Disintegrator/Dissolvers

From Bulk Solids to Finished Product — In a Single Operation

The Silverson Disintegrator 2500 is a high-capacity system engineered to disintegrate, solubilize, and disperse large-scale solids, up to 1 meter or 40" across, directly in the vessel, eliminating upstream processing and significantly reducing processing time.

Buoyant solids? No problem.

At the core of the system is a uniquely robust high shear mixer located at the base of a custom-built vessel. This configuration generates a massive downward suction, drawing even the most buoyant solids from the liquid surface directly into the workhead. Large blocks are rapidly reduced and dispersed throughout the mix, while the integrated In-Line mixer ensures total solubilization or suspension of fine particles.

Key application: Viscosity index improvers for lube oils

Specified by many of the world’s leading oil companies, the Disintegrator 2500 is widely used in the production of viscosity index improvers for multigrade lubricating oils, one of the most demanding mixing processes.

Silverson has been at the forefront of this application for over 60 years, helping manufacturers reduce processing times from days to just a matter of hours.

Smaller Batch alternative: the Silverson Duplex

For smaller solids, the Duplex Disintegrator/Dissolver offers the same vigorous disintegrating action as the D2500 in an in-tank batch configuration.

A dual workhead system simultaneously processes buoyant material from the surface and heavier solids from the vessel base, creating an intense mixing cycle ideal for high-viscosity materials. Used for applications ranging from lube oils and resins to purées and smoothies.

Case Study: Saving $3M+ Annually through Waste Reprocessing

How It Works

The D2500 is a self-contained, high-power system combining a specially designed Silverson high shear rotor/stator disintegrating workhead set into a custom-built dedicated vessel, coupled with a Silverson In-Line mixer.
This system works as follows:

1. Rapid Disintegration

The vessel is charged with liquid and the mixer started. Large solids are fed into the vessel and drawn down to the workhead, which rapidly shears lumps and slices off edges and corners. The resulting particles are drawn into the interior of the workhead, driven by centrifugal force to the periphery, and further sheared by the rotor tips against the stator perforations as they are expelled radially from the head.

2. Particle Reduction

Rapid fragmentation of the large solids continues until all the particles are small enough to be drawn into the workhead for further disintegration. Materials are discharged horizontally from the workhead and forced up the vessel walls. This cycle continues until all solids are reduced to granular size.

3. In-Line Refinement

Once the solids are reduced to granular size the self-pumping In-Line mixer is started. The product is drawn from the bottom of the vessel, processed through the In-Line mixer’s high shear rotor/stator workhead and passed back into the top of the vessel ensuring complete solution or suspension.

1. Rapid Disintegration 2. Particle Reduction 3. In-Line Refinement

1. Rapid Disintegration

1. Rapid Disintegration

The vessel is charged with liquid and the mixer started. Large solids are fed into the vessel and drawn down to the workhead, which rapidly shears lumps and slices off edges and corners. The resulting particles are drawn into the interior of the workhead, driven by centrifugal force to the periphery, and further sheared by the rotor tips against the stator perforations as they are expelled radially from the head.
2. Particle Reduction

2. Particle Reduction

Rapid fragmentation of the large solids continues until all the particles are small enough to be drawn into the workhead for further disintegration. Materials are discharged horizontally from the workhead and forced up the vessel walls. This cycle continues until all solids are reduced to granular size.
3. In-Line Refinement

3. In-Line Refinement

Once the solids are reduced to granular size the self-pumping In-Line mixer is started. The product is drawn from the bottom of the vessel, processed through the In-Line mixer’s high shear rotor/stator workhead and passed back into the top of the vessel ensuring complete solution or suspension.

Videos

D2500 – Disintegrator/Dissolver

How does the D2500 work?

Duplex – Disintegrator/Dissolver

Mixer Options

Disintegrator 2500

No need for pregrinding, slicing, or cutting of large solids. The Disintegrator 2500 can easily process irregular shapes and the largest size polymer bales commercially produced. Available in capacities from 250 to 25,000 gallons for high-volume industrial applications.

Pilot Disintegrator Plant

This compact version of the D2500 offers a standard 65-gallon capacity, providing the same high shear performance as our larger units. Ideal for R&D and pilot-scale production and can be custom-built to your specifications.

Duplex Disintegrator/Dissolver

Specialized dual-head design featuring opposing workheads - the upper head draws material down while the lower head pulls up from the vessel base. Perfect for challenging applications like polymer dissolution, high-viscosity mixing, and incorporating floating solids.

Duplex Mixing Assembly

This assembly converts our versatile Silverson Lab Mixer into a benchtop version of the Duplex. By replicating the same high shear dual-action mechanics in a smaller format, it enables accurate process development and validation prior to full-scale production.

Confectionery Reclaim

Turn waste into profit with a system designed for the rapid reclamation of confectionery and food byproducts. Scaled down from our D2500, this unit disintegrates and solubilizes even the toughest off-cuts without the need for pre-grinding or chopping.

Technical Information

Capacity

250 to 25,000 gallons

System Configuration

Each Disintegrator 2500 system is engineered to suit the application and typically includes:

Silverson Bottom Entry Disintegrator/Dissolver for rapid disintegration of solids and wetting of powders. This is the prime mover of the fluid in the vessel.
Silverson In-Line High Shear Mixer maximizes the solution of the fine particles created by the Bottom Entry unit and allows for instant homogenization of additive fluids.
Custom-designed vessel, pipework, valves, and controls tailored to process requirements.

Typical Applications

Rapid solution of rubber and polymer blocks into lubricating oils, solvents, and asphalt for the production of VM lube oils, adhesives, and polymer-modified asphalts for road surfacing.
Recovery of waste candy.
Wet crumbing of waste rubber.
Rapid dispersion of large volumes of powder or materials which are difficult to wet out and have a tendency to “raft.”
Dispersion of filter cakes.