Frustoconical Mixing Element for Solids Suspension
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Solution Overview
Problem
Existing mixing apparatuses for liquids and particulate matter are inefficient in ensuring thorough mixing, often causing solids to accumulate at the corners or bottom of tanks, leading to ineffective mixing and increased horsepower requirements, with prior designs experiencing unstable flow and poor particulate distribution.
Innovation Solution
A vertical mixing apparatus with a rotating shaft and angularly adjustable mixing elements featuring a frustoconical section, throat, and diffuser with scalloped cutouts, generating turbulent vortices and low-pressure regions to enhance mixing and lift solids from the bottom and corners of the tank, reducing horsepower needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional impeller agitators are used for mixing liquids and particulate matter, then the mixing process can be performed, but solids accumulate at corners or edges of tanks and mixing effectiveness decreases
Solution Approach 1:
The mixing element is divided into multiple blades arranged in a circular pattern around the shaft, with each blade segment independently contributing to the mixing action. This segmentation creates multiple flow paths and prevents solid accumulation by ensuring comprehensive coverage of the tank interior surfaces.
Solution Approach 2:
The mixing element transitions from conventional two-dimensional blade designs to a three-dimensional configuration with blades extending radially outward from the shaft. This dimensional change creates volumetric mixing action that effectively engages solids throughout the entire tank volume, preventing corner accumulation.
2Productivity
If conventional impeller agitators operate at high speeds to improve mixing, then mixing intensity increases, but horsepower requirements increase
Solution Approach 1:
The mixing element utilizes optimized blade geometry parameters including specific angles (30-60 degrees from horizontal), radial positioning, and spacing calculations based on tank dimensions. These parameter optimizations enable effective mixing at lower rotational speeds, reducing the horsepower required while maintaining mixing intensity.
Solution Approach 2:
The mixing element employs curved blade surfaces and rounded geometric features that optimize fluid flow patterns. The curved design reduces flow separation and turbulence-induced energy losses, allowing the system to achieve effective mixing with lower power consumption compared to conventional angular blade designs.
3Productivity
If conventional propeller or turbine impellers are used, then liquid mixing can be achieved, but flow is unstable and circumferential velocity fluctuates
Solution Approach 1:
The mixing element employs asymmetric blade spacing and non-uniform radial positioning of blades around the shaft. This asymmetric configuration creates a more stable flow pattern by preventing the periodic flow separation that occurs with symmetric propeller or turbine designs, thereby reducing circumferential velocity fluctuations.
Solution Approach 2:
The mixing element design incorporates flexible blade mounting and adjustable blade angles that can dynamically adapt to flow conditions. This dynamic capability allows the mixing element to maintain optimal performance across varying operating conditions while stabilizing the flow pattern and reducing velocity fluctuations.
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 apparatus effectively mixes liquids and particulates with reduced static head and horsepower requirements, ensuring thorough mixing without degrading the product, and minimizing the need for post-mixing clean-outs by generating overlapping vortices and controlling boundary layers.
Implementation Method 1
generating turbulent vortices and low-pressure regions to enhance mixing and lift solids from the bottom and corners of the tank
Implementation Method 2
generating turbulent vortices and low-pressure regions to enhance mixing and lift solids from the bottom and corners of the tank
Implementation Method 3
generating turbulent vortices and low-pressure regions to enhance mixing
Implementation Method 4
generating overlapping vortices and controlling boundary layers
Implementation Method 5
lift solids from the bottom and corners of the tank
Data Source
AI summary
A mixing apparatus has a shaft, at least one arm radiating outwardly of the shaft, and a mixing element affixed to the arm away from the shaft. The mixing element has a generally frustoconical member with a wide opening at an end thereof and a narrow opening at an opposite end thereof. The mixing element also includes a throat section of a generally constant diameter connected to the narrow opening of the frustoconical member and a diffuser section having an end affixed to an end of the throat section opposite the frustoconical member. The mixing elements have a longitudinal axis extending at an acute angle to horizontal. A motor is cooperative with the shaft so as to rotate the shaft. Each of the mixing elements includes a Venturi.