Acid Mixing Nozzle Deflects Streams 90 Degrees
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Solution Overview
Problem
Existing methods for adjusting the concentration of acids or lyes, such as sulfuric acid, result in non-uniform concentration distributions and significant pressure losses due to the limited intermixing of concentrated acid and dilution medium within the mixing chamber.
Innovation Solution
The medium for concentration adjustment is charged before the mixing chamber inlet, where it intersects the acid or lye stream at a 90-degree angle, utilizing a nozzle device with multiple nozzle openings or a ring-shaped flange to ensure uniform distribution and deflection, eliminating the need for static mixers and reducing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the medium for concentration adjustment is charged inside the mixing chamber through a lance with nozzle openings, then the concentration adjustment can be performed, but the intermixing is insufficient leading to non-uniform concentration distribution with deviations of about 0.5 wt-%
Solution Approach 1:
The medium for concentration adjustment is charged to the acid or lye stream before the inlet to the mixing chamber, rather than inside the mixing chamber. This preliminary charging allows the streams to begin mixing earlier and be deflected by 90 degrees at the inlet, creating intensive intermixing and turbulent flow that results in homogeneous concentration distribution with deviations below 0.1 wt-%.
2Manufacturing precision
If static mixers are incorporated in the mixing chamber to improve intermixing, then the concentration uniformity improves, but the flow cross-section is reduced leading to increased pressure loss
Solution Approach 1:
The static mixers are removed from the mixing chamber entirely. Instead, the medium is charged before the inlet and the streams are deflected by 90 degrees, creating intensive intermixing through the deflection geometry itself. This eliminates the flow resistance and pressure loss associated with static mixers while achieving superior concentration uniformity.
3Manufacturing precision
If the mixing chamber is designed with a large volume to accommodate thorough mixing, then the concentration uniformity improves, but the equipment size and complexity increase
Solution Approach 1:
The mixing process begins before the inlet to the mixing chamber by charging the medium to the acid or lye stream in advance. The 90-degree deflection at the inlet creates intensive intermixing that continues through a compact mixing chamber, achieving homogeneous concentration distribution without requiring a large chamber volume.
4Manufacturing precision
If the medium is charged uniformly distributed over the cross-section of the acid stream using a nozzle device, then the concentration deviation at the outlet is minimized, but the nozzle device complexity increases
Solution Approach 1:
The nozzle device divides the medium flow into multiple streams through multiple nozzle openings arranged to distribute the medium uniformly across the cross-section of the acid or lye stream. This segmentation of the medium flow, combined with the 90-degree deflection, creates intensive intermixing and achieves concentration deviations below 0.1 wt-% at the outlet.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves a highly homogeneous concentration distribution with reduced concentration deviations from 0.5 wt-% to below 0.1 wt-%, while minimizing pressure loss by promoting intensive intermixing and turbulent mixing.
Implementation Method 1
the medium for adjusting the concentration, in particular water, is charged to the acid or lye before the inlet to the mixing chamber
Implementation Method 2
an intensive intermixing is achieved, which leads to a distinctly more homogeneous concentration distribution in the acid or lye
Data Source
Figure 1~2
Figure 3~4
AI summary
For adjusting the concentration of acids or lyes, in particular of sulfuric acid, the acid or lye is supplied through an inlet to a mixing chamber, is mixed therein with a medium for adjusting the concentration, and the concentration-adjusted acid or lye is discharged from the mixing chamber through an outlet. To achieve a uniform dilution of the acid or lye and small concentration deviations with low pressure loss, the medium for adjusting the concentration, in particular water, is charged to the acid or lye before the inlet to the mixing chamber and the acid stream or lye stream and the stream of the medium subsequently are deflected preferably by 90°.