A high-efficiency temperature-controlled inner-outer helical static mixing reactor and a mixing method thereof

Abstract

The application discloses a high-efficiency temperature-controllable inner-outer helical static mixing reactor and a mixing method thereof, and belongs to the technical field of gas-liquid mixing heat transfer. The mixing reactor comprises a cylinder body, a reaction tube is arranged in the cylinder body, an inlet and an outlet are arranged on the cylinder body, a plurality of feeding pipes for feeding gas or liquid are arranged at one end of the reaction tube, a discharging pipe is arranged at the other end of the reaction tube and is connected in a closed mode through a helical end cover, outer helical fins are arranged on the outer wall of the reaction tube, inner helical turbulent fins are arranged in the reaction tube, and the two ends of the inner helical turbulent fins are fixedly connected with the reaction tube through first and second positioning sleeves respectively. The high-efficiency temperature-controllable inner-outer helical static mixing reactor and the mixing method thereof solve the technical problems of the single mixing mechanism, the low turbulent intensity and mass transfer efficiency, the slow temperature regulation response and the local overheating, the separation of the mixing and heat exchange functions, the low integration degree, the large volume and the high energy consumption of the traditional fluid static mixing reactor.

Description

Technical Field

[0001] This invention relates to the field of gas-liquid mixing and heat transfer technology, and in particular to a high-efficiency temperature-controlled internal and external spiral static mixing reactor and its mixing method. Background Technology

[0002] Gas-liquid two-phase reaction processes are widely used in fine chemicals, environmental engineering, and energy conversion. These processes require high levels of fluid mixing uniformity and precise reaction temperature control, which directly affect reaction efficiency, product selectivity, and equipment operational safety. Current static mixing devices typically rely on a single structural form; however, these structures generally suffer from a limited mixing mechanism and turbulence intensity. In gas-liquid systems with short residence times or significant differences in physical properties, achieving sufficient contact and efficient mass transfer is difficult, thus limiting reaction efficiency.

[0003] On the other hand, given the exothermic or endothermic behavior commonly observed in gas-liquid reactions, existing static mixers often employ external heat exchange equipment or simple jacket structures for temperature control. These methods result in long heat transfer paths and potential temperature response lag, leading to problems such as localized overheating or overcooling. This not only reduces the stability of the reaction process but may also trigger side reactions and even safety risks.

[0004] Furthermore, traditional mixing and heat exchange functions are typically independent, resulting in dispersed device structures and low system integration. This leads to large equipment size and high energy consumption, making it difficult to meet the current development requirements for process intensification and compact design. Therefore, developing a novel static mixer structure capable of achieving efficient mixing and rapid temperature control of various fluids synergistically within a single device will help solve the aforementioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to provide a high-efficiency temperature-controlled internal and external spiral static mixing reactor and its mixing method, which solves the technical problems of traditional fluid static mixers, such as simple mixing mechanism, low turbulence intensity and mass transfer efficiency, slow temperature control response and easy local overheating, and separation of mixing and heat exchange functions, resulting in low device integration, large size and high energy consumption.

[0006] To achieve the above objectives, the present invention provides a high-efficiency temperature-controlled internal and external spiral static mixing reactor, comprising a cylindrical body, a reaction tube disposed within the cylindrical body, an inlet and an outlet disposed on the cylindrical body, a plurality of feed pipes for gas or liquid feeding disposed at one end of the reaction tube, and a discharge pipe disposed at the other end of the reaction tube and sealed by a spiral end cap, an outer spiral fin disposed on the outer wall of the reaction tube, and an inner spiral turbulent fin disposed inside the reaction tube, the two ends of the inner spiral turbulent fin being fixedly connected to the reaction tube by a first positioning sleeve and a second positioning sleeve, respectively.

[0007] Preferably, the feed pipe has a feed port at the end away from the reaction pipe, and multiple feed ports are arranged in different directions. Multiple feed pipes are connected and converged into one inlet pipe to form an impinging flow for preliminary mixing of gas and gas, gas and liquid, or liquid and liquid before entering the reaction pipe.

[0008] Preferably, the internal spiral turbulence fins are spirally distributed along the axial direction of the reaction tube to enhance fluid turbulence and achieve efficient mass transfer. The spiral structure of the internal spiral turbulence fins adopts a forward spiral, a reverse spiral, or a combination of forward and reverse spirals.

[0009] Preferably, the outer spiral fins are spirally arranged along the outer wall of the reaction tube to increase the heat transfer area.

[0010] Preferably, the inner spiral turbulence fins are connected to the reaction tube via a first positioning sleeve and a second positioning sleeve. The two ends of the inner spiral turbulence fins are fixedly connected to one end of the first positioning sleeve and one end of the second positioning sleeve, respectively. The other end of the first positioning sleeve is fixedly connected to the inside of the reaction tube, and the other end of the second positioning sleeve is fixedly connected to the inside of the reaction tube. A nozzle is provided inside the first positioning sleeve. The inlet tube is inserted into the first positioning sleeve and communicates with the nozzle. The nozzle is used to remix the initially mixed fluid.

[0011] Preferably, the second positioning sleeve has a hollow opening that connects to one end of the discharge pipe, and the other end of the discharge pipe has a discharge port.

[0012] Preferably, the spiral end cap is connected to the end of the reaction tube by a thread.

[0013] Preferably, the inlet and outlet are respectively located at both ends of the cylinder, and the space between the cylinder and the reaction tube is the heat transfer space. The inlet and outlet are used for the heat transfer medium to enter or exit the heat transfer space, and the flow direction of the heat transfer medium in the cylinder is opposite to the flow direction of the fluid in the reaction tube.

[0014] Preferably, the reaction tube is completely immersed in the heat transfer medium inside the cylinder.

[0015] This invention also provides a mixing method for a high-efficiency temperature-controlled internal and external spiral static mixing reactor, comprising the following steps: the gases to be mixed, gas and liquid, or liquid and liquid enter the reactor tube from feed pipes in different directions, respectively. Initial mixing occurs as the feeds from different directions first aggregate to form impinging flows, and then secondary mixing occurs as they enter the reactor tube again, forming impinging flows. The mixed fluid enters the reactor tube axially under the action of a driving force, and turbulence is generated and splitting occurs under the shearing action of the inner spiral turbulent fins. Simultaneously, the heat transfer medium enters the cylinder from the inlet, and the outer spiral fins increase the contact area of ​​the heat transfer medium. The heat transfer medium exits from the outlet, forming a counter-current flow with the mixed fluid in the reactor tube, achieving rapid heat exchange and thus controlling the temperature of the mixing process. The mixed fluid is then discharged from the outlet of the reactor tube.

[0016] The advantages and positive effects of the high-efficiency temperature-controlled internal and external spiral static mixing reactor and its mixing method described in this invention are as follows: This invention features a rational structure and scientific design. The inner spiral turbulence fins effectively enhance internal turbulence and reduce boundary layer thickness, while the outer spiral fins increase the external heat exchange area. Together, they create a synergistic effect that enhances heat exchange and mixing, significantly improving mixing efficiency and strengthening the fluid mass transfer process. Furthermore, the combination of the outer spiral fins and immersion heat exchange effectively improves heat transfer efficiency, enabling rapid temperature control during the reaction process and preventing localized overheating. In addition, the inner spiral turbulence fins are detachable for easy cleaning and maintenance. The overall device is compact, operates stably, and has significant engineering application value.

[0017] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of an embodiment of a high-efficiency temperature-controlled internal and external spiral static mixing reactor according to the present invention; Figure 2 This is a schematic diagram of the overall structure of the discharge port side of an embodiment of the high-efficiency temperature-controlled internal and external spiral static mixing reactor of the present invention; Figure 3 This is a schematic diagram of the internal structure of the cylindrical body of an embodiment of a high-efficiency temperature-controlled internal and external spiral static mixing reactor according to the present invention; Figure 4 This is a schematic diagram of the external structure of the reaction tube in an embodiment of a high-efficiency temperature-controlled internal and external spiral static mixing reactor according to the present invention; Figure 5 This is a schematic diagram of the internal structure of the reaction tube in an embodiment of a high-efficiency temperature-controlled internal and external spiral static mixing reactor according to the present invention; Figure 6 This is a schematic diagram of the internal spiral turbulent fin structure of an embodiment of the high-efficiency temperature-controlled internal and external spiral static mixing reactor of the present invention; Figure 7 This is a schematic diagram of the alternating positive and negative spiral structure of the inner spiral turbulent fins in an embodiment of the present invention, which is a high-efficiency temperature-controlled inner and outer spiral static mixing reactor.

[0019] Figure label: 1. Gas feed pipe; 2. Liquid feed pipe; 3. First positioning sleeve; 4. Outer spiral fins; 5. Discharge pipe; 6. Second positioning sleeve; 7. Spiral end cap; 8. Cylinder body; 9. Inner spiral turbulence fins; 10. Inlet; 11. Outlet; 12. Reaction tube; 13. Nozzle; 14. Inlet pipe. Detailed Implementation

[0020] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. They are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] In this application, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. In case of any inconsistency, the meaning set forth in this specification or derived from the content described herein shall prevail. Furthermore, the terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit the scope of this application.

[0022] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0023] Example: like Figure 1 , Figure 2 As shown, the present invention discloses a high-efficiency temperature-controlled internal and external spiral static mixing reactor, comprising a cylindrical body 8, a reaction tube 12 disposed inside the cylindrical body 8, and an inlet 10 and an outlet 11 disposed on the cylindrical body 8. Multiple support frames are disposed below the cylindrical body 8 to support and stabilize the entire device.

[0024] like Figure 3 As shown, the space between the outer wall of the reaction tube 12 and the inner wall of the cylinder 8 forms a heat transfer space for accommodating the heat transfer medium (condensate in this embodiment), thereby achieving immersion heat exchange of the reaction tube 12. The inlet 10 and outlet 11 are respectively located at both ends of the cylinder 8, and are used for the heat transfer medium to enter or exit the heat transfer space. The flow direction of the heat transfer medium within the cylinder 8 is opposite to the flow direction of the fluid within the reaction tube 12. The heat transfer medium can be hot oil, hot steam, hot water, or condensate, etc.

[0025] In this embodiment, one end of the reaction tube 12 is provided with a gas feed pipe 1 and a liquid feed pipe 2 (one end of the reaction tube 12 is closed, one end of the gas feed pipe 1 and the liquid feed pipe 2 are connected to the reaction tube 12, and the other end extends out of the cylinder 8 and is sealed to the cylinder 8). The other end of the reaction tube 12 is provided with a discharge pipe 5 and is sealed to the cylinder 8 by a spiral end cap 7 (the other end of the reaction tube 12 extends out of the cylinder 8 and is sealed to the cylinder 8, and the discharge pipe 5 is located outside the cylinder 8). The spiral end cap 7 is threaded to the end of the reaction tube 12. The gas feed pipe 1 has a gas inlet at the end away from the reaction tube 12, and the liquid feed pipe 2 has a liquid inlet at the end away from the reaction tube 12. The gas inlet and the liquid inlet are arranged in different directions and are connected by the gas feed pipe 1 and the liquid feed pipe 2, respectively. After the gas feed pipe 1 and the liquid feed pipe 2 are connected, they converge into an inlet pipe 14, so that the gas and liquid form an impact flow before entering the reaction tube 12 to initially enhance the mixing effect. Two gas inlets are provided and arranged symmetrically about the central axis of the reaction tube 12, which facilitates the entry of gas into the reaction tube 12 from multiple directions, thereby further enhancing the mixing.

[0026] like Figure 4 As shown, the outer wall of the reaction tube 12 is provided with external spiral fins 4, which are spirally arranged along the outer wall of the reaction tube 12 to increase the heat transfer area. In this embodiment, condensate enters through the inlet 10 of the cylinder 8 and exits through the outlet 11, forming an immersion heat exchange environment inside the cylinder 8. This allows the condensate to flow in the opposite direction to the fluid in the reaction tube 12 within the cylinder 8, achieving countercurrent heat exchange.

[0027] like Figure 5 As shown, an inner spiral turbulence fin 9 is installed inside the reaction tube 12. The inner spiral turbulence fin 9 is a detachable structure, positioned and installed using a first positioning sleeve 3 and a second positioning sleeve 6 to fix it in the reaction tube 12. Both ends of the inner spiral turbulence fin 9 are inserted and fixed to one end of the first positioning sleeve 3 and one end of the second positioning sleeve 6, respectively. The other end of the first positioning sleeve 3 is snapped into the interior of the reaction tube 12, and the other end of the second positioning sleeve 6 is snapped into the interior of the reaction tube 12. A nozzle 13 is installed inside the first positioning sleeve. An inlet pipe 14 is inserted into the first positioning sleeve 3 and communicates with the nozzle 13. The nozzle 13 is used to re-form an impact flow from the initially mixed fluid to achieve secondary mixing. In this embodiment, the inner spiral turbulence fin 9 is installed and fixed using two positioning sleeves, allowing for easy disassembly and connection, facilitating subsequent cleaning and maintenance.

[0028] The inner spiral turbulence fins 9 are spirally distributed along the axial direction of the reaction tube 12 to enhance fluid turbulence and achieve efficient mass transfer. The second positioning sleeve 6 has a hollowed-out opening that connects to one end of the discharge pipe 5, and the other end of the discharge pipe 5 has a discharge port. The mixed fluid formed by gas and liquid enters the inner spiral turbulence fins 9 along the axial direction of the reaction tube 12, enhancing the mixing effect during the propulsion process.

[0029] The inner spiral turbulence fins 9 extend spirally along the central axis of the reaction tube 12 to enhance fluid turbulence and improve mass transfer efficiency. The pitch, spiral angle, and structural width of the inner spiral turbulence fins 9 can be adjusted according to the flow rate, viscosity, and reaction intensity of the reaction system to meet the mixing requirements under different operating conditions. The inner spiral turbulence fins 9 are fixed and limited by the first positioning sleeve 33 and the second positioning sleeve 6, which ensures structural stability and facilitates disassembly, cleaning, and subsequent maintenance.

[0030] like Figure 6 , Figure 7 As shown, the spiral structure of the inner spiral turbulence fin 9 can be arranged in the form of a positive spiral, a negative spiral, or a combination of both. The combination of positive and negative spirals can further enhance the mixing effect. There can be one or more sets of positive and negative spirals. The specific number and length of the spirals are designed according to the actual situation.

[0031] The present invention discloses a mixing method for a high-efficiency temperature-controlled internal and external spiral static mixing reactor: the gas and liquid to be mixed enter the reactor tube 12 through the gas inlet and liquid inlet, respectively. Due to the different inlet directions of the gas and liquid, the two-phase fluids first aggregate through the inlet pipe 14 before entering the reactor tube 1, forming an impinging flow and undergoing preliminary mixing. Upon entering the reactor tube, they again form an impinging flow through the nozzle 13 for secondary mixing. Subsequently, under the action of driving force, the mixed fluid enters the inner spiral turbulent fins 9 along the axial direction of the reactor tube 12. Under the shearing action of the inner spiral turbulent fins 9, turbulence is generated and the mixture is split, further enhancing the mixing process. At the same time, the outer spiral fins 4 increase the contact area with the heat transfer medium and promote heat exchange. Condensate enters the cylinder 8 through the inlet 10 and exits through the outlet 11, forming a countercurrent flow with the mixed fluid in the reactor tube 12, achieving rapid heat exchange and thus enabling rapid temperature control of the mixing process. The mixed fluid is discharged from the outlet at the end of the reactor tube 12.

[0032] In this invention, the fluid can effectively reduce material adhesion under the shearing action of the inner spiral fins 9, effectively ensuring that the material will not adhere to the inner spiral turbulent fins 9 for a long time, thereby avoiding the occurrence of blockage. In addition, the double spiral structure is conducive to enhancing the continuous conveying effect of the fluid and ensuring smooth flow of materials during the mixing process.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-efficiency temperature-controlled internal and external spiral static mixing reactor, characterized in that: The device includes a cylinder, inside which a reaction tube is installed. The cylinder has an inlet and an outlet. One end of the reaction tube has multiple feed pipes for gas or liquid feeding, and the other end of the reaction tube has a discharge pipe that is sealed by a spiral end cap. The outer wall of the reaction tube is provided with outer spiral fins, and the inside of the reaction tube is provided with inner spiral turbulence fins. The two ends of the inner spiral turbulence fins are fixedly connected to the reaction tube by a first positioning sleeve and a second positioning sleeve, respectively.

2. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 1, characterized in that: The feed pipe has a feed port at the end away from the reaction tube. Multiple feed ports are arranged in different directions. Multiple feed pipes are connected and converged into one inlet pipe, which is used to form an impinging flow for preliminary mixing of gas and gas, gas and liquid, or liquid and liquid before entering the reaction tube.

3. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 1, characterized in that: The internal spiral turbulence fins are spirally distributed along the axial direction of the reaction tube to enhance fluid turbulence and achieve efficient mass transfer. The spiral structure of the internal spiral turbulence fins adopts a combination of positive spiral, negative spiral, or alternating positive and negative spiral configurations.

4. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 1, characterized in that: The outer spiral fins are spirally arranged along the outer wall of the reaction tube to increase the heat transfer area.

5. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 2, characterized in that: The inner spiral turbulent fins are connected to the reaction tube through the first positioning sleeve and the second positioning sleeve. The two ends of the inner spiral turbulent fins are fixedly connected to one end of the first positioning sleeve and one end of the second positioning sleeve, respectively. The other end of the first positioning sleeve is fixedly connected to the inside of the reaction tube, and the other end of the second positioning sleeve is fixedly connected to the inside of the reaction tube. A nozzle is provided inside the first positioning sleeve. The inlet pipe is inserted into the first positioning sleeve and communicates with the nozzle. The nozzle is used to re-form the impinging flow of the initially mixed fluid to achieve secondary mixing.

6. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 5, characterized in that: The second positioning sleeve has a hollowed-out opening that connects to one end of the discharge pipe, and the other end of the discharge pipe has a discharge port.

7. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 1, characterized in that: The spiral end cap is connected to the end of the reaction tube by threads.

8. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 1, characterized in that: The inlet and outlet are respectively located at both ends of the cylinder. The space between the cylinder and the reaction tube is the heat transfer space. The inlet and outlet are used for the heat transfer medium to enter or exit the heat transfer space. The flow direction of the heat transfer medium in the cylinder is opposite to the flow direction of the fluid in the reaction tube.

9. The high-efficiency temperature-controlled internal and external spiral static mixing reactor according to claim 8, characterized in that: The reaction tube is completely immersed in the heat transfer medium inside the cylinder.

10. A mixing method for a high-efficiency temperature-controlled internal and external spiral static mixing reactor according to any one of claims 1-9, characterized in that, The steps include: Gases to be mixed, gases to liquids, or liquids to liquids enter the reaction tube from feed pipes in different directions. Initial mixing occurs as the feeds aggregate to form impinging flows upon entering the reaction tube. Further impinging flows then form upon entering the tube, resulting in secondary mixing. The mixed fluids enter the reaction tube axially under driving force, where they are subjected to turbulence and splitting by the shearing action of the inner spiral turbulent fins. Simultaneously, the heat transfer medium enters the tube through the inlet, while the outer spiral fins increase the contact area. The heat transfer medium exits through the outlet, forming a counter-current flow with the mixed fluid inside the reaction tube, achieving rapid heat exchange and thus controlling the temperature during the mixing process. The mixed fluid is then discharged from the outlet of the reaction tube.

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