Fluid mixing device and method

Abstract

One fluid is mixed into another to provide a high degree of surface contact between the fluids. In operation, a first fluid flows into a mixing device with aerodynamic perforated blades in a laminar flow state and swirls in the mixing device; the second fluid is contacted with the first fluid, and then the mixture flows through a scallop-shaped device with a regulated venturi expander. A system for mixing one fluid into another fluid and rotationally shearing and homogenizing the material is also disclosed. One or more aerodynamic anomalies are employed to achieve full mixing of multiple fluids, one or more of which may be viscous laminar fluids. The shearing may be performed by a shearer that is rotationally driven by a hydraulic, pneumatic or electric motor. The sheared material may include, for example, paraffin within the crude oil. If desired, the second fluid may be introduced through the multi-physics fluid delivery device.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Patent Application No. 18 / 486,719, filed October 13, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] This disclosure relates to apparatus and methods for mixing one or more fluids in different states, such as gaseous, liquid, colloidal, or particulate states (e.g., including nanoparticles). The fluids involved in this disclosure may exhibit Newtonian flow, laminar flow, or other flow types or states. This disclosure is applicable to a wide range of fluids, including but not limited to water, one or more fuels, and one or more solvents. Fluids can include mixtures of fluids in various states and types. According to one embodiment of the teachings herein, at least one fluid is a relatively viscous liquid in a laminar state, such as crude oil (an example of a bulk fluid).

[0004] If desired, the viscous liquid can be delivered via a fluid delivery system that may include one or more pipes or conduits. This disclosure also applies to fluid carriers other than pipes and conduits. For example, this disclosure relates to fluids (which may be mixtures of fluids) flowing through one or more hoses, conduits, or other devices. The configurability and scalability of the apparatus according to this disclosure allow for its application in a wide range of laboratory, industrial, and remote field uses.

[0005] As used herein, the term "fluid" means "one or more fluids." Therefore, a "fluid" can be a single fluid, or it can be more than one fluid. If a fluid includes more than one fluid, these fluids can be mixed together. Thus, a "second fluid" can include two or more fluids mixed together, and the phrase "first and second fluids" refers to a first fluid that includes one or more fluids and a second fluid that includes one or more other fluids.

[0006] Indian Patent No. 343369 relates to a bladed static device for swirling / mixing two viscous liquids (paint and polymer) within a pipe. The liquids are introduced coaxially into the pipe upstream of the mixing device. The second liquid is not introduced into the first liquid anywhere within or adjacent to the mixing device. Compared to the device mentioned in Indian Patent No. 343369, the system constructed according to this disclosure may, when needed, include one or more recessed cavities for forcing or carrying a portion of the non-uniform multi-fluid flow into or towards a throttling orifice, thereby accelerating the fluid through an expansion structure located on the output side of the recessed cavity.

[0007] If desired, the system constructed according to this disclosure may include one or more hydrocyclones stacked with a first hydrocyclone. Each hydrocyclone may have perforations on its blade surface, which are supplied with fluid by internal channels supplied by a circumferential manifold located at the outer diameter of an envelope tube or conduit. In operation, the hydrocyclone blades guide the fluid flow in a clockwise or counterclockwise direction into a second hydrocyclone with an opposite swirling direction (e.g., if the first hydrocyclone has a clockwise flow direction, the next hydrocyclone has a counterclockwise flow direction), and this sequence may continue until the final hydrocyclone. Additional hydrocyclones may be included sequentially with alternating flow directions.

[0008] It may be necessary to fold and mix the fluid multiple times, especially when dealing with highly laminar flows in viscous fluids, where highly Newtonian flow can be difficult to achieve. If desired, hydrocyclones can be interconnected by the outer diameter of the tubes through which they are manufactured, allowing the entire flow to be unobstructed and the vortices to fold and mix in full motion, without any straightened paths. If desired, multiple hydrocyclone layers can have perforated surfaces supplied with fluid via internal channels through a main manifold located at the outer diameter of the pipe and at the root of the internal pipe. However, this disclosure should not be limited to the examples described herein unless such examples are covered by the claims at the end of this specification.

[0009] U.S. Patent No. 8,033,714 ('714 Patent) relates to a stator with blades and an opening for swirling a first fluid, the opening for radially introducing a second fluid into the swirling first fluid adjacent to the stator. This system is a urea water metering device for reducing nitrogen oxides (NOx) in engine exhaust, an exhaust gas recirculation (EGR) device for drawing exhaust gas into the intake air, a combustion chamber in which fuel is mixed with air, or a reformer for mixing air with carbon monoxide and oxidizing the carbon monoxide. The '714 Patent does not involve mixing fluids into a liquid and does not use stator blades to guide the second fluid into the first fluid.

[0010] If needed, the system constructed according to this disclosure can provide a second fluid via a circumferential manifold channel in the outer diameter of the perforated blade assembly unit. The second fluid supply channel can extend radially inward through the blade and intersect with a distribution channel extending distally from the supply channel to the distal end of each blade. Perforations can extend from the distribution channel to a first surface of each blade. The perforations supply a continuous second fluid film to contact the first fluid as a high-viscosity first fluid passes through the perforated blade structure. The perforated blade surface provides extremely high surface contact between the first and second fluids, thereby ensuring uniform mixing of the second fluid with the high-viscosity laminar flow of the first fluid.

[0011] U.S. Patent No. 9,879,862 ('862 Patent) relates to an afterburner for a gas turbine engine. According to this patent, the trailing edge portion of the afterburner blades may have openings for introducing combustion products into the flow path of the working fluid. The patent also states that fuel injection openings may be distributed on the side of the upstream blade portion. Like the '714 patent, the '862 Patent does not address mixing fluid into the liquid flowing through the system.

[0012] Compared to the '862 patent, the orifice constructed according to this disclosure can receive a second fluid from a central dispensing channel or manifold. The second fluid can be released into a viscous first fluid flow, wherein the first fluid flow folds itself upon exiting the hydrocyclone blade segment due to the vortex motion exerted by the hydrocyclone blades. According to this aspect of the disclosure, the second fluid is received and folded into the first fluid flow. However, this disclosure should not be limited to the examples described herein. The claimed subject matter is set forth in the claims at the end of the specification.

[0013] The shortcomings of the prior art are largely overcome by this disclosure. Among other things, the method according to this disclosure can have reduced hybrid energy requirements, reduced system entropy, modular design that facilitates automated assembly, and reduced maintenance requirements. Summary of the Invention This disclosure relates to a fluid mixing apparatus and method for introducing one or more variable fluids into a first fluid. To meet resource conservation and economic constraints, the amount of the second fluid can be precisely adjusted and limited to the most effective amount to achieve the desired effect on the first fluid. Therefore, if desired, a high degree of surface contact can be achieved while precisely metering the second fluid into the first fluid.

[0014] The fluids can then be swirled or their flow altered to perform work on the mixture, thereby promoting homogeneity (thorough mixing) of the two fluids. The first fluid can be a relatively viscous liquid in a laminar flow state, such as crude oil transported by the system. The second fluid can be introduced immediately downstream of the hydrocyclone through a radially outward-extending pipe or through an opening built into the hydrocyclone blades, and a scallop-shaped disc device can be placed downstream of the hydrocyclone where the liquid mixture flows through a venturi orifice.

[0015] According to one aspect of this disclosure, the cross-sectional area of ​​each component of the system is equal to the cross-sectional area of ​​the first fluid channel or pipe plus an additional flow area factor determined by fluid dynamics, numerical methods, or simulation, so as to make it an ideal and efficient cross-section that allows the first fluid to flow without changing the flow rate, friction, or pressure drop.

[0016] If desired, the system constructed according to this disclosure can have perforated blades operating according to aeronautical / hydrodynamic principles. According to this aspect of the disclosure, one or more perforated blade modules can have an airfoil shape typical of an aircraft wing. Features such as surface undulations or serrations, especially on the leading and / or trailing edges of such blades, can be used to enhance flow anomalies to improve fluid mixing.

[0017] Therefore, unlike prior art swirlers used for mixing and flow enhancement, the swirler constructed according to this disclosure can have an airfoil configuration with an aerodynamic geometry and surface tuned to the inherent frequencies of one or more fluids to be homogenized. This swirler can achieve fully interactive surface contact and optimize mixing, thereby utilizing the flow anomalies inherent in the airfoil and, in some configurations, amplifying these anomalies to improve mixing.

[0018] If needed, numerical methods can be used to tune the desired geometry and achieve optimized hydrodynamics for mixing. These aeronautical or hydrodynamic features can amplify flow anomalies typically encountered in airfoil and flow design to induce multiple vortices. Leading and trailing edges, or blade surfaces, can include undulations, serrations, or other geometries to amplify flow anomalies.

[0019] This disclosure also relates to a method for mixing a second fluid into a first fluid to achieve high surface contact between the fluids, wherein the first fluid is a liquid, and wherein the method comprises: allowing the first fluid to flow in a laminar state into one or more fluid distributions in a mixing device; swirling the first fluid within the mixing device; contacting the second fluid with the first fluid; and subsequently, allowing the mixture of fluids to flow through a residence region in which the first mixing is primarily completed and preliminary homogenization is achieved. The combined fluids then enter a scallop-shaped parabolic disk device, in which the combined fluids are focused and expanded through a plurality of parallel Venturi features. The focused streams exiting the Venturi tubes expand into each other to promote further mixing, and partial backflow mixing of the combined fluids occurs within the cone of the outflow.

[0020] According to another aspect of this disclosure, a second fluid is provided via a circumferential manifold channel in the outer diameter of the perforated blade assembly unit. The second fluid supply channel extends radially inward through the blade and intersects with a distribution channel extending distally from the supply channel to the distal end of each blade. Perforations extend from the distribution channel to a first surface of each blade.

[0021] Such perforations can be used to supply a continuous second fluid membrane to contact the first fluid as it passes through the perforated blade structure. The perforated blade surface provides extremely high surface contact between the first and second fluids, thereby ensuring uniform mixing of the second fluid with the high-viscosity first fluid laminar flow. However, as previously stated, this disclosure should not be limited to these examples unless they are covered by the claims.

[0022] In conventional applications of viscous laminar fluids, relatively rigid and tortuous channels may be required to force separate fluids to interact, achieve high surface contact ratios, reduce inhomogeneities, and facilitate homogeneity (thorough or complete mixing) for various process purposes. This disclosure recognizes that such rigid and tortuous channels are inefficient due to throttling, pressure drop, and increased friction required to force and facilitate contact between multiple fluids. This disclosure overcomes these drawbacks and achieves high surface area contact and homogeneous mixing of multiple fluids by presenting a second fluid to the first fluid at extremely high surface contact. By achieving this high surface contact at the second fluid distribution point, the desired effects can be achieved through less vigorous, lower entropy, or lower energy consumption mixing, while maintaining the natural flow rate and pressure of the first fluid.

[0023] This disclosure also relates to an apparatus for mixing a second fluid into a first fluid to achieve a high surface contact between the first and second fluids, wherein the first fluid is a liquid, and wherein the apparatus comprises: a mixing device; an inlet for allowing the first fluid to flow into the mixing device in a laminar flow state; and a swirling device. If desired, the swirling device has a plurality of blades for swirling the first fluid within the mixing device. Each blade may have an airfoil configuration to induce pressure differentials and turbulent vortices at the blade edges.

[0024] Furthermore, the device may include a flow channel located within a swirling device and a scallop-shaped parabolic disc device. The flow channel is used to bring the second fluid into contact with the first fluid. In the scallop-shaped parabolic disc device, the merging fluids expand through multiple parallel Venturi features. The focused streams exiting the Venturi features expand into each other, while backflow mixing of partially merged fluids occurs within the cone of the streams exiting the Venturi features, further mixing the fluids.

[0025] Certain liquids present unique mixing challenges due to their sometimes highly laminar flow characteristics. One object of this disclosure is to entrain a second fluid flow into a first main fluid flow to obtain a homogeneous or uniform mixture and to achieve a significantly reduced residence time to reach homogeneity (thorough or complete mixing), aiming for near-zero residence time, thereby eliminating entropy and reducing energy input. The second fluid may comprise small particles, or it may be a fully contacted thin film.

[0026] According to one aspect of this disclosure, a receiving container, pipe, or flange insert guides the product flow through the process. The apparatus constructed according to this disclosure can be scalable and configurable for a range of pipe diameters, fluid viscosities, and flow rates. If desired, the system components can have a modular construction to facilitate machine assembly and maintenance. Each element of the system can be inserted from either the proximal or distal end of the receiving container to stack with each other to form a sequential processing unit. A processor constructed according to this disclosure may include modified airfoil-shaped vortex-induced cyclone blades, a residence zone or one or more residence elements, a reaction or mixing chamber, and a flow-regulating processing device. This processing device may have one or more pressure and velocity flow regulators with the same geometry and function as Laval nozzles, Venturi tubes, or other suitable hydrodynamic regulators.

[0027] The second fluid (which is mixed into the first fluid) may be an inoculant, reactant, or other modifier. The second fluid may be one or more fluids of different viscosities and states. The second fluid may be in a gaseous or liquid state and may be an additive, modifier, inoculant, or reactant of the first viscous fluid. The second fluid may be a micron or nanoparticle solid that can be transported in a medium as a colloid, nanoparticle fluid, or by other suitable methods of suspension.

[0028] As stated above, the term "fluid" as used herein refers to "one or more fluids." Therefore, if desired, the second fluid may include two or more fluids mixed with the first fluid. Similarly, the first fluid may be a viscous liquid or a mixture of more than one fluid. If desired, precise metering and dispensing of the fluids can be employed to ensure efficient and economical fluid volumes, thereby minimizing resource consumption while maximizing mixing and reaction benefits. However, as previously stated, this disclosure should not be limited to the examples described herein unless such examples are covered by the claims.

[0029] If desired, during manufacturing processes such as lost-wax casting, 3D printing, or other suitable processes, a delivery channel for introducing a second fluid into the first fluid can be attached, covered, or built into the hydrocyclone blades. According to another aspect of this disclosure, the delivery channel can be located within an airfoil-shaped blade. The delivery channel can terminate at the leading or trailing edge of the vortex-induced hydrocyclone blade. A thin film along such edges can have a high surface area contact with the first fluid flowing over these edges. In operation, the flow can be controlled to utilize aerodynamic anomalies to induce folding and backflow inside and around the hydrocyclone blades.

[0030] According to this aspect of the disclosure, factors that might otherwise be considered airfoil anomalies and inherent inefficiencies can be utilized, and leading-edge and trailing-edge anomalies can be advantageously used for mixing. Therefore, an apparatus constructed according to the disclosure can have one or more airfoil elements and vortex-induced cyclone blades that improve airflow dynamics. A perforated channel (or tube) can be integrated into the leading or trailing edge of the blade. This perforated channel can serve as a source for the delivery of a second fluid.

[0031] If desired, the mixing of the second fluid into the first fluid can occur where the viscous first fluid exits the aerodynamic cyclone blades and undergoes aerodynamic anomalies, inducing folding and backflow inside and around the cyclone blades. During operation, the mixed fluid folds itself due to the added vortex motion provided by the cyclone blades. Preferably, the second fluid is received and folded into the first fluid in or near the outlet region defined by the cyclone blades.

[0032] If necessary, a residence, reaction, or mixing chamber can be located between the vortex-induced cyclone blades and the flow regulation and treatment device. The length and diameter of the residence chamber can be determined numerically based on the flow characteristics and natural frequency of the working fluid, so that the induced flow motion is consumed and the uniformity is optimized.

[0033] If needed, the mixing device can be configured as a single unit that can be flipped or reversed as a whole within the system to position the vortex-induced cyclone blades upstream or downstream relative to the flow direction within the system.

[0034] According to another embodiment of this disclosure, the vortex-induced cyclone blade has one or more channels located inside the blade, said channels starting directly below the leading edge surface and terminating before opening at the trailing edge of the blade. These channels may have perforations to form a perforated first blade surface. According to this embodiment, the perforated surface of the blade can be a source of delivery for a second fluid.

[0035] According to another embodiment, the blades of the vortex-induced cyclone generator have a honeycomb or porous structure (e.g., partially made of metal foam). The first surface of each blade can be porous, while the second surface of the blade is closed and smooth. Channels can be constructed inside the blades. If desired, the channels have porous surfaces along their entire length. The function of the honeycomb (metal foam) structure is to facilitate the extensive distribution of the second fluid, as it is not limited to the array of small holes supplied to the surface of the first blade.

[0036] If required, the components of the mixing device (including the blades of the vortex-induced cyclone generator) can be manufactured according to standard machining methods. For example, tubes, channels, and separators (perforated and / or solid) can be manufactured separately and then joined or assembled by one or more joining or fusion methods.

[0037] The device preferably has one or more residence / mixing elements or regions in which the first fluid and the second fluid interact. The residence / mixing elements or regions may be located between the hydrocyclone blades and the flow regulating treatment device. In other words, the residence / mixing elements / regions may be located downstream of the channel opening that introduces the second fluid into the first fluid and upstream of the flow regulating treatment device that further mixes the first and second fluids.

[0038] Another embodiment of the flow regulation processing device has vortex-induced hydrocyclone blades in the concave inlet feature for further swirling and mixing the first and second fluids, thereby creating more contact between the fluids. In operation, the viscous first fluid in a laminar state is pumped or compressed to the upstream side of the vortex-induced hydrocyclone blades. A thin film of the second fluid (which may be an inoculant) forms on the contact surface of the hydrocyclone blades (the first surface in contact with the first fluid). The first fluid is forced to flow through the film of the second fluid, resulting in complete interfacial contact between the second and first fluids, and the swirling configuration of the hydrocyclone blades entrains the second fluid into the first fluid.

[0039] If desired, a multiphysics fluid atomizer of the type described in U.S. Patent No. 10,883,454 ('454 Patent) can be employed in the apparatus according to this disclosure. In such an apparatus, the fluid atomizer receives one or more fluids and produces a plume of finely atomized particles or droplets. This plume is arranged such that the cross-section of the plume is uniformly distributed at the inlet of a first cyclone separator or shearing device (in the case of a motorized shear homogenizer). Small particles with a high surface area-to-volume ratio are released in a certain quantity and distribution to achieve maximum contact with the first fluid. A subsequent mixing stage can be used to ensure complete homogeneity.

[0040] If desired, a shear homogenizer can be used to direct the second fluid into the head inlet of the rotor and stator. The first fluid can be introduced via a fluid atomizer as described in the '454 patent. If desired, the two or more fluids generate small droplets or particles dispersed in a uniform plume with a specific plume angle covering the diameter of the rotor / stator assembly. In another embodiment, a perforated blade device is positioned in front of the shear rotor / stator assembly, thereby introducing a thin film of the second fluid into the first fluid flow and guiding it into the rotor / stator shear homogenizer.

[0041] The shear homogenizer constructed according to this disclosure can utilize a machine-driven rotor and stator. The rotational speed of the machine can be variably controlled to produce a fluid flow segment of the desired duration or length with a specific process result. For example, according to one instance, excessively large and unprocessable paraffin wax is embedded in a first fluid flow. By variably setting the rotational speed of the rotor / stator to the flow rate of the first fluid, thereby shearing the paraffin wax to the desired length for further processing, such paraffin wax can be reduced to a practical size (or length).

[0042] The structure according to this disclosure can be configured to manage the first and second fluid flows to: a) converge them into a folded viscous laminar dynamic vortex to facilitate high surface contact between the two fluids, and b) manage the first and second viscous laminar fluid flows into a progressive annular dynamic flow to facilitate high surface contact between the fluids.

[0043] Furthermore, this disclosure relates to an apparatus and method for mixing a second fluid into a first fluid to achieve high surface contact between the first and second fluids, wherein the first fluid is a liquid, and wherein the method comprises: allowing the first fluid to flow into a mixing apparatus in a laminar flow state; contacting the second fluid with the first fluid; and subsequently, rotating and shearing a material in the mixture of the first and second fluids. If desired, the material to be rotated and sheared includes paraffin wax located within crude oil flowing through the system.

[0044] The shear homogenizer constructed according to this disclosure can direct a second fluid into the head inlet of the rotor and stator. The first fluid can be input via a multiphysics fluid atomizer as described in U.S. Patent No. 11,674,479. This fluid atomizer can convert two or more fluids into small droplets or particles dispersed in a uniform plume, the plume angle covering the diameter of the rotor / stator assembly. In another embodiment, a perforated blade device can be positioned in front of the shear rotor / stator assembly such that the perforated blade device introduces a second fluid film into the first fluid flow and guides it into the rotor / stator shear homogenizer.

[0045] The shear homogenizer of this example can have a machine-driven rotor and stator, and the rotational speed of the machine can be variably controlled to produce a fluid flow segment of the desired duration or length with a specific process result. For example, in one embodiment, excessively large and unprocessable paraffin wax is embedded in a first fluid flow. This paraffin wax can be sheared to the desired length for further processing by variably setting the rotational speed of the rotor / stator to the first fluid flow rate, thereby reducing it to a practical size (or length). Attached Figure Description Figure 1 It is a side view of an example of a system for conveying a first fluid, wherein the system has a mixing device aligned between two parts of the system;

[0046] Figure 2 yes Figure 1 A partial cross-sectional view of the mixing device shows an example of vortex-induced cyclone blades, a guide tube for introducing a second fluid into a first fluid, a mixing element, a mixing and residence chamber (described in more detail below), and a flow regulation processing device, all located within the housing of the mixing device.

[0047] Figure 3 , Figure 4 and Figure 5 They are Figure 2 Side view, front perspective view and rear perspective view of the hydrocyclone blades and guide tubes;

[0048] Figure 6 , Figure 7 and Figure 8 These are, respectively, a side view, a front perspective view, and a rear perspective view of a hydrocyclone blade and guide tube with another configuration (incorporating a perforated blade module, described in more detail below) used in... Figure 1 and Figure 2 Used in mixing devices;

[0049] Figure 9 and Figure 10 These are front and rear perspective views of a hydrocyclone blade and guide tube (incorporating a perforated blade module) of another configuration, used for... Figure 1 and Figure 2 Used in mixing devices;

[0050] Figure 11 yes Figure 9 and Figure 10 A cross-sectional view of the perforated blade shown, wherein the cross-section is parallel to and located between the front and back surfaces of the blade.

[0051] Figure 12 An example of an intermediate swirl plate constructed according to this disclosure is shown;

[0052] Figure 13 and Figure 14 They are Figure 2 Front perspective view and side view of the flow regulation processing device;

[0053] Figure 15 and Figure 16 They are used for Figure 1 and Figure 2 A front perspective view and a side view of another flow regulation processing device in the mixing unit;

[0054] Figure 17 and Figure 18 It is a partial cross-sectional view of a system example containing apparatus for mixing, shearing, and homogenizing the first and second fluids;

[0055] Figure 19 It is a schematic cross-sectional view of a swirl blade with an airfoil (or hydrofoil) configuration;

[0056] Figure 20 This is a schematic diagram illustrating the operation of a Venturi regulator;

[0057] Figure 21 This is a front perspective view of a flow regulation and processing device with an upstream swirl element; and

[0058] Figure 22 It is used for Figure 17 and Figure 18 A front perspective view of a coaxial mixer in a mixing, shearing, and homogenizing system. Detailed Implementation Referring now to the accompanying drawings, where similar reference numerals denote similar elements. Figure 1 The diagram illustrates a system 10 constructed according to this disclosure. System 10 may include, for example, a pipe, one or more pipelines, one or more conduits, or one or more other suitable devices. A mixing device 12 is located within system 10. Opposite ends 14, 16 of the mixing device 12 are connected to the upstream portion 18 and downstream portion 20 of system 10 via flanges 22, 24 or other suitable connecting devices. Figure 1 As shown, the first fluid ( Figure 1 (Not shown in the image) flows from left to right in system 10.

[0059] The mixing device 12 may take the form of a container, pipe, or flange insert. In the illustrated embodiment, system 10 and mixing device 12 are cylindrical, but may also have certain other suitable configurations. As shown, the inner diameter of the mixing device 12 is preferably larger than the inner diameter of the main pipe sections 18, 20, as discussed in more detail below. The inner diameter of the main pipe sections 18, 20 may be around two inches (or other suitable size). This disclosure should not be limited to the examples described herein.

[0060] like Figure 2 As shown, the mixing device 12 has the following components: vortex-induced cyclone blades 30, a channel 32 for introducing a second fluid (not shown), and a residence / mixing element or region 34 (in Figure 2 (shown schematically in the diagram), and flow regulation processing element 36. The three elements 30, 34, and 36 within the mixing device 12 have cylindrical outer surfaces 38, 40, and 42 that mate with the cylindrical inner surface 44 of the mixing device housing 26.

[0061] If desired, the inner surface 44 of the shell 26 may include surface geometries such as topography-driven Langmuir circulation to induce longitudinal vortex flow. These longitudinal geometries may be further modified to be helical along a length through the shell 26, thereby inducing progressive annular flow and further enhancing homogenization. Surface geometries employed in conjunction with other features of this disclosure are described in the paper “Designing vortices in pipe flow with topography-driven Langmuir circulation” by Ellingsen et al. (Journal of Fluid Mechanics, Vol. 926, September 6, 2021) (Ellingsen et al.). The entire disclosure by Ellingsen et al. is incorporated herein by reference.

[0062] If needed, the components 30, 34, and 36 of the mixing device 12 can be configured for field maintenance that facilitates automated assembly and quick replacement. The components 30, 34, and 36 shown can have a modular construction, allowing them to be inserted into the device 12 from either the input or output end (near to far end) for assembly.

[0063] like Figure 2 As shown, device 12 may have a mixing and residence chamber 34, where the first and second fluids consume the turbulent energy generated by the second fluid inlet and swirler module 30. As the fluid returns to a laminar state in residence chamber 34, the second fluid continues to interact with the first fluid. As the fluid flow straightens, it immediately contacts flow regulation module 36, where it is subjected to expansion forces, imparting further turbulence and mixing. If desired, residence chamber 34 may also include a swirling induction module (discussed below) to impart additional turbulence to the laminar fluid.

[0064] Now go to Figures 3 to 4 Channel 32 includes devices for drawing a second fluid from outside the mixing device 12 (in Figures 3 to 5 (Not shown in the image) The mixing device 12 is introduced (metered in). Figure 2 The second fluid inlet channel 50 is located in the cylindrical housing 26. The blades 30 are inclined relative to the flow axis 25 passing through the cylindrical housing 26, so that when the first fluid travels from left to right (e.g., ...), the flow path 25 is obliquely positioned. Figure 3 As shown, swirling motion is generated in the first fluid.

[0065] In the illustrated apparatus 12, two or more fluids (one of which may be highly laminar and viscous) are introduced into each other such that a high surface contact is established between the fluids at the point of introduction, where the fluids are immediately subjected to confluence fluid pressure and applied turbulence. In the illustrated apparatus 12, uniform mixing can occur immediately at the point where the multiple fluids are introduced.

[0066] Channel 32 may include a radially guided single-hole tube 52 located on the trailing edge of blade 30. Figure 5 ), used to introduce a second fluid into a first fluid. According to one aspect of this disclosure, fluid pressure and induced turbulence are immediately imposed after the introduction of the second fluid. The input channel 50 passes through the central portion 54 of the blade 30 ( Figure 4 It is connected to the radial inner end of the single-hole tube 52. During operation, the first fluid flows into the blade 30 in a laminar flow state, and the second fluid flows from the outside of the mixing device 12 through the input channel 50, through the central portion 54, and radially outward through the open end of the tube 52, where the second fluid is mixed with the swirling first fluid.

[0067] In another implementation, such as Figures 6 to 8 As shown, another blade assembly 60 can be used instead. Figures 2 to 5 The blade shown is 30. In Figures 6 to 8 In one embodiment, the second fluid flows through the input manifold (or annular channel) 62 into the blade assembly 60 and exits the blade 60 at the output opening 64 located at the trailing edge 66 of the blade 60. Figures 6 to 8 In the structure shown, the first fluid flowing in a laminar state flows from right to left (e.g., Figure 7 The first fluid (shown) travels through the blade assembly 60 while the second fluid flows within a channel (not shown) inside the blade 60 and comes into contact with the swirling first fluid as it flows through the opening 64 and leaves the trailing edge 66.

[0068] In the illustrated embodiment, the second fluid flows through an outlet opening 64 on the trailing edge 66 of the blade 60 and exits the blade 60. However, whether the second fluid exits the leading or trailing edge of the blade, if desired, depends on the application. The required location and layout can be determined using numerical methods of fluid dynamics to efficiently and productively introduce the second fluid, thereby utilizing the flow energy of the first fluid to initiate and execute the mixing process without incurring parasitic losses. As mentioned above, the term "second fluid" includes one or more fluids.

[0069] In the illustrated embodiment, the input manifold 62 extends around the full circumference of the respective blade assembly. However, if desired, multiple manifolds may be present, each extending only partially around the blade assembly in a "crescent-shaped" configuration. Alternatively, when the second fluid comprises multiple fluids, one of these multiple fluids may be supplied to every other blade via separate manifold channels.

[0070] Now go to Figure 9 and Figure 10 Alternatively, another blade assembly 70 can be used to replace it. Figures 2 to 5 The blade 30 shown. Figure 9 and Figure 10 In one embodiment, the second fluid flows through the input manifold (or annular channel) 62 into the blade assembly 70 and exits the blade 70 at the output opening 72 on the upstream surface of the blade 70. Figure 9 and Figure 10 In the configuration shown, the first fluid reaches the blade assembly 70 in the form of a laminar liquid and flows from right to left (e.g., ...). Figure 9 As shown, the second fluid travels through the blade assembly 70, while the second fluid passes through the channel 74 inside the blade 70. Figure 11 It flows inside and exits through opening 72.

[0071] Therefore, the second fluid forms a thin film on the upstream surface 76 of the blade 70. This film comes into contact with the swirling first fluid as it is swirled by the upstream blade surface 76. Figure 11 As shown, the openings 72 are spaced apart from each other and diagonally aligned, such that each opening 72 is aligned with a different streamline of the first fluid crossing the upstream blade surface 76.

[0072] If desired, each fixed blade may have multiple perforations 72 oriented at a columnar angle such that no perforation overlaps with another. This orientation effectively allows the second fluid to form a thin film across the first fluid impact surface of each blade. Forming the second fluid into a thin film in this manner makes it possible to provide a programmed amount of the second fluid to the first fluid, thereby promoting a desired degree of uniform mixing between the first and second fluids. The diagonal array of openings (or perforations) 72 on the blade 70 improves the distribution of the second fluid to the first fluid.

[0073] If necessary, it can be used in the dwell or mixing element or area 34 ( Figure 2 Inside, an intermediate swirl plate 80 is provided between the swirler blade element 30, 60 or 70 and the required flow regulation and processing element 36. Figure 12 The intermediate swirl plate 80 has additional swirler blades 112 for further swirling the first fluid and mixing the second fluid into the first fluid.

[0074] Figure 13 and Figure 14 An example of a flow regulation processing element 36 is shown. Element 36 has multiple upstream parabolic scallop-shaped disc openings 100, which are used to focus the flow and increase the flow velocity into the venturi orifices 102. In operation, a mixture of the first and second fluids flows into and through the respective venturi orifices 102. Figure 20 As shown, each Venturi orifice 102 may have a Venturi regulator 106 at its outlet. Figure 20 The optional Venturi regulator 106 is not included. Figure 13 As shown in, and possibly Figure 14 The middle part is hidden and cannot be seen. Opening 100 operates as a separate collector for receiving corresponding portions of the mixture of the first and second fluids. Venturi orifice 102 is located downstream of parabolic disc opening 100.

[0075] Generally, the flow regulation processing element 36 may have one or more pressure and velocity flow regulators, whose geometry and function are the same as those of a Laval nozzle, Venturi tube, or other suitable hydrodynamic regulator / expander. For each Venturi tube 102, a Venturi regulator 106 may be arranged at its outlet (in... Figure 20 One of them is shown in the figure. The flow regulator 106 directs the core flow, which is normally at high speed, toward a direction away from the center of the Venturi outlet, thereby promoting Venturi expansion 107.

[0076] As a result, the flow velocity increases near the conical wall 108 of the Venturi tube 102. As the fluid bypasses the regulator 106 and accelerates, a blocking pressure drop occurs behind the regulator 106. This blocking effect creates a backflow zone 109. The high-speed fluid bypassing the regulator 106 interacts with the fluid from the adjacent Venturi tube (not in the...) Figure 20 (as shown in the diagram) the flow interaction, while the first and second fluids in the return zone 109 are more completely mixed together.

[0077] During operation, the mixture of the first and second fluids can pass through residence, reaction, or mixing chamber 34 ( Figure 2 The fluid mixture is then introduced into the flow regulating treatment element 36, where the parabolic concave collector 100 focuses or directs a portion of the fluid mixture into its respective outlet orifice and corresponding expander 102. The generally conical Venturi regulator 106 directs the high-velocity focused flow characteristic of Laval flow outwards to the Venturi wall 108, thereby raising the wall flow to the same high velocity and creating a reflux zone 109 behind the Venturi regulator for further mixing in the fluid flow. The fluid mixture can then be piped to a downstream processing stage or storage stage of the flow regulating treatment device.

[0078] If necessary, while imparting an angular change to the straightening flow, backflow or eddies are induced within the angled (or conical) moving flow, thereby further inducing mixing when the viscous fluid with residual second fluid is compressed, increasing the homogeneity of the final fluid flow.

[0079] Element 36 operates as a multiple pressure and velocity flow regulator, such as a Laval nozzle, Venturi tube, or other suitable fluid dynamics regulator, thereby providing additional mixing for the first and second fluids. Therefore, element 36 can take the form of a disc with one or more concave inlet sides that guide the mixture of multiple fluids through a throttling section, and then through an expansion feature that guides it out into the main fluid streamline 25, forming an extended, coherent, and uniform flow stream evenly distributed over the open area of ​​device 12. This rapid expansion further enhances mixing to achieve homogeneity of the multiple fluids within conduit 10. As explained above, conical or expansion-shaped flows will induce backflow or eddies, thereby promoting mixing.

[0080] If desired, element 36 may have additional structural features, not shown in the figures, that may advantageously affect flow characteristics. Such features may induce changes in the flow vector or induce localized high pressures that can alter fluid viscosity and improve mixing. This disclosure should not be limited to the examples described herein unless such examples are covered by the claims.

[0081] Figure 15 and Figure 16 Another example of the flow regulation processing element 110 is shown. Element 110 and Figure 13 and Figure 14 The components shown are basically similar to 36, the difference being... Figure 15 and Figure 16 The element 110 has additional cyclone blades 112 within its downstream opening. If necessary, Figure 15 and Figure 16 Component 110 can be used to replace Figure 2 , Figure 13 and Figure 14 Element 36. Where such additional mixing is required, additional cyclone blades 112 provide additional mixing for the first and second fluids. The additional cyclone blades 112 are located downstream of each concave inlet position 100 of the flow regulating treatment element 110 to further aid in establishing full contact mixing between the first and second fluids.

[0082] According to another embodiment of this disclosure, the flow regulation processing element 400 ( Figure 21The system may have a cyclone separator 402 located upstream of the corresponding parabolic receiver and downstream Venturi element. The cyclone separator 402 facilitates thorough mixing of the second fluid into the first fluid before the mixture enters the Venturi element for further hydrodynamic processing. If desired, the mixing and turbulence-generating elements described herein can be used together in various combinations, and some of these elements can replace others to suit flow conditions and mixing requirements.

[0083] Figure 19 This is a schematic cross-sectional view of swirl blades 600 and 602 constructed according to one aspect of this disclosure. The swirl blades 600 and 602 are shaped similarly to airfoils (or hydrofoils). Each blade 600 and 602 has a leading edge 604 and a trailing edge 606. The leading edge 604 is blunter than the trailing edge 606. The trailing edge 606 forms a sharper cross-sectional angle than the leading edge 604. Figure 19 As shown, the distance measured from the leading edge 604 to the trailing edge 606 on the first surface 608 is greater than the distance measured from the leading edge 604 to the trailing edge 606 on the second surface 610.

[0084] Each blade 600, 602 has an angle of attack relative to the fluid flow direction 611. This angle of attack is (1) the angle between the chord from the leading edge 604 to the trailing edge 606 and (2) the fluid flow direction 611. In the example shown, the second blade 602 has a larger angle of attack than the first blade 600. Vortexes and backflows of the fluid flow (which may be the flow of the first fluid) are formed on the first surface 608 and downstream of the trailing edge 604. These vortices and backflows can be increased or decreased by modifying the shape of the swirling blades 600, 602 and changing the angle of attack. Figure 19 The flow vectors passing through and downstream of airfoil blades 600 and 602 are described, which induce folding and backflow along the leading and trailing edges 604 and 606, and induce folding and backflow within the flow downstream of swirl blades 600 and 602.

[0085] Any one or more swirl blades discussed above, including Figure 4 , Figure 5 and Figures 7 to 10 The blades 30, 60, and 70 shown can all have the following characteristics: Figure 19 The airfoil shape configuration is shown. If desired, the second fluid can be introduced into the first fluid through a perforation located on the second surface 610 near the trailing edge 606 of the swirl blade. The airfoil shape configuration of the swirl blade and the angle of attack of the swirl blade can advantageously generate eddies, backflows, and turbulence, thereby promoting thorough mixing of the second fluid into the first fluid.

[0086] Furthermore, if desired, aerospace / hydrodynamic swirl blades (such as...) can be used in the dwelling chamber 34. Figure 19The swirl blades shown further improve mixing. These aerodynamic “wing” structures can be tuned for hydrodynamics to induce a main vortex flow through swirl effects (e.g., depending on the angle of attack) and can also induce wake turbulence by generating smaller vortices at the blade tips (e.g., depending on the configuration of the trailing edge 606 relative to the other elements of the swirl structure). Tip wake vortices can be generated downstream of the trailing edge 606 through outward, upward, and bypassing vortex circulation at each blade tip (trailing edge 606). These vortices induce turbulence, thereby improving mixing with minimal energy requirements.

[0087] The open cross-sectional surface area of ​​the blade elements 30, 60, 70, or any other equipment within the mixing unit 12 should be in the range of 90% to 140% of the open cross-sectional surface area of ​​the processing pipes 18, 20, more preferably in the range of 100% to 130%, to ensure unobstructed, or at least satisfactory, flow through the mixing unit 12. If desired, the preferred open cross-sectional surface area of ​​the mixing unit 12 can be determined by numerical methods or simulations of fluid dynamics uniquely related to its intended use. To accommodate this required difference in open cross-sectional surface area, the inner diameter of the mixing unit housing 26 should be larger than the inner diameter of the main pipe sections 18, 20.

[0088] Figure 17 A device 200 for mixing, shearing, and homogenizing fluids within pipes 18 and 20 is shown. In operation, a first fluid (which may be similar to the first fluid processed in mixing device 12) flows from left to right through pipes 18 and 20 as a laminar liquid. A second fluid (which may be similar to the second fluid introduced by mixing device 12) flows out from a suitable source 33 and is immediately mixed into the first fluid after it has been swirled by the swirl vane element 30.

[0089] The mixture of the first and second fluids then flows through a rotary shearing device 202, which shears the material within the mixture into smaller fragments and improves the mixing of the first and second fluids. This shearing can be performed by one or more rotary shears (an example of a rotor / stator assembly). The one or more shears can be driven by a suitable motor 204. The motor 204 can be a hydraulic, pneumatic, or electric motor.

[0090] The housing length of motor 204 provides a residence mixing chamber, which may include one or more flow enhancement or mixing devices (modules) described herein. Figure 17 In the illustrated embodiment, the first fluid may be crude oil, the second fluid may be an inoculant or reactant for processing the crude oil, and the material sheared by the shearing device 202 may be paraffin microspheres within the crude oil. However, this disclosure should not be limited to the materials described herein unless such materials are mentioned in the subsequent claims.

[0091] If needed, the rotary shearing device 202 can rotate at high speed to homogenize the paraffin fragments cut within the fluid mixture. The rotational speed of the rotary shearing device 202 can be variable. The speed of the device 202 can be timed variableally according to the flow rate of the first fluid, thereby cutting the sheared fluid component into a programmed size or length.

[0092] Figure 18 Another device 300 for mixing, shearing and homogenizing fluids within pipes 18 and 20 is shown. Figure 18 The device 300 is basically the same as Figure 17 The device is similar to 200, except that, Figure 18 The device 300 has a multiphysics fluid transport device 302 instead of a swirl vane 30 for transporting a second fluid. The multiphysics fluid transport device 302 can be used to transport the second fluid into the first fluid. Figure 18 In the illustrated embodiment, the second fluid includes multiple fluids, at least one of which may be a pressurized gas. If desired, the multiphysics fluid delivery device 302 may be one or more multiphysics fluid delivery devices shown and described in U.S. Patent No. 9,982,643, published May 29, 2018.

[0093] Combination Figure 17 and Figure 18 An example of the coaxial mixer 700 used in the mixing-shearing devices 200 and 300 is shown in Figure 22 As shown in the diagram, the coaxial mixer 700 has an inner blade ring 702 and a coaxial outer blade ring 704. The blade rings 702 and 704 are aligned with each other and are substantially coplanar, such that they lie approximately or exactly in the same common plane. The inner blade ring 702 has a cylindrical inner surface 706 and outwardly guiding blades 708. The outer blade ring 704 has a cylindrical outer surface 710 and inwardly guiding blades 712. The blades 708 and 712 shown in the diagram may have the following characteristics: Figure 19 It is constructed in an airfoil shape as shown, and can be constructed as a winglet.

[0094] The diameter of the cylindrical surface 706 of the inner blade ring 702 is the same as that of the motor 204. Figure 17 and Figure 18 The outer diameter of the outer surface is substantially the same. The cylindrical surface 706 is fitted to and connected to the outer surface of the motor 204. The diameter of the cylindrical surface 710 of the outer blade ring 704 is approximately the same as the inner diameter surrounding the motor within the system. Figure 17 and Figure 18They are essentially the same. The outer cylindrical surface 710 is fitted to and connected to the inner surface 44 of the system. During shearing and mixing operations, the interaction between the inner blade ring 702 and the outer blade ring 704 promotes thorough and efficient mixing of the second fluid into the first fluid.

[0095] This disclosure should not be limited to the features of the examples described herein, unless such features are referred to in the following claims.

Claims

1. A method for mixing a second fluid into a first fluid to achieve high surface contact between the first fluid and the second fluid, wherein, The first fluid is a liquid, characterized in that the method comprises: The first fluid flows into the mixing device in a laminar flow state; The first fluid is swirled within the mixing device; The second fluid is brought into contact with the first fluid; and Subsequently, the mixture of the first fluid and the second fluid is allowed to flow through a disc-shaped device with a parabolic scallop-shaped fluid focusing mechanism and out into a Venturi tube containing a Venturi regulator, so that the first fluid and the second fluid are further mixed.

2. The method according to claim 1, characterized in that, The first fluid is the bulk fluid.

3. The method according to claim 1, characterized in that, The second fluid is a prebiotic or reactant used to treat the first fluid.

4. The method according to claim 1, characterized in that, The mixture of the first fluid and the second fluid contains more of the first fluid than the second fluid.

5. The method according to claim 1, characterized in that, The mixing device is located within the fluid delivery system.

6. The method according to claim 1, characterized in that, The swirling of the first fluid is achieved by radially arranged aerodynamic blades.

7. The method according to claim 6, characterized in that, The second fluid flows through an opening in the upstream surface of the aerodynamic blade to form a film on the blade, thereby promoting the mixing of the second fluid into the first fluid.

8. The method according to claim 6, characterized in that, The second fluid flows through an opening at the leading or trailing edge of the blade.

9. An apparatus for mixing a second fluid into a first fluid to achieve a high surface contact between the first fluid and the second fluid, wherein, The first fluid is a liquid, characterized in that the device comprises: An inlet is provided to allow the first fluid to flow into the mixing device in a laminar flow state. A swirling device for causing the first fluid to swirl within the mixing apparatus; A flow channel, located within the swirling device, is used to bring the second fluid into contact with the first fluid; and A parabolic scallop-shaped disc device, located downstream of the vortex device, has an adjustable venturi outlet for further mixing of the first and second fluids.

10. The apparatus according to claim 9, characterized in that, The device is configured to operate within a fluid delivery system.

11. The apparatus according to claim 9, characterized in that, The swirling device includes radially arranged aerodynamic blades.

12. The apparatus according to claim 11, characterized in that, The blade has an upstream surface and an opening in the upstream surface for the second fluid to form a film on the upstream surface of the blade, thereby providing full surface area contact.

13. The apparatus according to claim 12, characterized in that, The openings are spaced apart from each other and diagonally aligned, such that each opening is aligned with a different streamline of the first fluid across the upstream surface of the blade, thereby improving the distribution of the second fluid into the first fluid.

14. The apparatus according to claim 11, characterized in that, The blade includes a leading edge and a trailing edge, and an opening located at the leading edge or the trailing edge for the second fluid.

15. The apparatus according to claim 9, characterized in that, It also includes one or more intermediate swirl plates located between the swirl device and the parabolic scallop-shaped disc device.

16. A method for mixing a second fluid into a first fluid to achieve high surface contact between the first fluid and the second fluid, wherein, The first fluid is a liquid, characterized in that the method comprises: The first fluid flows into the mixing device in a laminar flow state; Make the second fluid contact the entire surface of the first fluid; Subsequently, the material is rotated and sheared in a mixture of the first and second fluids; and Shearing rotation is performed with variable timing to provide programmable and precise laminar filament size or length.

17. The method according to claim 16, characterized in that, The second fluid is a prebiotic or reactant used to treat the first fluid.

18. The method according to claim 16, characterized in that, The second fluid is introduced into the first fluid through an aerodynamic swirl vane assembly.

19. The method according to claim 16, characterized in that, The second fluid includes pressurized gas and at least one other fluid, and the second fluid is introduced into the first fluid via a multiphysics fluid delivery device.

20. An apparatus for mixing a second fluid into a first fluid, wherein, The first fluid is a liquid, characterized in that the device comprises: An inlet is provided to allow the first fluid to flow into the device in a laminar flow state. Flow channels, for bringing the second fluid into contact with the first fluid; and A rotatable shearing device for shearing material in a mixture of the first fluid and the second fluid.

21. The apparatus according to claim 20, characterized in that, The shearing device includes a variable-speed rotatable shear for shearing the material in the mixture of the first fluid and the second fluid into a programmed size or length.

22. The apparatus according to claim 21, characterized in that, It also includes a motor for rotating the shear, the motor being located downstream of the flow channel for contacting the second fluid with the first fluid.

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