Hydrodynamic Cavitation Manifold for High-Viscosity Fluid Mixing
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Solution Overview
Problem
Existing fluid handling technologies, such as static mixers and hydrodynamic cavitation devices, are ineffective for mixing high viscosity fluids and fail to provide uniform mixing at high flow rates, especially in Frac sites, where efficient and portable solutions are needed for recycling frac water.
Innovation Solution
A portable hydrodynamic cavitation manifold with cylindrical tubes and strategically positioned baffle units, featuring curved and angled plates with apertures, creates a cavitation field that induces uniform mixing by collapsing cavitation bubbles, allowing for high flow rates and efficient mixing of fluids from multiple sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If static mixers are used for fluid mixing, then mixing function is achieved, but they are ineffective with high viscosity fluids and cannot provide rapid mixing at high flow rates
Solution Approach 1:
The patent replaces traditional mechanical static mixers with a hydrodynamic cavitation system that uses fluid dynamics and cavitation bubble collapse to achieve mixing. The cavitation bubbles are generated through flow constrictions and their implosive collapse creates intense local mixing forces that are effective for high viscosity fluids and high flow rates without mechanical moving parts.
Solution Approach 2:
The system changes the physical state and parameters of the fluid by creating cavitation conditions - pressure drops below vapor pressure to form bubbles, then rapid pressure increase causes bubble collapse. This parameter change approach (pressure, temperature, phase) creates extreme local conditions that enable effective mixing of high viscosity fluids at high flow rates.
2Productivity
If hydrodynamic cavitation devices with baffles are used, then cavitation effects are produced, but uniform mixing of fluids from multiple sources at high flow rates is not achieved
Solution Approach 1:
The mixing chamber is segmented into multiple zones with strategically positioned baffles that create separate cavitation regions. Fluids from multiple sources are introduced into different zones, and the segmentation ensures each fluid stream undergoes cavitation mixing independently before combining, achieving uniform mixing at high flow rates.
Solution Approach 2:
Different regions of the mixing chamber are designed with specific baffle configurations and flow constrictions tailored to local mixing requirements. Each zone has optimized cavitation characteristics for its specific function, creating local quality variations that ensure uniform overall mixing while maintaining high flow rates.
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 solution enables efficient and uniform mixing of fluids at high velocities, preventing clogging and ensuring predictable pressure losses, making it suitable for high-flow applications like Frac sites, where it can recycle frac water effectively and reduce waste.
Implementation Method 1
If during the process of movement of the fluid the pressure at some point decreases to a magnitude under which the fluid reaches a boiling point for this pressure, then a great number of vapor-filled cavities and bubbles are formed
Implementation Method 2
Hydrodynamic cavitation is the result of a flow constriction wherein a liquid falls below the vapor pressure and forms vapor-filled gas bubbles
Implementation Method 3
If the static pressure then increases and exceeds the vapor pressure, these vapor-filled gas bubbles collapse implosively. Cavitation and the associated effects are also known to be useful in mixing, emulsifying and dispersing various components in a flowing liquid
Implementation Method 4
The magnitude of the pressure impulses within the collapsing cavities and bubbles may reach ultra high pressures implosions leading to the formation of shock waves that emanate from the point of each collapsed bubble
Implementation Method 5
Hydrodynamic cavitation is the result of a flow constriction wherein a liquid falls below the vapor pressure
Implementation Method 6
The phenomenon consists in the formation of hollow spaces which are filled with a vapor gas mixture in the interior of a fast-flowing liquid flow or at peripheral regions of a fixed body which is difficult for the fluid to flow around and the result is a local pressure drop caused by the liquid movement
Data Source
AI summary
A portable hydrodynamic cavitation manifold assembly formed from cylindrical tubes having flow-through chambers for collection and distribution of fluids. Each chamber includes a series of baffle units each unit formed from a first plate defined by a first end spaced apart from a second end by a length. The first plate includes a curved outer edge sized to follow the inner side wall of the chamber and a straight inner edge extending from the first end to the second end along the approximate center line of the chamber and positioned at a 45 degree angle relative to the longitudinal length of the tube. A second plate, forming a mirror image of the first plate, is also positioned at a 45 degree angle relative to the longitudinal length of the tube and at a 90 degree angle to the first plate. Each plate includes a plurality of apertures sized to control the velocity of the fluid flow, each aperture having edge walls to induce constriction for hydrodynamic cavitation mixing of fluids.