Helical Vane Pipe Mixing for High Gas Dissolution
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Solution Overview
Problem
Existing systems for mixing gases with liquids, such as aerators and diffusers, face inefficiencies in gas transfer due to competition with water flow and require recirculation for higher gas saturation, which can be costly and ineffective in achieving high dissolved gas levels, especially in applications like algae control and water treatment.
Innovation Solution
A helical vane apparatus integrated with a pipe, utilizing a 3D printing method to create a unitary structure with a gas injection port upstream of the vane, enhances gas transfer efficiency by dispersing gas through multiple holes and a venturi design, allowing for higher gas saturation without recirculation, and a controller maintains optimal pH for carbon dioxide injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas is injected into liquid using conventional aerators and diffusers, then gas transfer occurs, but gas transfer efficiency is reduced due to competition with water flow
Solution Approach 1:
The gas injection system is segmented into multiple injection ports distributed along the pipe, with multiple holes in the injection port allowing gas to be injected at multiple locations simultaneously. This segmentation reduces competition with water flow at any single point and distributes the gas transfer process along the length of the pipe.
Solution Approach 2:
A helical vane is introduced as an intermediary element between the gas injection port and the liquid flow. The vane creates a venturi effect that mediates the interaction between injected gas and water flow, enhancing gas transfer efficiency by controlling the mixing process.
2Quantity of substance
If recirculation is used to achieve higher gas saturation, then dissolved gas levels increase, but operational costs and energy consumption increase
Solution Approach 1:
Gas is injected upstream of the helical vane before the liquid flow fully develops, allowing gas transfer to occur in the high-velocity region created by the venturi effect. This preliminary gas injection achieves high saturation levels in a single pass without requiring recirculation.
Solution Approach 2:
The system changes the flow parameters by creating a venturi effect that increases liquid velocity and decreases pressure in the measurement region, optimizing conditions for gas transfer. This parameter change enables high gas saturation without the need for recirculation.
3Productivity
If conventional mixing apparatus is used, then gas and liquid mix, but mixing efficiency is insufficient for effective algae control and water treatment
Solution Approach 1:
A helical (curved) vane is used instead of a straight or conventional mixing element. The curved geometry of the helical vane creates rotational flow patterns and enhances turbulence, significantly improving gas-liquid mixing efficiency and contact time for effective treatment applications.
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 solution achieves up to 300% increase in gas transfer efficiency, effectively increasing dissolved oxygen levels in liquids, enabling effective algae control and water treatment, and reducing operational costs by minimizing the need for recirculation and energy consumption.
Implementation Method 1
dispersing gas through multiple holes and a venturi design
Implementation Method 2
A helical vane may be disposed inside the pipe, dividing a portion of the fluid path into two fluid path regions
Data Source
AI summary
Aspects of the present disclosure provide various apparatus and methods. In some embodiments, an apparatus is provided for mixing a gas with a liquid. The apparatus may include a pipe having two ends. The pipe may provide a main fluid path and may have an interior surface having a first groove. The apparatus may also include a helical vane disposed inside the pipe. The vane may have a first projecting tongue that engages the first groove. The apparatus may also include a gas injection port on the pipe adapted to inject gas into the fluid path upstream of the helical vane. In some embodiments, the helical vane may be a 3D printed component.