Ammonia Mixing System With Perpendicular Injection Tubes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mixing devices struggle to achieve high mixing efficiency over a wide range of flow rates, often requiring long channels or conduits, which can lead to uneven temperature distribution and catalyst wear in applications like ammonia converters.
Innovation Solution
A mixing system comprising a distribution channel, an injection unit with a manifold and parallel injection tubes of varying lengths, and a static mixing unit, which injects a fluid or gas perpendicularly into the mainstream, promoting efficient mixing over a short length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing devices use long channels or conduits to achieve satisfactory mixing efficiency, then mixing homogeneity is improved, but device length and pressure drop increase
Solution Approach 1:
The mixing channel is segmented into multiple sections with static mixing units distributed throughout. The injection tubes are also segmented with varying lengths to create staged injection points. This segmentation allows progressive mixing to occur over a shorter overall length while maintaining homogeneity.
Solution Approach 2:
The invention introduces a second spatial dimension by arranging injection tubes perpendicular to the main flow direction and varying their lengths radially. This creates multi-dimensional mixing patterns that achieve homogeneity faster than conventional single-direction mixing, reducing the required channel length.
2Manufacturing precision
If conventional mixing devices use long channels to ensure mixing homogeneity, then mixing efficiency is improved, but pressure drop increases
Solution Approach 1:
The mixing process is segmented into multiple stages with static mixing units positioned at intervals. This allows mixing to occur in discrete steps rather than requiring a single long channel, reducing cumulative pressure drop while achieving the same homogeneity.
Solution Approach 2:
Static mixing units are positioned upstream to pre-mix the injected fluid with the mainstream before the full length of the channel is traversed. This preliminary mixing action reduces the distance over which mixing must occur, thereby reducing pressure drop.
3Manufacturing precision
If conventional mixing devices are designed for high mixing efficiency, then homogeneity is improved, but adaptability to wide range of flow rates deteriorates
Solution Approach 1:
Different sections of the mixing channel have different characteristics - the injection tubes have varying lengths and the static mixing units are positioned at different locations. This local variation in mixing intensity and injection points allows the system to adapt to different flow rates while maintaining overall homogeneity.
Solution Approach 2:
The system incorporates variable geometry through injection tubes of different lengths that can be optimized for different operating conditions. This dynamic design allows the mixing characteristics to be adjusted for wide ranges of flow rates while maintaining effective mixing homogeneity.
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
The system achieves high mixing efficiency and homogeneity over a wide range of flow rates, reducing pressure drop, preventing ammonia slip, and enhancing plant efficiency by ensuring uniform temperature distribution and catalyst wear prevention.
Implementation Method 1
The injection tubes are provided with an aperture configured to eject said fluid or gas with a flow direction perpendicular to the main longitudinal axis of the distribution channel
Implementation Method 2
the static mixer comprises a plurality of channel to promote the mixing between the injected fluid and the mainstream
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Is described a mixing system (1) configured to inject an ammonia stream (50) into a main airstream (2). The mixing system (1) comprises an injection unit 10, a static mixing unit (3) and distribution channel (4). The injection unit (10) comprises a manifold (5) and a plurality of injection tubes (11). Each injection tube (11) is provided with an aperture (6) configured to discharge the ammonia stream having a perpendicular direction to the flow direction of the mainstream (2).