Fractal Mixer Reactor with Passive Mixing Structure

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Solution Overview

Problem

Conventional mixing equipment often results in inhomogeneities and inefficiencies due to large-scale turbulence and eddies, which can disrupt fluid mixing and reactions, and existing fractal mixers face issues such as plugging, manufacturing challenges, high costs, and laminar flow limitations at the smallest scale.

Innovation Solution

The implementation of fractal mixers with independent flows progressively scaled through smaller conduits, where a passive mixing structure completes the mixing process at the smallest fractal scale, utilizing static, turbulent, or laminar mixing structures to ensure efficient and homogeneous fluid contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional mixing equipment is used to force large scale turbulence upon the fluid mixture, then mixing action is achieved, but inhomogeneities and eddies are created that hamper proper mixing and disrupt reactions

Engineering Contradiction:

Improvemixing actionVSAvoidinhomogeneities and eddies

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The mixing system is segmented into multiple fractal iterations with progressively smaller conduits. Each iteration divides the fluid streams into smaller sub-streams, creating a hierarchical structure that eliminates large-scale eddies while maintaining mixing effectiveness through controlled progression from larger to smaller scales.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the mixing system have different conduit sizes and flow characteristics. The fractal structure provides local optimization where each iteration level is designed with appropriate scale for its specific mixing function, transitioning from bulk mixing at larger scales to fine mixing at smaller scales.

Inventive Principle:

Principle #3Local quality

2Productivity

If the smallest desired fractal scale is used to complete mixing, then mixing efficiency is improved, but plugging occurs due to suspended solids

Engineering Contradiction:

Improvemixing efficiencyVSAvoidplugging

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fractal mixing process performs preliminary mixing actions at progressively larger scales before reaching the smallest conduit scale. Suspended solids are partially mixed and distributed in larger conduits first, preventing them from accumulating and plugging the smallest conduits while still achieving efficient mixing through the progressive scaling approach.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the smallest desired fractal scale is reduced to avoid plugging, then plugging is reduced, but manufacturing problems and costs increase

Engineering Contradiction:

Improveplugging preventionVSAvoidmanufacturing problems and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system changes the scale parameter progressively through discrete fractal iterations rather than using a single smallest scale. This allows the smallest conduit dimensions to be optimized for manufacturability while the progressive scaling from larger iterations ensures mixing efficiency is maintained without requiring excessively small final conduit sizes.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If conventional mixing equipment is used, then mixing occurs, but energy consumption is high due to forcing large scale turbulence

Engineering Contradiction:

Improvemixing occursVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system replaces conventional mechanical turbulence-forcing mechanisms with a passive fractal conduit structure. Mixing is achieved through the geometric progression of conduit sizes and flow division rather than through forced turbulence, significantly reducing energy consumption while maintaining mixing effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This approach enhances mixing efficiency, reduces energy consumption, minimizes inhomogeneities, and allows for reliable scaling to any size, while maintaining the benefits of fractal mixers by using passive structures to address issues at the smallest scale, resulting in fast mixing times and high efficiency for both turbulent and laminar flows.

Implementation Method 1

At the smallest fractal scale, specifically where the mixing components come into contact with one another, a passive mixing structure completes the mixing process

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS20230256399A1Fractal mixer reactor

Publication Date: 2023.08.17 AMALGAMATED RESEARCH LLC

AI summary

Systems and methods for mixing at least two mixing components, including a first mixing component independent fractal for transporting the first mixing component, a second mixing component independent fractal for transporting the second mixing component, wherein each of the first mixing component independent fractal and the second mixing component independent fractal comprise at least a first iteration of a fractal shape and a last iteration of the fractal shape, a contact channel in fluid communication with each of the last iterations for the first mixing component independent fractal and the second mixing component independent fractal, and a passive mixing structure located in at least a portion of the contact channel.