A spoiler with enhanced spoiler effect and a method of manufacturing the same

Abstract

This invention provides a flow disruptor with enhanced turbulence effect, comprising a guide plate, at least two turbulence units extending from one end of the guide plate along its longitudinal axis, each turbulence unit comprising a turbulence column and at least one helical ribbon surrounding the turbulence column, the at least two turbulence units being sequentially connected end-to-end, with the rotation directions of the helical ribbons at the connection points of adjacent turbulence units differing by 80° to 100°, and each turbulence column having at least two column units, each column unit being rugby ball-shaped. This invention also provides a corresponding processing method. The flow disruptor with enhanced turbulence effect of this invention and its processing method have been proven through multiple simulations to have a relatively uniform material distribution at the equipment outlet, demonstrating superior performance in practical applications.

Description

Technical Field

[0001] This invention belongs to the field of static mixers, specifically relating to a turbulence diffuser with enhanced turbulence effect and its processing method. Background Technology

[0002] A flow disruptor is a highly efficient industrial fluid mixing device, a common type of static mixer. Its core feature is the absence of moving parts; it relies entirely on a special internal fixed unit structure, utilizing the fluid's own kinetic energy to cut, shear, rotate, and remix the fluid stream. A static mixer is like installing a "smart maze" in the pipeline; as the fluid flows through, it is forced to continuously split, merge, and change direction, thus achieving uniform mixing. This process repeats continuously, enabling thorough radial mixing (not just axial thrust) of the fluid within a very short pipeline length, significantly shortening the mixing and diffusion path.

[0003] Based on the different internal unit structures, flow disruptors are mainly divided into: spiral blade type, which is the most common form, consisting of a series of alternating left-handed and right-handed spiral blades welded together. The fluid is continuously divided and rotated as it passes through, resulting in high mixing efficiency; corrugated plate type, which consists of multiple corrugated plates stacked together to form complex cross-flow channels. It is mainly used for gas-gas mixing, static heat exchange, and reaction, and is commonly found in air separation and environmental protection industries; grid type, which has the simplest structure, usually consisting of a set of perforated grid plates inserted into the pipe.

[0004] A flow disruptor is a highly efficient, energy-saving, and low-maintenance continuous flow mixing device. Through its ingenious internal structural design, it converts the kinetic energy of fluids into mixing energy, playing an irreplaceable role in various fields such as chemical, petrochemical, environmental protection, and food processing. When selecting one, it is necessary to comprehensively consider fluid characteristics, process requirements, and cost to ensure optimal performance.

[0005] In particular, there is a need for a type of turbulent that can handle fluids with relatively high viscosity, prone to fouling, or requiring efficient heat transfer at low flow rates. This turbulent should be widely used in tubular heat exchangers in the petroleum, chemical, energy, and refrigeration industries. At the same time, this turbulent should achieve a doubling of heat transfer efficiency while maintaining an acceptable increase in pressure drop, and simultaneously achieve significant improvements in anti-fouling ability and temperature uniformity. Ultimately, this would provide a comprehensive competitive advantage in terms of equipment miniaturization, maximum energy efficiency, stable operation, and minimum maintenance costs. Summary of the Invention

[0006] The main objective of this invention is to address the above-mentioned problems by providing a turbulence diffuser with enhanced turbulence effect and its processing method.

[0007] The purpose of this invention is to provide a spoiler with enhanced turbulence effect. Its main features are: a guide plate, at least two turbulence units extending from one end of the guide plate along the longitudinal axis of the guide plate, each of the turbulence units including a turbulence column and at least one helical ribbon arranged around the turbulence column, the at least two turbulence units being connected end to end in sequence, the rotation directions of the helical ribbons at the connection of two adjacent turbulence units differing by 80° to 100°, and the turbulence column having at least two column units, each of the column units being rugby ball-shaped.

[0008] Preferably, each spoiler unit includes a pair of spiral ribbons disposed on opposite sides of the spoiler column and spiraling simultaneously in a clockwise or counterclockwise direction, with one side of the spiral ribbons extending on the side of the spoiler column in a direction parallel to the longitudinal axis of the spoiler column.

[0009] Preferably, the beginning and end of a pair of spiral ribbons in each turbulence unit are straight.

[0010] Preferably, the length of each column unit is the same as the axial length of the ribbon after it has been spiraled 180°.

[0011] Preferably, the turbulence column in each turbulence unit has three column units, and the helical ribbon in each turbulence unit rotates 540° from the first end to the last end.

[0012] Preferably, the rotation directions of the spiral ribbons at the connection points of two adjacent turbulence units differ by 90°.

[0013] Preferably, the spoiler is provided with three spoiler units.

[0014] Preferably, the other end of the guide plate is provided with a mounting part.

[0015] The present invention also provides a method for processing the aforementioned spoiler with enhanced turbulence effect, characterized in that it includes:

[0016] The first and last ends of the processed sheet are rotated 540° relative to each other to form a turbulence unit;

[0017] At least two turbulence units are fixed end to end and connected to one end of the guide plate, and the rotation directions of the screws at the end of the connection between two adjacent turbulence units differ by 80° to 100°.

[0018] The central axis of the processed sheet is the turbulence column.

[0019] Preferably, the outer contour of the processed sheet is a square contour.

[0020] The flow disruptor and its processing method of the present invention, which enhance the turbulence effect, have been proven through multiple simulations to have a relatively uniform material distribution at the equipment outlet and superior performance in practical applications. It is suitable for handling fluids with relatively high viscosity, easy scaling, or requiring efficient heat transfer at low flow rates. It can be widely used in tubular heat exchange equipment in the petroleum, chemical, energy, and refrigeration industries. At the same time, the flow disruptor achieves a doubling of heat transfer efficiency under the premise of acceptable pressure drop, and simultaneously obtains significant improvements in anti-scaling ability and temperature uniformity. Ultimately, it provides a comprehensive competitive advantage in terms of equipment miniaturization, maximum energy efficiency, stable operation, and minimum maintenance costs. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the turbulence-enhancing device of the present invention.

[0022] Figure 2 This is a schematic diagram of the turbulence unit in the turbulence-enhancing device of the present invention.

[0023] Figure 3 To make Figure 2 A schematic diagram of the processing sheet of the turbulence unit shown.

[0024] Figures 4 to 6 The figures show the outlet velocity results of the present invention's turbulence disruptor, the first control model, and the second control model in the simulation.

[0025] Figures 7 to 9 The figures show the inlet pressure results of the present invention's turbulence disruptor, the first control model, and the second control model in the simulation.

[0026] Figures 10A to 12B The images show the particle trace diagrams and volume fraction diagrams of the present invention's turbulence disruptor, the first control model, and the second control model in the simulation.

[0027] Figures 13 to 15 The figures show the propylene glycol volume fraction at the outlet of the present invention's turbulence disruptor, the first control model, and the second control model, respectively, in the simulation. Detailed Implementation

[0028] To provide a clearer understanding of the technical content of this invention, the following embodiments are provided in detail. However, it is important to note that these descriptions are merely for further illustrating the features and advantages of this invention, and not for limiting the scope of the claims.

[0029] like Figures 1 to 3The diagram shows an embodiment of the spoiler with enhanced turbulence effect according to the present invention. The spoiler includes a guide plate 1, and three turbulence units 2 extending from one end of the guide plate 1 along its longitudinal axis. A mounting portion is provided at the other end of the guide plate 1 for fixing the spoiler to a device. The three turbulence units 2 are connected end-to-end sequentially, with the rotation directions of the screw threads at the connection points of adjacent turbulence units differing by 90°.

[0030] like Figure 2 As shown, each of the aforementioned turbulence units 2 includes a turbulence column 3 and a pair of helical ribbons, a first helical ribbon 4 and a second helical ribbon 5, arranged around the turbulence column 3. The pair of helical ribbons are arranged on opposite sides of the turbulence column and spiral clockwise simultaneously. One side of the helical ribbons extends on the side of the turbulence column in a direction parallel to the longitudinal axis of the turbulence column. The turbulence column 3 has three column units, each of which is rugby ball-shaped. In each turbulence unit, the helical ribbon rotates 540° from the first end 6 to the last end 7. The length of each column unit is the same as the axial length of the helical ribbon after it has spiraled 180°.

[0031] like Figure 2 As shown, the beginning 6 and the end 7 of a pair of spiral ribbons in each turbulence unit are both straight.

[0032] like Figure 1 As shown, the rotation directions of the spiral ribbons at the connection points of two adjacent turbulence units differ by 90°.

[0033] The present invention also provides a method for processing the aforementioned spoiler with enhanced turbulence effect, characterized in that it includes:

[0034] Will as Figure 3 The processing sheet shown is rotated 540° relative to each other at its ends to form a flow-disrupting unit, with the central axis of the processing sheet serving as the flow-disrupting column. The processing sheet is a 142mm flat plate, rotated 540° around its generatrix. The outer contour of the processing sheet is square. In other words, the flow-disrupting unit unfolds into a square sheet.

[0035] The three turbulence units are fixed end to end and connected to one end of the guide plate. The rotation directions of the screws at the end of the connection between two adjacent turbulence units are 90° apart.

[0036] The spoiler of the present invention was simulated. The spoiler unit of the present invention is formed by rotating a 142mm plate around a generatrix by 540°. Three spoiler units are spliced ​​together to form the spoiler model of the present invention. The first control model is a 50mm long plate that is rotated around a generatrix by 180° and is composed of 9 spliced ​​units. The second control model differs from the spoiler model of the present invention only in that it does not have spoiler columns. Instead, a plate without spoiler columns is directly rotated around a generatrix by 540° to form a spoiler unit. Other structural details are the same as the spoiler model of the present invention.

[0037] The simulation model uses the same mesh size and the same boundary conditions for analysis:

[0038] Gravity; the velocity inlet is on the side of the baffle plate, the velocity is constant, inlet velocity = 0.1m / s; the tail end of the vortex spiral is the pressure outlet, the measured gauge pressure is 0; initially there is no liquid in the heat exchange tube, only air, liquid is gradually added from the inlet until equilibrium is reached; fluid: air, propylene glycol.

[0039] Results for outlet velocity, inlet pressure, particle trajectory plot and volume fraction plot, and propylene glycol volume fraction at the outlet are as follows: Figures 4 to 15 As shown, where, Figure 13 , Figure 14 , Figure 15 The resulting release surface is the XY plane, with the red part being liquid and the blue part being gas. Based on the gas distribution, we can know the aggregation of the fluid after it is intended to be reorganized.

[0040] This flow disruptor utilizes the high inertia of the fluid in the center due to its spiral action. At bends, this fluid scours the inner wall and repeatedly alters its flow state. The rugby ball-shaped flow disruptor also influences the flow, increasing turbulence. The connection points of the flow disruptor units further cut and divide the fluid, increasing the turbulence. Therefore, this flow disruptor is suitable for fluids with a wide viscosity range. The spiral structure allows fluids of various velocities to mix and transfer heat effectively within the heat exchange tubes. Furthermore, within the heat exchange tubes, the flow disruptor continuously changes the direction and turbulence of the fluid through its spiral structure and rugby ball-shaped flow disruptor, effectively improving its anti-fouling ability.

[0041] The spiral edge of this turbulence diffuser is connected to the inner wall of the heat exchange tube. For other sizes and types of heat exchange tubes and other fluids, the rotation angle of the turbulence unit and the length of individual components can be adjusted to achieve better heat exchange performance.

[0042] The flow turbulence enhancer of this invention has been proven through multiple simulations to have a relatively uniform material distribution at the equipment outlet, resulting in superior performance in practical applications. It is suitable for handling fluids with relatively high viscosity, prone to scaling, or requiring efficient heat transfer at low flow rates. It can be widely used in tubular heat exchange equipment in the petroleum, chemical, energy, and refrigeration industries. At the same time, this flow turbulence enhances heat transfer efficiency by doubling under an acceptable increase in pressure drop, while simultaneously achieving significant improvements in anti-scaling ability and temperature uniformity. Ultimately, it provides a comprehensive competitive advantage in terms of equipment miniaturization, maximum energy efficiency, stable operation, and minimum maintenance costs.

[0043] In this specification, the invention has been described with reference to specific embodiments thereof. However, it will be apparent that various modifications and variations can be made without departing from the spirit and scope of the invention. Therefore, this specification should be considered illustrative rather than restrictive.

Claims

1. A turbulence diffuser with enhanced turbulence effect, characterized in that, The device includes a guide vane and at least two turbulence units extending from one end of the guide vane along its longitudinal axis. Each turbulence unit includes a turbulence column and at least one spiral ribbon arranged around the turbulence column. The at least two turbulence units are connected end to end in sequence, and the rotation directions of the spiral ribbons at the connection points of two adjacent turbulence units differ by 80° to 100°. The turbulence column has at least two column units, and each column unit is rugby ball-shaped.

2. The turbulence diffuser with enhanced turbulence effect according to claim 1, characterized in that, Each spoiler unit includes a pair of spiral ribbons disposed on opposite sides of the spoiler column and spiraling simultaneously in a clockwise or counterclockwise direction. One side of the spiral ribbons extends on the side of the spoiler column in a direction parallel to the longitudinal axis of the spoiler column.

3. The turbulence diffuser with enhanced turbulence effect according to claim 2, characterized in that, In each turbulence unit, the beginning and end of a pair of spiral ribbons are straight.

4. The turbulence diffuser with enhanced turbulence effect according to claim 1, characterized in that, The length of each column unit is the same as the axial length of the ribbon after it has been spiraled 180°.

5. The turbulence diffuser with enhanced turbulence effect according to claim 4, characterized in that, Each turbulence unit has three column units, and the spiral ribbon in each turbulence unit rotates 540° from the beginning to the end.

6. The turbulence diffuser with enhanced turbulence effect according to claim 1, characterized in that, The rotation directions of the spiral ribbons at the connection points of two adjacent turbulence units differ by 90°.

7. The turbulence diffuser with enhanced turbulence effect according to claim 1, characterized in that, The aforementioned spoiler is equipped with three spoiler units.

8. The turbulence diffuser with enhanced turbulence effect according to claim 1, characterized in that, The other end of the guide plate is provided with a mounting part.

9. A method for processing a spoiler with enhanced turbulence effect according to any one of claims 1 to 8, characterized in that, include: The first and last ends of the processed sheet are rotated 540° relative to each other to create a turbulence unit; At least two turbulence units are fixed end to end and connected to one end of the guide plate, and the rotation directions of the screws at the end of the connection between two adjacent turbulence units differ by 80° to 100°. The central axis of the processed sheet is the turbulence column.

10. The processing method according to claim 9, characterized in that, The outer contour of the processed sheet is square.

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