Horizontal high solid content zigzag helical shear continuous mixing reactor

Abstract

The utility model discloses a horizontal high solid content sawtooth spiral shearing continuous mixing reactor, including the stirring shaft, the reaction cavity and the jacket pipe, the stirring shaft is arranged in the reaction cavity inside, the jacket pipe coaxially is sleeved in the outside of reaction cavity, the both ends of reaction cavity are installed with the feed tray and the discharge tray respectively, the both ends of jacket pipe are fixed in the end face of discharge tray and the end face of feed tray respectively, the both ends of stirring shaft respectively from the middle through -hole of feed tray and the middle through -hole of discharge tray, the end face sealing unit is installed with respectively to the position of stirring shaft being close to two ends, and two end face sealing units are used for respectively to the middle through -hole of feed tray and the middle through -hole of discharge tray are sealed, the segment of stirring shaft is located in the reaction cavity inside and has a plurality of sawtooth protrusions, the utility model discloses can give consideration to mixing efficiency and temperature control when the continuous mixing high solid content material.

Description

Technical Field

[0001] This utility model belongs to the field of chemical equipment technology, and in particular relates to a horizontal high-solids-content sawtooth spiral shearing continuous mixing reactor. Background Technology

[0002] In the chemical production field, especially in continuous mixing operations involving high-solids-content materials, such as coatings manufacturing, polymer synthesis, or pharmaceutical preparations, traditional technologies generally face serious technical bottlenecks. Existing technologies widely employ vertical reactors as the main equipment, whose structural design relies on a central shaft agitator and gravity-driven flow field. However, when processing materials with high solids content (typically slurries or suspensions with a solids content approaching 30%), solid particles tend to deposit at the bottom of the reactor, forming "dead zones" that are difficult for the agitator to reach. This leads to uneven and inefficient overall mixing. Furthermore, temperature control during agitation is also challenging; uneven temperature control within the chamber often causes batch-to-batch instability, such as localized component separation or uneven texture. Therefore, the main technical challenge lies in how to effectively prevent material deposition and achieve overall mixing uniformity during continuous mixing of high-solids-content materials. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide a horizontal high-solids-content sawtooth spiral shear continuous mixing reactor that can balance mixing efficiency and temperature control when continuously mixing high-solids-content materials, in order to address the shortcomings of the prior art.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: a horizontal high-solids-content sawtooth spiral shearing continuous mixing reactor, including a stirring shaft, a reaction chamber, and a jacketed tube; the stirring shaft passes through the inside of the reaction chamber, and the jacketed tube is coaxially fitted on the outside of the reaction chamber; a feed plate and a discharge plate are respectively installed at both ends of the reaction chamber, the feed plate has a feed port communicating with the inside of the reaction chamber, and the discharge plate has a discharge port communicating with the inside of the reaction chamber;

[0005] The two ends of the jacket tube are respectively fixed to the end face of the discharge plate and the end face of the feed plate;

[0006] The two ends of the stirring shaft pass through the middle through hole of the feed plate and the middle through hole of the discharge plate, respectively.

[0007] The stirring shaft is fitted with end face sealing units near both ends, and the two end face sealing units are used to seal the middle through hole of the feed plate and the middle through hole of the discharge plate, respectively.

[0008] In the above-mentioned horizontal high-solids-content sawtooth spiral shearing continuous mixing reactor, a spiral guide plate is provided inside the jacket tube, and the axis of the spiral guide plate is the axis of the reaction chamber.

[0009] In the above-mentioned horizontal high-solids-content sawtooth spiral shearing continuous mixing reactor, the stirring shaft has multiple sawtooth protrusions on the segment located inside the reaction chamber, and the multiple sawtooth protrusions are arranged in a spiral curve or multiple segments are distributed on the stirring shaft.

[0010] The above-mentioned horizontal high-solids-content sawtooth spiral shear continuous mixing reactor has rectangular baffle plates installed on the inner wall of the reaction chamber.

[0011] The above-mentioned horizontal high-solids-content sawtooth spiral shear continuous mixing reactor has a hollow flow channel inside the stirring shaft, which is used for the inflow and outflow of the heating medium.

[0012] In the above-mentioned horizontal high-solids-content sawtooth spiral shear continuous mixing reactor, the hollow flow channel is located inside the segment of the reaction chamber and is equipped with a baffle assembly. The baffle assembly includes multiple baffles connected in sequence, and two adjacent baffles are arranged vertically.

[0013] The aforementioned horizontal high-solids-content sawtooth spiral shear continuous mixing reactor has a media inlet and a media outlet on the jacket tube, which are used for the inflow and outflow of heating media.

[0014] The aforementioned horizontal high-solids-content sawtooth spiral shear continuous mixing reactor is further equipped with a pressure measuring port and a temperature measuring port on the jacket.

[0015] This utility model has the following advantages compared with the prior art:

[0016] 1. The spiral blades on the stirring shaft adopt a serrated design (unlike conventional smooth spiral blades). By enhancing shear force, it can efficiently process materials with high solid content, reduce particle agglomeration, and improve mixing uniformity. Traditional spiral blades mainly rely on axial propulsion and radial diffusion, while the serrated design increases local turbulence and material tearing effect, which is especially suitable for high viscosity and easy sedimentation solid-liquid mixtures (such as mineral slurry and activated carbon desalination liquid).

[0017] 2. The sealing unit is located near the inlet / outlet disc through-holes at both ends of the stirring shaft, rather than a traditional central shaft seal. This design directly isolates the seal from wear caused by high-solids materials, avoiding malfunctions caused by powder leakage from the bottom bearing (a common problem in traditional vertical reactors).

[0018] Combined with mechanical seal technology (such as magnetic seal), it can adapt to high temperature and high pressure conditions (such as 2.5MPa pressure), significantly improving equipment life.

[0019] 3. The jacketed tube is coaxially fitted onto the outside of the reaction chamber, with both ends directly fixed to the inlet / outlet trays, forming a closed heat exchange channel. It supports various heating / cooling methods, including external half-coil, steam, or heat transfer oil, enabling precise control of the reaction temperature. Compared to traditional jackets (such as integral welded jackets), this design reduces the number of welds, lowers the risk of thermal stress deformation, and is suitable for corrosive environments (such as acid leaching slurries).

[0020] The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model.

[0022] Figure 2 for Figure 1 CC section view.

[0023] Figure 3 for Figure 1 DD cross-sectional view.

[0024] Figure 4 for Figure 1 EE cross-sectional view.

[0025] Figure 5 This is a schematic diagram of the stirring shaft.

[0026] Figure 6 This is a schematic diagram of the spoiler assembly.

[0027] Explanation of reference numerals in the attached figures:

[0028] 1—Stirring shaft; 2—Reaction chamber; 3—Jacketed tube;

[0029] 4—Feed tray; 5—Discharge tray; 6—Feed inlet;

[0030] 7—Discharge port; 8—End face sealing unit; 9—Spiral guide plate;

[0031] 10—Serrated protrusion; 11—Rectangular baffle plate; 12—Spoiler assembly;

[0032] 13—Medium inlet; 14—Medium outlet; 15—Pressure test port;

[0033] 16—Temperature measuring port. Detailed Implementation

[0034] like Figure 1 — Figure 6As shown, a horizontal high-solids-content sawtooth spiral shearing continuous mixing reactor includes a stirring shaft 1, a reaction chamber 2, and a jacketed tube 3; the stirring shaft 1 passes through the inside of the reaction chamber 2, and the jacketed tube 3 is coaxially fitted on the outside of the reaction chamber 2; a feed plate 4 and a discharge plate 5 are respectively installed at both ends of the reaction chamber 2, the feed plate 4 has a feed inlet 6 communicating with the inside of the reaction chamber 2, and the discharge plate 5 has a discharge outlet 7 communicating with the inside of the reaction chamber 2;

[0035] The two ends of the jacket tube 3 are respectively fixed to the end face of the discharge plate 5 and the end face of the feed plate 4;

[0036] The two ends of the stirring shaft 1 pass through the middle through hole of the feed plate 4 and the middle through hole of the discharge plate 5, respectively.

[0037] The stirring shaft 1 is fitted with end face sealing units 8 near both ends. The two end face sealing units 8 are used to seal the middle through hole of the feed plate 4 and the middle through hole of the discharge plate 5, respectively.

[0038] By providing a fully sealed horizontal structure, it is suitable for continuous mixing reactions of materials with high solids content (such as chemical slurries containing 25% solid particles). The sealed unit prevents leakage and external contamination, and the horizontal design ensures continuous material flow, avoiding batch interruptions. It fundamentally solves the problems of leakage and low efficiency in the handling of high solids materials, improving production continuity.

[0039] In implementation, the reaction chamber 2 is made of stainless steel cylinder, with a wall thickness calculated based on the working pressure (e.g., 10-20 mm). The jacket tube 3 is a concentric cylinder, welded to the end faces of the feed plate 4 and the discharge plate 5 (the two plates can be connected by flanges). The stirring shaft 1 is a hollow steel shaft, heat-treated to enhance wear resistance, and its diameter is matched to the chamber size (e.g., a 200 mm diameter shaft is suitable for a 500 mm chamber). The end face sealing unit 8 uses a standard mechanical seal (e.g., a spring-loaded lip seal), installed in the gap between the shaft and the through hole of the plate. The diameter of the through hole is slightly larger than the shaft (gap approximately 0.1-0.5 mm), and the seal is pressed and fixed after being inserted.

[0040] During assembly, first fix the reaction chamber 2 on the base, then insert the stirring shaft 1 into the chamber: one end of the shaft passes through the hole in the feed plate 4, and the end face sealing unit 8 is installed (e.g., after applying grease, press in the sealing ring); the other end is treated similarly to the discharge plate 5. The jacket tube 3 is welded or bolted to the plate, keeping it coaxial (deviation <1mm). The material pipeline is connected to the feed port 6, and the discharge port 7 is connected to the collection tank.

[0041] Taking continuous synthetic rubber applications as an example, solid powder and liquid are continuously pumped in through inlet 6 (flow rate adjustable), and stirring shaft 1 rotates at 50-200 RPM, driving the materials to mix within the chamber for 5-10 minutes before flowing out through outlet 7. End-face sealing unit 8 prevents hot oil (if the jacket is heated) or material from overflowing. Technicians can maintain the system by observing the condition of the seals (e.g., checking for leaks every shift).

[0042] It should be noted that the end face sealing unit 8 can adopt an existing mechanical seal structure, as detailed in the appendix of this utility model. Figure 1 Alternatively, a common mechanical seal structure can be used. For example, the sealing unit employs a double-end mechanical seal design, consisting of a reinforced metal core (such as 304 stainless steel) and an elastic sealing ring (fluororubber FKM or perfluoroether rubber FFKM). The reinforced core is press-fitted into the inner wall of the central through-hole in the feed plate 4 and the discharge plate 5 via an interference fit. Its axial end face is machined with an annular groove (2-3mm deep) for embedding the elastic sealing ring. The lip of the elastic sealing ring is designed with a bidirectional lip structure: the inner lip (facing the reaction chamber 2) has a 45° inclination angle and an interference fit of 0.2-0.3mm with the surface of the stirring shaft 1, used to prevent leakage of high-solids content materials. The outer lip (facing the external environment) has a 30° inclination angle and an interference fit of 0.1-0.2mm with the shaft surface, preventing the heating medium (such as hot oil) inside the jacket from seeping in.

[0043] In this embodiment, a spiral guide plate 9 is provided inside the jacket tube 3, and the axis of the spiral guide plate 9 is the axis of the reaction chamber 2.

[0044] The spiral guide plate 9 guides the heating / cooling medium (such as hot oil or cooling water) to flow spirally within the jacket, uniformly distributing the temperature and preventing hot spots or cold spots on the outer wall of the chamber. This is particularly useful for high-solids materials requiring precise temperature control, improving reaction consistency.

[0045] The spiral guide plate 9 can be made of thin steel plate (1.5-3mm thick) wound into a spiral shape, with a pitch (distance between adjacent windings) of 1 / 2 to 1 times the pipe diameter (e.g., 100mm pitch for a 200mm pipe diameter), and welded to the inner wall of the jacketed tube 3. The length of the guide plate matches the jacketed tube 3 to ensure full coverage. The material should be the same as that of the jacketed tube 3 (e.g., stainless steel) to avoid corrosion.

[0046] When assembling the jacketed tube 3, the guide plate is pre-welded: starting from the medium inlet 13 end, it is spirally wound and fixed at a 45-degree angle. After installation, the distance between the guide plate and the outer wall of the cavity is uniform (approximately 10-20mm). The medium flow path is as follows: it enters from the inlet of the jacketed tube 3, the guide plate forces the medium to advance along the spiral path, and it flows out from the outlet.

[0047] In use: When the reaction temperature needs to be maintained at 80℃, hot oil is pumped in from the inlet and spirals around the flow path under the action of the guide plate. The temperature change of the chamber wall is <±2℃, which is suitable for high-solids pigment mixing. Technicians can optimize heat exchange by adjusting the medium flow rate (e.g., 1-2 m / s).

[0048] In this embodiment, the stirring shaft 1 has multiple serrated protrusions 10 on the segment inside the reaction chamber 2, and the multiple serrated protrusions 10 are arranged in a spiral curve or multiple segments are distributed on the stirring shaft 1.

[0049] The serrated protrusions 10 provide high-strength shearing force to tear apart agglomerated particles of high-solids materials (such as starch slurry); the spiral curve distribution simultaneously achieves axial propulsion and radial mixing, avoiding blind spots. This design fundamentally solves the problems of uneven mixing and high energy consumption in traditional mixers at high solids contents.

[0050] The stirring shaft 1 is machined on a lathe: first, the shaft body is turned, then serrations are cut with a milling cutter (the tooth shape is an equilateral triangle, with a height of 5-20mm and a tooth spacing of 10-30mm). The teeth are distributed along a helical line with a helix angle of 30-60 degrees (e.g., 45 degrees), ensuring that the tooth row continuously covers the entire cavity section. The shaft material is made of wear-resistant steel with surface hardening treatment.

[0051] The tooth segment length matches the reaction chamber 2 (e.g., a 1-meter shaft segment corresponds to a 1-meter chamber), and during assembly, the serrated protrusions face inward toward the material. During operation, the gap between the teeth and the chamber is small (approximately 2-5mm) to enhance shearing.

[0052] When using this product, if mixing high-solids clay slurry, the shaft speed should be 100 RPM. The saw teeth will cut into the material and break up lumps (similar to a spiral mixer blade in food processing). The material will be homogenized after 2-3 minutes of residence time. Technicians can control the shearing intensity by adjusting the speed (too high a speed will wear down the saw teeth).

[0053] In this embodiment, a rectangular baffle plate 11 is provided on the inner wall of the reaction chamber 2.

[0054] The rectangular baffle plate 11 increases material turbulence, interrupts straight flow, and prevents high-solids materials from flowing to the discharge port 7 without being fully mixed under the axial push (short-circuit effect). It improves mixing uniformity, especially in synergy with the serrated protrusions to amplify the shearing effect.

[0055] The rectangular baffle plate 11 is a rectangular steel sheet (e.g., 50mm × 100mm × 10mm), vertically welded or bolted to the inner wall. Distribution angle: One plate is placed every 200-500mm along the axial direction, with a 90-degree offset between plates to enhance disturbance. The surface is smooth to reduce adhesion.

[0056] Before welding the cavity, pre-drill mounting holes or spot weld directly. Each baffle should be perpendicular to the axial direction (or slightly inclined), with a gap of 10-20mm between it and the stirring shaft 1 to avoid collision.

[0057] During use, the material flow bounces off the rectangular baffle plate 11, forming a vortex, which reduces the mixing time by 20%. Technicians can periodically check the baffle for wear to ensure it is not loose.

[0058] In this embodiment, the stirring shaft 1 is provided with a hollow flow channel inside, which is used for the inflow and outflow of the heating medium.

[0059] The medium flows directly inside the shaft to heat the shaft body, rapidly transferring heat to high-solids materials (especially viscous substances), solving the problem of slow heat transfer in traditional jackets, and improving reaction rate and temperature consistency.

[0060] The stirring shaft 1 is made of seamless steel pipe (e.g., wall thickness 10-15mm), with a hollow flow channel diameter occupying 1 / 3 of the shaft (e.g., a φ50mm flow channel is suitable for a φ150mm shaft). Holes are drilled at the shaft end to connect the inlet and outlet fittings. The material is pressure- and temperature-resistant (e.g., stainless steel).

[0061] When installing the stirring shaft 1 into the cavity, connect one end to the media supply pipe (such as a rotary joint) and the other end to the return pipe. The inlet is at the feed end, and the outlet is at the discharge end.

[0062] When processing high-solids polymers, steam is introduced through the inlet at a pressure of 0.5-1 MPa, flowing through the shaft and heating the shaft wall. The material heats up through thermal conduction (e.g., from 20°C to 60°C). Technicians need to monitor the shaft temperature to prevent overheating and deformation.

[0063] In this embodiment, a baffle assembly 12 is provided inside the segment of the hollow flow channel located inside the reaction chamber 2. The baffle assembly 12 includes a plurality of baffles connected in sequence, and two adjacent baffles are arranged vertically.

[0064] The baffle disturbs the medium flow, increases turbulence, eliminates the "dead zone" caused by laminar flow, improves heat transfer efficiency (e.g., by more than 20%), and ensures uniform axial temperature.

[0065] The spoiler is a square metal sheet (e.g., 20mm on each side) with a thickness of 2-3mm, welded inside the flow channel: the first sheet is fixed vertically, and adjacent sheets are rotated 90 degrees and welded together (forming a cross-shaped structure). The spacing between the sheets is 50-100mm, covering the length of the flow channel.

[0066] During shaft manufacturing, insert and secure the spoiler assembly 12 through the axial opening (e.g., using a clamp for alignment). Seal the flow channel after completion.

[0067] When hot oil is used for heating, the medium continuously changes direction as it flows past the baffles, generating eddies that make the shaft wall temperature more uniform. Technicians can verify the efficiency by measuring the temperature at the flow channel outlet.

[0068] In this embodiment, the jacketed tube 3 has a medium inlet 13 and a medium outlet 14, which are used for the inflow and outflow of the heating medium. This enables external jacket temperature control, assists internal heating, provides redundant heat sources, and ensures flexible overall temperature control of the reactor.

[0069] A hole is made in the wall of the jacket tube 3, and a standard threaded connector (such as a 1 / 2-inch NPT connector) is welded on. The inlet is usually at the bottom of the jacket tube 3, and the outlet is at the top to facilitate media flow.

[0070] The inlet pipe is connected to the medium (such as hot water), and the outlet pipe is returned to the heat source system.

[0071] During low-temperature mixing, cooling water is pumped into the jacket from the inlet, and the cavity walls cool the material. Technicians adjust the valves to control the flow rate.

[0072] In this embodiment, the jacketed tube 3 is also provided with a pressure measuring port 15 and a temperature measuring port 16.

[0073] Real-time monitoring of temperature and pressure helps prevent overheating or overpressure risks, especially improving operational safety for high-pressure, high-temperature reactors.

[0074] The pressure measuring port 15 and temperature measuring port 16 are threaded interfaces with valves (e.g., 1 / 4 inch), which are installed by drilling holes in the wall of the jacketed tube 3.

[0075] Connect the pressure gauge and thermometer (such as a type K thermocouple) to the port, positioned close to the jacket inlet and outlet for representative readings.

[0076] If, during operation, pressure test port 15 shows a sudden increase in pressure (>1.5 times the design value), technicians can immediately stop the machine for inspection. Calibrate the instrument during routine maintenance.

[0077] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the present utility model. Any simple modifications, alterations, or equivalent structural changes made to the above embodiments based on the technical essence of the present utility model shall still fall within the protection scope of the present utility model.

Claims

1. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor, characterized in that, It includes a stirring shaft, a reaction chamber, and a jacketed tube; the stirring shaft passes through the inside of the reaction chamber, and the jacketed tube is coaxially fitted on the outside of the reaction chamber; a feed plate and a discharge plate are respectively installed at both ends of the reaction chamber, the feed plate has a feed port communicating with the inside of the reaction chamber, and the discharge plate has a discharge port communicating with the inside of the reaction chamber. The two ends of the jacket tube are respectively fixed to the end face of the discharge plate and the end face of the feed plate; The two ends of the stirring shaft pass through the middle through hole of the feed plate and the middle through hole of the discharge plate, respectively. The stirring shaft is fitted with end face sealing units near both ends, and the two end face sealing units are used to seal the middle through hole of the feed plate and the middle through hole of the discharge plate, respectively. The stirring shaft has multiple serrated protrusions on the segment located inside the reaction chamber.

2. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 1, characterized in that, A spiral guide plate is provided inside the jacket tube, and the axis of the spiral guide plate is the axis of the reaction chamber.

3. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 1, characterized in that, A rectangular baffle plate is provided on the inner wall of the reaction chamber.

4. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 1, characterized in that, The stirring shaft has a hollow flow channel inside, which is used for the inflow and outflow of the heating medium.

5. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 4, characterized in that, The hollow flow channel is located inside the segment of the reaction chamber and is equipped with a baffle assembly. The baffle assembly includes multiple baffles connected in sequence, and two adjacent baffles are arranged vertically.

6. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 1, characterized in that, The jacketed tube has a medium inlet and a medium outlet, which are used for the inflow and outflow of heating medium.

7. A horizontal high-solids-content sawtooth spiral shear continuous mixing reactor according to claim 1, characterized in that, The jacketed tube is also equipped with a pressure measuring port and a temperature measuring port.

Images