Dual-Function Impeller Radial-Axial Flow Rotary Injector

Solution Overview

Problem

Existing rotary injectors for treating molten aluminum are inefficient in both shearing fluxing agents and mixing alloy ingredients, leading to prolonged process durations and reduced productivity in aluminum production.

Innovation Solution

A dual-function impeller with radially extending and slanted blades is used in a rotary injector, generating both radial and axial flow components to enhance shearing and mixing efficiency simultaneously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a radial blade impeller is used for shearing fluxing agent, then shearing efficiency is improved, but mixing efficiency deteriorates

Engineering Contradiction:

Improveshearing efficiencyVSAvoidmixing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines radial blade portions and axial blade portions into a single impeller structure. The radial blade portions generate radial flow for shearing the fluxing agent, while the axial blade portions generate axial flow for mixing the molten metal. This merging of two previously separate impeller functions into one device resolves the contradiction between shearing efficiency and mixing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The impeller is designed to perform multiple functions simultaneously: it acts as both a shearing device (via radial blades) and a mixing device (via axial blades). This multi-functionality allows the single impeller to achieve both high shearing efficiency for fluxing agent integration and high mixing efficiency for alloy ingredient distribution, eliminating the need to switch between different impeller types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If a slanted blade impeller is used for mixing alloy ingredients, then mixing efficiency is improved, but shearing efficiency deteriorates

Engineering Contradiction:

Improvemixing efficiencyVSAvoidshearing efficiency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent combines radial blade portions and axial blade portions into a single impeller structure. The radial blade portions generate radial flow for shearing the fluxing agent, while the axial blade portions generate axial flow for mixing the molten metal. This merging of two previously separate impeller functions into one device resolves the contradiction between shearing efficiency and mixing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The impeller is designed to perform multiple functions simultaneously: it acts as both a shearing device (via radial blades) and a mixing device (via axial blades). This multi-functionality allows the single impeller to achieve both high shearing efficiency for fluxing agent integration and high mixing efficiency for alloy ingredient distribution, eliminating the need to switch between different impeller types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If sequential use of fluxing impeller and mixing impeller is employed, then both shearing and mixing functions are achieved, but process time increases

Engineering Contradiction:

Improveshearing and mixing function completenessVSAvoidprocess duration

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines radial blade portions and axial blade portions into a single impeller structure. The radial blade portions generate radial flow for shearing the fluxing agent, while the axial blade portions generate axial flow for mixing the molten metal. This merging of two previously separate impeller functions into one device resolves the contradiction between shearing efficiency and mixing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dual-function impeller enables continuous simultaneous performance of both shearing and mixing operations during a single rotation cycle. There is no need to stop and switch between different impeller types, allowing the furnace operation to proceed without interruption and significantly reducing the overall process time while maintaining both shearing and mixing functions.

Inventive Principle:

Principle #20Continuity of useful action

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 dual-function impeller reduces overall process time by combining shearing and mixing functions, achieving higher shearing efficiency and improved alloy ingredient dissolution with the same energy input compared to traditional high shear impellers.

Implementation Method 1

the radially extending portion collectively generating a radial flow component upon rotation

Methodology Applied

Scientific EffectRadial flow generation:

Implementation Method 2

the slanted portion collectively generating an axial flow component directed away from the rotary injector upon rotation

Methodology Applied

Scientific EffectAxial flow generation:

Data Source

PatentUS10465987B2Dual-function impeller for a rotary injector

Publication Date: 2019.11.05 RIOTINTO ALCAN INT LTD

AI summary

The dual-function impeller can be rotated in molten metal in a direction of rotation, as part of a rotary injector. The impeller can have a body having an axis, a plurality of blades circumferentially interspaced around an axis, and an aperture coinciding with the axis. The blades having both a radially extending portion facing the direction of rotation and collectively generating a radial flow component upon said rotation, and a slanted portion also facing the direction of rotation, inclined relative to a radial plane, and collectively generating an axial flow component directed away from the rotary injector upon said rotation.