Fluid Mixing Device for Catalytic Partial Oxidation
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Solution Overview
Problem
Existing mixing technologies for hydrocarbon and oxidant streams in catalytic partial oxidation processes fail to prevent local oxygen concentration gradients and heat back-propagation, leading to potential flame reactions and inefficient mixing.
Innovation Solution
A device with a specific geometry that includes axial and radial distribution of fluids through parallel pipes, a pipe-plate with slits for uniform discharge, and elements to prevent flame return, ensuring rapid mixing while minimizing flammability regions and residence time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tangential motion mixing is used, then mixing action is provided, but local oxygen concentration gradients are generated causing flame reactions
Solution Approach 1:
The mixing device divides the mixing function into multiple segments: a first mixing zone for initial mixing, a second mixing zone for further mixing, and a reaction zone for the actual reaction. This segmentation allows progressive mixing while controlling oxygen concentration gradients to prevent flame reactions.
Solution Approach 2:
The patent introduces a vertical dimension to the mixing process by arranging mixing zones at different heights and using upwardly directed jets. This three-dimensional arrangement enhances mixing effectiveness while distributing oxygen concentration more uniformly, preventing local gradients that cause flame reactions.
2Productivity
If turbulent motion mixing is used, then mixing is enhanced, but micro-quantities of reagents enter close contact allowing flame reactions to spread
Solution Approach 1:
The device performs preliminary mixing actions in the first and second mixing zones before the reagents reach the reaction zone. This preliminary mixing reduces the concentration of micro-quantities of reagents that could otherwise enter close contact and trigger flame reactions, while still maintaining sufficient mixing enhancement.
3Manufacturing precision
If micro-channels mixing is used, then precise mixing control is achieved, but positioning close to catalytic area causes heat back-propagation
Solution Approach 1:
The device separates the mixing function from the reaction function by creating distinct mixing zones and a reaction zone. This spatial segmentation allows precise mixing control in the mixing zones while maintaining sufficient distance from the catalytic area to prevent heat back-propagation during the reaction phase.
4Productivity
If incremental oxygen feeding is used, then reaction control is improved, but mixing geometry is not optimized for preventing flammability regions
Solution Approach 1:
The patent employs upwardly directed jets and a three-dimensional mixing geometry that distributes oxygen and fuel in the vertical dimension. This dimensional approach, combined with incremental feeding, ensures that oxygen is distributed uniformly throughout the mixture volume, preventing the formation of flammability regions while maintaining reaction control.
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 device effectively mixes hydrocarbon and oxidant streams, preventing flame reactions and ensuring complete mixing, thereby enhancing the safety and efficiency of catalytic partial oxidation processes.
Implementation Method 1
an underlying distribution zone containing a bundle of pipes preferably parallel to the axis inside which said fluid is uniformly distributed
Implementation Method 2
said pipe-plate having slits or openings in order to uniformly discharge the second fluid in an axial direction into the mixing area
Implementation Method 3
The device effectively mixes hydrocarbon and oxidant streams, preventing flame reactions and ensuring complete mixing
Implementation Method 4
it is also appropriate for the reagent gases to have high linear rates, so as to limit heat back-propagation phenomena from the catalytic surface to the stream of gaseous reagents
Data Source
AI summary
A device, system and method of mixing two fluids are described herein. A gaseous first fluid is distributed through a distribution zone to a mixing zone by a bundle of pipes parallel to an axis inside which the first fluid is uniformly distributed. A second fluid is uniformly distributed outside the pipes in the distribution zone. The mixing zone is separated from the distribution zone by a pipe-plate supporting the pipes. The pipe-plate has slits or openings to uniformly discharge the second fluid in an axial flow direction into the mixing zone. The pipes extend beyond the pipe-plate into the mixing zone to partialize an outlet flow of the first fluid. In one aspect, the pipes have different lengths to partialize the outlet flow. In another aspect, a terminal portion of the pipes partializes the outlet flow axially, radially, transversally or a combination thereof in the mixing zone.