Static mixers operate through a series of fixed geometric elements enclosed within a pipe, designed to continuously split, rotate, and recombine fluid streams without moving parts. As fluids flow through the mixer, the internal elements create repeated laminar shear and radial mixing by dividing the flow into multiple layers, changing flow direction, and inducing interfacial stretching.

In laminar flow regimes, the mixer sequentially splits the fluid into striations, exponentially increasing the interfacial surface area between components. For turbulent flows, the elements generate intense vortices and chaotic redistribution, ensuring rapid homogenization. The mixing efficiency depends on the number of elements, flow velocity, and fluid properties such as viscosity and density difference.

Key design features include helical twists, corrugated plates, or structured channels that manipulate flow patterns to achieve dispersion or diffusion-dominated mixing. This energy-efficient process eliminates need for mechanical agitation, providing consistent results across industries from chemical processing to water treatment.