Helical-Bar Mixing Arrangement for Faster Settler Separation
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Solution Overview
Problem
Existing mixer arrangements in solvent extraction processes are inefficient in intensifying and quickening the separation of liquid phases, leading to prolonged separation times and increased energy consumption.
Innovation Solution
A mixing arrangement with a specific ratio of mixing device diameter to mixing space diameter (D/T) of 0.38-0.47, combined with helical bars and supporting spokes, optimizes the mixing process to enhance dispersion maintenance and reduce separation time in a settler unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixer arrangements are used with larger mixing devices, then mixing capacity is improved, but separation time in the settler unit increases and power consumption increases
Solution Approach 1:
The patent applies parameter changes by optimizing the diameter ratio D/T to 0.47 or less, which fundamentally alters the flow dynamics and mixing characteristics. This parameter optimization enables effective mixing with reduced device size, consequently decreasing separation time in the settler unit while maintaining mixing capacity.
Solution Approach 2:
The mixing device is segmented into multiple helical bars arranged around the shaft, each contributing to the overall mixing action. This segmentation allows for distributed mixing throughout the mixing space, improving efficiency without requiring a larger single mixing element, thus reducing separation time.
2Productivity
If conventional mixer arrangements are used with larger mixing devices, then mixing capacity is improved, but power consumption increases
Solution Approach 1:
By changing the critical parameter D/T to 0.47 or less, the patent achieves optimal mixing efficiency at reduced scale. This parameter optimization reduces the energy requirements for mixing while maintaining effective dispersion, directly addressing the power consumption issue.
Solution Approach 2:
The use of helical bars with curved geometry creates efficient flow patterns that reduce energy dissipation. The curved geometry of the helical bars promotes gentle yet effective mixing, reducing the power needed compared to conventional straight-blade mixers.
3Loss of time
If mixing device diameter is reduced to decrease separation time, then separation time is shortened, but mixing capacity may be reduced
Solution Approach 1:
Multiple helical bars are arranged around the shaft to distribute mixing action throughout the mixing space. This segmentation compensates for the reduced diameter by providing distributed mixing zones, maintaining overall mixing capacity while enabling shorter separation times.
Solution Approach 2:
The patent transitions from a single-plane mixing approach to a three-dimensional arrangement with helical bars distributed around the shaft at different angular positions. This dimensional expansion maintains mixing capacity despite reduced device diameter, as mixing occurs simultaneously at multiple radial positions.
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 optimized mixing arrangement significantly shortens separation time and reduces power consumption while maintaining effective dispersion, suitable for industrial solvent extraction processes.
Implementation Method 1
amount of pressure pulses caused to the dispersion per revolution of the mixing device
Implementation Method 2
lower local shear forces are created
Implementation Method 3
separation time of the liquid phases in a settler unit
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A mixing arrangement (100) for mixing two solutions, a mixer settler unit (200) and a use. The mixing arrangement (100) comprises a mixing device (1) arranged in the mixing space (6) for rotating therein, the mixing device (1) comprising at least two helical bars (2a, 2b) supported around a shaft (3) and rising upwards from the bottom section of the mixing space (6), the helical bars (2a, 2b) being fixed to the shaft (3) with support spokes (4). The ratio of the diameter (D) of the mixing device to the average diameter (T) of the mixing space, that is D/T, is 0.47 at most.