When designing an efficient process or production system, success depends entirely on the properties of the medium. Viscosity is the most critical fluid property in this context. Whether you are sizing a single gear pump for fluid displacement or configuring a reactor for a chemical process, viscosity directly determines the choice of hardware, the power required and the ultimate efficiency.
The effect of viscosity on each component, explained:
Configuring a gear pump
When selecting a gear pump, the viscosity determines how the fluid behaves between the rotating gears and the housing:
- Low viscosity:
Causes internal leakage (slip) through the clearances in the pump. This reduces volumetric efficiency and requires tighter tolerances or a higher speed to achieve the desired flow rate. - High viscosity:
Creates greater flow resistance and friction. This requires a larger inlet, a reduced speed to prevent cavitation, and a more powerful drive to overcome the viscous forces.
Configuring a reactor
When configuring a reactor, it is all about creating the right conditions for mixing, reaction rate and heat transfer:
- Mixing intensity and agitators:
High viscosity requires a specific type of agitator (such as a spiral or anchor agitator) and a more powerful motor to keep the entire volume in motion without creating ‘dead zones’. - Heat transfer:
Viscous liquids have poorer heat exchange with the reactor wall. The configuration must be adapted accordingly, with additional cooling or heating capacity, to prevent hotspots and uncontrolled reactions. - Changing viscosity:
In many processes, the viscosity changes during the reaction (for example, during polymerisation). The reactor configuration must be flexible enough to continue to operate efficiently across the entire viscosity range.
Visit our stand at WoTS and win!
Would you like to discuss the right approach to configuring your gear pump or reactor? Do drop by our stand 10D051 at the World of Technology & Science (WoTS) from Tuesday 22 to Friday 25 September 2026. Our specialists will be happy to work with you to find solutions to your specific process challenges.
Win a fantastic Lego set
When you visit our stand, you could win a unique prize: every day of the fair, we’re giving away one fantastic LEGO set featuring Leonardo da Vinci! Test your knowledge of viscosity by completing our questionnaire at the stand and enter the draw!
