:

High-efficiency separation, suitable for multi-stage counter-current extraction.

Custom materials (PPH, HDPE, or stainless steel), tailored to corrosive or high-temperature environments.

Reduced solvent loss through enclosed, low-shear design.

Automation compatibility, enabling real-time data collection and flow control.

EPC project integration, allowing seamless scaling from lab to industrial operations.

Clients such as GEM Co., Ltd. and Ganfeng Lithium have adopted TYIC’s mixer-settler systems in high-purity metal extraction lines with proven long-term reliability.

Disadvantages Of Mixer-Settlers

Despite their advantages, these systems can present challenges:

Space requirements for settlers can be considerable in large-scale setups.

Maintenance access is needed for cleaning fouled coalescers.

Initial capital investment may be higher than centrifugal alternatives.

Slow separation speed in the presence of fine solids or surfactants.

However, TYIC mitigates these issues through compact modular designs, removable phase barriers, and predictive maintenance tools integrated into their automation systems.

Summary

Backed by TYIC NEW ENERGY’s proven engineering, mixer-settlers offer precision, efficiency, and scalability for industrial liquid-liquid extraction applications.