Concentric Nozzle Mixing System for Low Reynolds Number Homogeneity
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Solution Overview
Problem
Current mixing technologies, such as static and jet mixers, face challenges in achieving efficient mixing at low Reynolds numbers, suffer from significant pressure drops at high Reynolds numbers, and struggle with scaling up to large pipe sizes, leading to inaccurate sampling and increased operational costs.
Innovation Solution
A novel nozzle system with concentric cylinders and strategically placed holes to create a horseshoe vortex and turbulent structures, enhancing mixing by injecting a first liquid into a stream of a second liquid within a pipe, using a variable speed pump and advanced control systems to optimize mixing efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If jet mixing systems are used to improve mixing efficiency at low Reynolds numbers, then mixing performance is improved, but pressure drop increases significantly at high Reynolds numbers
Solution Approach 1:
The mixing system divides the liquid stream into multiple discrete jets through multiple nozzles arranged in a circular pattern. This segmentation creates multiple mixing zones along the pipe length, distributing the mixing action rather than relying on a single high-energy jet, thereby reducing overall pressure drop while maintaining mixing efficiency.
Solution Approach 2:
The invention transitions from conventional single-point jet injection to a distributed multi-dimensional array of nozzles arranged in a circular pattern. This spatial distribution across multiple dimensions allows the system to achieve thorough mixing through cumulative effect of multiple lower-energy jets, reducing the pressure drop penalty associated with high-velocity single jets.
2Productivity
If conventional jet mixing systems are used, then mixing capability is improved, but scaling up to large pipe sizes becomes difficult due to dependence on jet penetration strength
Solution Approach 1:
The nozzle assembly design with multiple nozzles in a circular pattern creates a universal mixing solution that can be adapted to various pipe diameters. The system maintains effectiveness across different scales by distributing jets around the pipe circumference, allowing the same basic configuration to serve multiple pipe sizes without requiring fundamental redesign.
Solution Approach 2:
By arranging nozzles in a circular pattern around the pipe circumference, the system adds a radial dimension to jet distribution. This multi-dimensional approach allows scaling to larger pipe sizes by simply increasing the radius of the circular nozzle arrangement, rather than increasing jet velocity or penetration strength, thus providing scalability across different pipe diameters.
3Manufacturing precision
If single-path nozzles with similar sized nozzles injecting at different angles are used, then jet break up mechanism is achieved, but sampling accuracy deteriorates due to cyclic sampling of diverted sample
Solution Approach 1:
The invention merges the sample diversion function with the mixing function by positioning the sample withdrawal port within the mixing zone where all liquid streams are thoroughly combined. This ensures that the diverted sample represents the homogeneous mixture rather than cyclic portions from different locations, eliminating sampling accuracy errors while maintaining droplet size control through the multi-nozzle injection pattern.
4Productivity
If vertical mixing configuration is used to achieve sufficient mixing at very low Reynolds numbers, then mixing performance is improved, but device complexity and operational costs increase due to design changes for large pipe diameters
Solution Approach 1:
The system uses the natural dynamics of liquid jets to create vertical mixing patterns within a horizontal pipe configuration. The injected jets rise vertically due to momentum and buoyancy, creating turbulent mixing zones that extend upward, thereby achieving vertical mixing effectiveness without requiring the pipe itself to be oriented vertically, simplifying installation in large diameter pipes.
Solution Approach 2:
The invention creates vertical mixing action through a horizontal pipe configuration by injecting jets that rise vertically. This separates the mixing dimension (vertical) from the pipe orientation (horizontal), allowing the system to achieve effective mixing in large diameter pipes without the complexity of vertical pipe installation, welding, and bends required by conventional vertical configurations.
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 better than 90% homogeneity in mixing, exceeding ISO 3171 standards, ensuring accurate representative sampling while reducing operational costs and pressure drops, and effectively handling a wide range of Reynolds numbers.
Implementation Method 1
The pump injects fluid to the pipe creating jet mixing
Implementation Method 2
creating a horseshoe vortex and turbulent structures, enhancing mixing
Implementation Method 3
creating a horseshoe vortex and turbulent structures, enhancing mixing
Data Source
AI summary
A nozzle for injecting a first liquid mass into a stream of second liquid mass flowing within a pipe, comprising a first, outer, cylinder and second, inner, cylinder concentrically arranged about a nozzle axis, securing means for securing the nozzle to a wall of the pipe with the nozzle axis orthogonal to the pipe wall, the nozzle projecting into an interior of the pipe in use, duct means for receiving the first liquid mass and transporting it to the interior of the inner and outer cylinders, the inner cylinder comprising at least one hole arranged to expel liquid therethrough, and the outer cylinder comprising at least one hole arranged to expel liquid therethrough.