A static pipe mixer

Abstract

The utility model relates to fluid treatment equipment technical field especially relates to a static pipeline mixer, it includes: main pipe and branch pipe, main pipe includes: injection reinforcement section and spiral disturbance mixing section, injection reinforcement section includes the first section, second section and third section that set up in proper order, the pipe diameter of second section is less than the pipe diameter of first section, the pipe diameter of first section to second section gradually becomes small, the pipe diameter of third section is greater than the pipe diameter of second section, the pipe diameter of second section to third section gradually becomes big, spiral disturbance mixing section is connected in the downstream of third section, is provided with central shaft in spiral disturbance mixing section, is provided with spiral blade on central shaft, multiple spiral disturbance mixing sections are sequentially arranged along the axial direction, the spiral direction of spiral blade in adjacent spiral disturbance mixing sections is opposite, is provided with ceramic lining on the inner wall of main pipe, branch pipe is connected on second section or first section, adopts the utility model can realize to the efficient, depth mixing of complex fluid, improves the wear resistance, prolongs the life.

Description

Technical Field

[0001] This utility model relates to the field of fluid processing equipment technology, and in particular to a static pipeline mixer. Background Technology

[0002] Static inline mixer technology emerged in the 1970s, modifying fluid flow states through fixed mixing units; achieving fluid segmentation, displacement, and recombination in laminar flow; and enhancing mixing through vortices in turbulent flow. Currently, various models such as SV and SK are available, suitable for viscosity ranges ≤10. 6 Centipoise liquid-liquid and gas-liquid mixing scenarios are widely used in chemical, food, environmental protection, pharmaceutical and new energy fields.

[0003] Existing technologies are mainly divided into two categories: 1. Helical mixers, which mix fluids by setting helical blades inside the pipe to induce a "stretching-folding" process. However, they have significant drawbacks: Mixing efficiency bottleneck: When handling high-viscosity (>1000 cP) or viscoelastic fluids, it is difficult to disrupt the laminar core in the center of the pipe, forming a mixing dead zone and resulting in unsatisfactory uniformity; High energy consumption: Improving the mixing effect requires increasing the number of components or reducing the pitch, leading to a sharp increase in pressure drop and high pumping energy consumption. 2. Turbulent mixers, which promote mixing by generating turbulence through guide plates, but have limitations: Insufficient mixing: Insufficient mass exchange between the symmetrical vortex regions generated by simple guide plates, low turbulence intensity in the central region, and easy occurrence of localized uneven mixing; Poor adaptability: The mixing effect is sensitive to flow velocity, and performance drops sharply at low flow velocities. The common drawback of both types of mixers is wear: when processing fluids containing hard particles (such as slurry or catalyst) or corrosive fluids in mining, chemical and other scenarios, metal materials (such as 304 / 316L stainless steel) or PTFE liners are easily corroded by high-speed erosion, resulting in rapid wear of critical parts (front surface, elbows), shortening equipment life; frequent shutdowns for replacement increase maintenance costs; and wear products may contaminate the product.

[0004] Therefore, there is an urgent need to develop a static pipeline mixer that combines high-efficiency mixing, low energy consumption, and ultra-strong wear resistance to solve the comprehensive technical challenges of mixing high-viscosity, high-solids-content, and highly abrasive fluids. Utility Model Content

[0005] In view of this, the present invention provides a static pipeline mixer, the main purpose of which is to achieve efficient and deep mixing of high viscosity, high solid content and highly abrasive fluids, improve wear resistance and extend service life.

[0006] To achieve the above objectives, this utility model mainly provides the following technical solutions:

[0007] An embodiment of this utility model provides a static pipe mixer, comprising: a main pipe and branch pipes;

[0008] The main tube includes: a jet enhancement section and a spiral turbulence mixing section;

[0009] The spray enhancement section includes a first section, a second section, and a third section arranged sequentially.

[0010] The diameter of the second section is smaller than the diameter of the first section;

[0011] The pipe diameter gradually decreases from the first section to the second section;

[0012] The diameter of the third section is larger than that of the second section;

[0013] The diameter of the pipe gradually increases from the second section to the third section;

[0014] The spiral turbulence mixing section is connected downstream of the third section; a central shaft is fixedly provided inside the spiral turbulence mixing section; the central shaft is fixed to the inner wall of the spiral turbulence mixing section by a connecting rod;

[0015] Helical blades are provided on the central shaft;

[0016] The spiral turbulence mixing section is multiple; the multiple spiral turbulence mixing sections are arranged sequentially along the axial direction; the spiral blades in adjacent spiral turbulence mixing sections have opposite rotation directions and their installation angles are staggered by 90 degrees.

[0017] The inner wall of the main tube is lined with a ceramic lining;

[0018] The branch pipe is connected to the second section or the first section;

[0019] The branch pipe is a Laval nozzle structure.

[0020] Furthermore, the branch pipe is tangentially connected to the second segment.

[0021] Furthermore, the torsion angle of the helical blades in the upstream helical turbulence mixing section is greater than the torsion angle of the helical blades in the downstream helical turbulence mixing section.

[0022] Furthermore, the torsion angle of the helical blades in the upstream helical turbulence mixing section is 180°;

[0023] The twist angle of the helical blades in the downstream helical turbulence mixing section is 120° or 90°.

[0024] Furthermore, a baffle rod is fixedly mounted on the central shaft;

[0025] The spoiler bar is located between adjacent helical blades.

[0026] Furthermore, the length of the spoiler bar is 1 / 4 to 1 / 2 of the inner diameter of the main pipe.

[0027] Furthermore, there is a gap between the outer edge of the helical blade and the ceramic liner.

[0028] Furthermore, the gap is 1-2 mm.

[0029] Furthermore, the thickness of the ceramic liner is 4mm to 25mm.

[0030] Furthermore, the ceramic lining is corundum ceramic composite on the inner wall of the main tube.

[0031] By employing the above technical solution, the static pipeline mixer of this utility model has at least the following advantages:

[0032] It can achieve efficient and deep mixing of high-viscosity, high-solids-content, and highly abrasive fluids, thereby improving wear resistance and extending service life.

[0033] The above description is only an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, the preferred embodiments of this utility model are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0034] Figure 1 A schematic diagram of a static pipe mixer provided for an embodiment of this utility model;

[0035] Figure 2 This is a schematic diagram showing the connection between the baffle rod and the central shaft in a static pipe mixer provided as an embodiment of the present invention.

[0036] As shown in the figure:

[0037] 1 is the main pipe, 1-1 is the first section, 1-2 is the second section, 1-3 is the third section, 1-4 is the spiral turbulence mixing section, 2 is the branch pipe, 3 is the central shaft, 4 is the turbulence rod, and 5 is the spiral blade. Detailed Implementation

[0038] To further illustrate the technical means and effects adopted by this utility model to achieve its intended purpose, the specific implementation methods, structures, features, and effects according to this utility model application are described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "embodiments" or "embodiments" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0039] like Figure 1As shown, an embodiment of this utility model proposes a static pipe mixer, comprising: a main pipe 1 and a branch pipe 2; the main pipe 1 includes: a jet enhancement section and a spiral turbulence mixing section 1-4; the jet enhancement section includes a first section 1-1, a second section 1-2, and a third section 1-3 arranged sequentially; the first section 1-1, the second section 1-2, and the third section 1-3 are arranged coaxially in sequence; the diameter of the second section 1-2 is smaller than the diameter of the first section 1-1; the diameter of the first section 1-1 to the second section 1-2 gradually decreases; the diameter of the third section 1-3 is larger than the diameter of the second section 1-2; the diameter of the second section 1-2 to the third section 1-3 gradually increases; the pipe inner diameter ratio of the first section 1-1: second section 1-2: third section 1-3 can be 1.2:1:1.5; the first section 1-1, the second section 1-2, and the third section 1-3 form a Venturi tube structure. The third section 1-3 is integrally formed with the spiral turbulence mixing section 1-4.

[0040] The spiral turbulence mixing section 1-4 is connected downstream of the third section 1-3; a central shaft 3 is fixedly installed inside the spiral turbulence mixing section 1-4; the central shaft 3 is fixed to the inner wall of the spiral turbulence mixing section 1-4 by a connecting rod; a spiral blade 5 is installed on the central shaft 3; multiple spiral blades 5 are installed on a single spiral turbulence mixing section 1-4; 2 to 4 can be selected.

[0041] There are multiple spiral turbulence mixing sections 1-4; multiple spiral turbulence mixing sections 1-4 are arranged sequentially along the axial direction; the spiral blades 5 in adjacent spiral turbulence mixing sections 1-4 have opposite rotation directions and their installation angles are staggered by 90 degrees.

[0042] Main pipe 1 is a pressure-bearing metal pipe; it can be made of 304 or 316L stainless steel to provide sufficient mechanical strength and toughness to withstand pipeline pressure.

[0043] The inner wall of the main pipe 1 is lined with a ceramic lining to ensure long-term stable operation under harsh conditions. Preferably, the thickness of the ceramic lining is 4mm to 25mm. Of course, other thicknesses can be selected according to the nominal diameter of the pipe and the degree of wear under operating conditions. Preferably, the ceramic lining is corundum ceramic composite on the inner wall of the main pipe 1.

[0044] The inner wall of the main pipe 1 can be firmly bonded with a single, seamless, high-purity alumina (Al2O3) ceramic liner using advanced manufacturing processes. This bonding technology can be either self-propagating high-temperature synthesis (SHS) or special ceramic adhesive bonding and sintering technology, ensuring a tight bond between the ceramic layer and the metal shell, preventing detachment. Key parameters and characteristics: The ceramic liner is preferably made of corundum ceramic with an α-Al2O3 content of not less than 92%. This ceramic material has extremely high hardness, with a Rockwell hardness exceeding HRA90, far surpassing various metal materials, thus possessing unparalleled wear resistance. Simultaneously, it also exhibits excellent chemical stability and corrosion resistance, resisting the erosion of various chemical media such as acids and alkalis; its temperature resistance is also excellent, allowing for long-term stable operation within a wide temperature range of -50℃ to 900℃. The ceramic liner material can also be selected from silicon carbide (SiC) or zirconium oxide (ZrO2).

[0045] Branch pipe 2 connects to the second section 1-2 or the first section 1-1. Branch pipe 2 is tangentially connected to the second section 1-2 and is a Laval nozzle structure. The diameter of the second section 1-2 is a key design parameter, determining the acceleration of the main stream. One, two, or three branch pipes 2 can be installed; multiple branch pipes can also be installed as needed.

[0046] When the main phase fluid (usually a fluid with a large flow rate or high viscosity) flows through the convergence section (section 1-2), its velocity increases sharply, forming a significant low-pressure zone at the throat according to Bernoulli's principle. At this time, the secondary phase fluid (a fluid with a smaller flow rate or to be dispersed) is injected through branch pipe 2. Due to the pressure difference, the secondary phase fluid is drawn in or pumped in at a higher velocity, and violently collides with the accelerating main fluid in the form of a high-speed tangential jet. This design can instantly generate two powerful mixing effects: ① Strong rotating vortex: Tangential injection gives the entire fluid a macroscopic and strong initial rotational momentum. ② Efficient shear breaking: The huge velocity gradient between the main and secondary phases generates a strong shear force, which can effectively break up and disperse larger droplets or clumps. This is completely different from the way fluid smoothly enters the mixing section in traditional mixers; it injects huge mixing energy at the source of mixing.

[0047] The jet-enhanced mixing section utilizes fluid dynamics principles to generate strong macroscopic eddies and high-intensity shear forces at the initial stage of the mixing process, efficiently pre-dispersing the input fluid. The subsequent spiral turbulence mixing sections 1-4 then receive and further process this eddy carrying enormous turbulent kinetic energy. Through their complex internal geometry, they continuously divide, stretch, tumble, and reorganize the fluid, achieving deep and uniform mixing from macroscopic to microscopic levels. One embodiment of this invention proposes a static pipeline mixer that, through the synergistic design of strong eddy premixing technology at the inlet and multi-stage spiral turbulence technology downstream, achieves efficient and deep mixing of complex fluids with high viscosity, high solids content, and strong abrasiveness with low energy consumption. Simultaneously, by employing an integrated composite ceramic lining structure, it fundamentally solves the wear and corrosion problems of the equipment under harsh operating conditions, thereby significantly extending its service life, reducing operating costs, and improving process stability.

[0048] As a preferred embodiment, the torsion angle of the helical blades 5 in the upstream helical turbulence mixing section 1-4 is greater than that in the downstream helical turbulence mixing section 1-4; this utilizes the high turbulent kinetic energy from the inlet section to achieve strong shearing and overturning; while the helical turbulence mixing section 1-4 near the outlet can employ a smaller torsion angle, effectively reducing pressure drop while maintaining mixing effect, thereby optimizing overall energy consumption and balancing mixing effect and pressure loss. More preferably, the torsion angle of the helical blades 5 in the most upstream helical turbulence mixing section 1-4 is 180°; the torsion angle of the helical blades 5 in the most downstream helical turbulence mixing section 1-4 is 120° or 90°, to achieve a better balanced mixing effect.

[0049] As a preferred embodiment of the above, refer to Figure 2 A flow-disrupting rod 4 is fixedly mounted on the central shaft 3; the flow-disrupting rod 4 is welded perpendicular to the central shaft 3. The flow-disrupting rod 4 is located between adjacent spiral blades 5, and its core function is to disrupt and disturb the laminar flow core in the central region of the pipe. In high-viscosity fluids, the fluid in the central region flows fastest and mixes worst due to the lowest shear force. The presence of the flow-disrupting rod 4 forcibly obstructs and disturbs this "lazy" fluid, forcing it to undergo radial exchange with the well-mixed fluid near the pipe wall, thereby completely eliminating dead zones and greatly improving the uniformity of mixing. Preferably, the length of the flow-disrupting rod 4 is 1 / 4 to 1 / 2 of the inner diameter of the main pipe 1. More preferably, the length of the flow-disrupting rod 4 is 1 / 3 of the inner diameter of the main pipe 1, which provides a better mixing effect.

[0050] As a preferred embodiment of the above, there is a gap between the outer edge of the helical blade 5 and the ceramic liner. Maintaining a precise and minute gap between the outer edge of the helical blade 5 and the ceramic liner of the tube ensures that the boundary layer fluid near the tube wall can be effectively "scraped" and overturned when the fluid flows through the blade, further enhancing radial mixing and preventing material deposition on the tube wall. More preferably, a gap of 1-2 mm is even better.

[0051] One embodiment of this utility model proposes a static pipeline mixer suitable for handling high-viscosity, solid particle-containing, easily abrasive, or corrosive fluids.

[0052] Working principle and process breakdown description:

[0053] Phase 1: Eddy Premixing and Initial Breakup

[0054] The main phase fluid A (such as a high-viscosity polymer melt) enters through the main pipe 1 and flows through the jet-enhanced section. In the second section 1-2, fluid A is accelerated, its kinetic energy increases, and its pressure decreases. Simultaneously, the secondary phase fluid B (such as a low-viscosity additive) is injected through the branch pipe 2 in the form of a high-speed jet. Due to the tangential velocity and the significant velocity difference between the two fluids and the main fluid A, the two fluids collide and shear violently near the throat of the jet-enhanced section, instantly forming a macroscopic, intense, overall rotating vortex. During this stage, fluid B is initially broken into smaller droplets and coarsely entrained into fluid A, completing efficient premixing.

[0055] Phase Two: Multi-level Deep Mixing and Refinement

[0056] The mixed fluid, carrying enormous eddy energy and a preliminary dispersed phase, enters at high speed into the multi-stage spiral turbulence mixing sections 1-4. Here, the mixing process is further deepened and refined:

[0057] Segmentation and Radial Mixing: When the fluid encounters the first left-handed helical blade 5, it is split into two streams and forced to rotate 180° (or other predetermined angle) along the helical surface. During this process, the fluid on the pipe wall is pushed towards the center, while the fluid in the center is thrown towards the pipe wall. Immediately afterwards, the fluid enters the next right-handed blade, where it is again split and rotated in the opposite direction. This process repeats, with the number of fluid layers increasing exponentially from 2 to the power of N (where N is the number of components), achieving the classic "stretch-fold" radial mixing.

[0058] Central enhanced disturbance: In the gap between the fluid and the next blade, the fluid located at the center of the flow field, which was originally the least mixed, will directly impact the vertically installed disturbance rod 4. This impact forcibly breaks the laminar flow state in the central region, generates local small-scale eddies, and forces the central fluid to diffuse outwards, engaging in a violent exchange of matter and energy with the already fully mixed surrounding fluid, effectively eliminating mixing dead zones.

[0059] Differentiated processing: In the upstream spiral turbulence mixing section 1-4, due to the still high fluid kinetic energy, the blades with large torsion angles provide strong shear force, further refining the dispersed phase. In the downstream spiral turbulence mixing section 1-4, the fluid gradually becomes more homogeneous, and the blades with small torsion angles maintain the mixing state while reducing unnecessary energy loss.

[0060] Phase 3: Homogenized Output and Wear-Resistant Protection

[0061] Through the synergistic effect of multiple spiral turbulence mixing sections 1-4, the fluid achieves a high degree of homogenization in concentration, temperature, and velocity across the entire cross-section of the pipe. Finally, the homogeneous mixture is discharged from the mixer outlet. It is worth emphasizing that the entire vigorous mixing process—including the impact of the high-speed jet, the scouring of the blades and turbulence bar 4 by the fluid, and the abrasion of any hard particles that may be entrained—acts on the hard alumina ceramic liner. The ceramic liner, with its superior wear resistance, protects the internal structure and pipe body of the mixer, ensuring long-term, reliable operation of the entire unit even in the harshest industrial environments.

[0062] Example 1: Mixing of high-viscosity polymer melt with additives

[0063] Structural parameter settings: A wear-resistant vortex-enhanced static pipe mixer with a nominal diameter of DN50 is selected. Its integrated wear-resistant ceramic-lined pipe body (1) has an outer shell of 316L stainless steel and an inner lining of 92% Al2O3 ceramic with a thickness of 5mm. The second section 1-2 of the spray-enhanced section is designed with a diameter of 25mm and is equipped with a G1 / 2" tangential support. The multi-stage spiral turbulence mixing section 1-4 has a total length of 500mm and contains 4 mixing units. Among them, the spiral blades 5 of the first 2 units have a twist angle of 180°, and the twist angle of the last 2 units is 120°. On the central shaft 3, 4 turbulence rods 4 with a diameter of 5mm are evenly welded between every two mixing units.

[0064] Operating conditions and results: Polymer A with a viscosity of 50,000 cP was used as the main phase fluid, and the flow rate was 10 m... 3 A flow rate of / h is pumped into main pipe 1. Simultaneously, liquid additive B with a viscosity of 100 cP is used as the secondary phase fluid, pumped at a rate of 0.1 m... 3A flow rate of / h (volume ratio 100:1) is pumped in through branch pipe 2. The total pressure drop at the mixer outlet is 0.5MPa. Continuous sampling is performed at a pipe diameter twice downstream of the mixer outlet, and the concentration distribution of additive B is detected by colorimetric analysis. The calculated mixing non-uniformity coefficient (COV) is <3%, indicating that the mixture has achieved a high degree of homogeneity. In contrast, using a conventional Kenics KM type mixer (6 180° torsion units) with the same pipe diameter and length, under similar pressure drop, its outlet COV value is still around 15%, and there are obvious streaks of unmixed material in the central area.

[0065] Example 2: Mixing of flocculants in slurry of a chemical plant

[0066] Structural parameter settings: To meet the high flow rate requirements, a mixer with a nominal diameter of DN200 was selected. Its main pipe 1 has a shell made of Q235 carbon steel, and to cope with severe wear, the inner lining thickness is increased to 15mm with 95% Al2O3 ceramic. The throat diameter of the jet-enhanced section is 120mm. The multi-stage spiral turbulence mixing sections 1-4 contain 6 mixing units. Considering the fluidity of the slurry, all spiral blades 5 adopt a uniform twist angle of 150° to obtain better flowability and moderate pressure drop. A turbulence bar 4 is also installed on the central shaft 3 to prevent particle settling and short-circuiting in the central area.

[0067] Operating conditions and results: A highly abrasive slurry containing 30% solid particles (Mohs hardness approximately 6-7) was processed at a flow rate of 150 m³ / h. 3 / h. The flocculant solution is injected through main pipe 1 to promote subsequent sedimentation and separation. The mixer of the present invention is operated in parallel with an ordinary carbon steel inner wall SK type mixer of the same pipe diameter. After continuous operation for 6 months (approximately 4320 hours), the machine is shut down for inspection. The results show that the surface of the ceramic liner of the present invention is smooth, with no visible wear marks, only slight scratches; while the carbon steel mixer operating in parallel has severe erosion pits on the leading edge of the internal blades and the pipe wall, with local thinning exceeding 5mm, reaching the scrap standard and requiring shutdown and replacement. This embodiment strongly demonstrates the great advantage of the present invention in terms of wear resistance.

[0068] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0069] All standard parts used in this utility model can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here.

[0070] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A static pipe mixer, characterized in that, Includes: supervisors and branch managers; The main tube includes: a jet enhancement section and a spiral turbulence mixing section; The spray enhancement section includes a first section, a second section, and a third section arranged sequentially. The diameter of the second section is smaller than the diameter of the first section; The pipe diameter gradually decreases from the first section to the second section; The diameter of the third section is larger than that of the second section; The diameter of the pipe gradually increases from the second section to the third section; The spiral turbulence mixing section is connected downstream of the third section; a central shaft is fixedly provided inside the spiral turbulence mixing section; the central shaft is fixed to the inner wall of the spiral turbulence mixing section by a connecting rod; Helical blades are provided on the central shaft; The spiral turbulence mixing section is multiple; the multiple spiral turbulence mixing sections are arranged sequentially along the axial direction; the spiral blades in adjacent spiral turbulence mixing sections have opposite rotation directions and their installation angles are staggered by 90 degrees. The inner wall of the main tube is lined with a ceramic lining; The branch pipe is connected to the second section or the first section; The branch pipe is a Laval nozzle structure.

2. The static pipe mixer according to claim 1, characterized in that, The branch pipe is tangentially connected to the second section.

3. The static pipe mixer according to claim 1, characterized in that, The torsion angle of the helical blades in the upstream helical turbulence mixing section is greater than that of the helical blades in the downstream helical turbulence mixing section.

4. The static pipe mixer according to claim 3, characterized in that, The torsion angle of the helical blades in the upstream helical turbulence mixing section is 180°; The twist angle of the helical blades in the downstream helical turbulence mixing section is 120° or 90°.

5. The static pipe mixer according to claim 1, characterized in that, A baffle rod is fixedly mounted on the central shaft; The spoiler bar is located between adjacent helical blades.

6. The static pipe mixer according to claim 5, characterized in that, The length of the spoiler bar is 1 / 4 to 1 / 2 of the inner diameter of the main pipe.

7. The static pipe mixer according to claim 1, characterized in that, There is a gap between the outer edge of the helical blade and the ceramic liner.

8. The static pipe mixer according to claim 7, characterized in that, The gap is 1-2 mm.

9. The static pipe mixer according to claim 1, characterized in that, The thickness of the ceramic liner is 4mm to 25mm.

10. The static pipe mixer according to claim 9, characterized in that, The ceramic lining is corundum ceramic composite on the inner wall of the main tube.

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