Hydration Tank With Under-Over Baffles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flow-through tank techniques for hydrating polymers often create a slipstream, leading to uneven hydration where some polymers flow too quickly and are not fully hydrated as intended.
Innovation Solution
The system employs multiple mixing chambers with an under-over baffle configuration, where each chamber has a generally rectangular shape with rounded corners, and mixing devices to ensure uniform hydration, along with a controller for adjusting the polymer addition rate based on polymer solution levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flow-through tank techniques are used for hydrating polymers, then the structure is simple, but a slipstream is created causing uneven hydration and reduced manufacturing precision
Solution Approach 1:
The tank is divided into multiple mixing chambers (first mixing chamber, second mixing chamber, etc.) connected in series. Each chamber performs a segment of the hydration process, with polymers sequentially passing through each chamber. This segmentation eliminates the slipstream effect by creating controlled mixing zones, thereby improving hydration uniformity while managing complexity through modular design.
Solution Approach 2:
Baffles are introduced as intermediary structures between mixing chambers to control fluid flow. The baffles force the polymer-liquid mixture to follow a specific path through under-over configurations, preventing direct shortcuts and ensuring uniform distribution across chambers. This intermediary structure resolves the contradiction by enforcing controlled flow patterns.
2Manufacturing precision
If multiple mixing chambers with under-over baffles are used, then hydration uniformity is improved, but device complexity increases
Solution Approach 1:
Multiple mixing chambers are merged into a single integrated tank structure, sharing common walls and support frameworks. The chambers are arranged in series within one vessel, allowing the system to achieve improved hydration consistency through multi-chamber processing while minimizing the increase in overall device complexity through spatial consolidation.
3Productivity
If polymers flow quickly through the tank, then productivity is high, but hydration is insufficient and manufacturing precision deteriorates
Solution Approach 1:
The system performs preliminary mixing actions in each sequential chamber before the polymer mixture progresses to the next chamber. Each chamber provides a staged mixing operation, ensuring incremental hydration occurs before the polymer moves forward. This preliminary action in each stage maintains productivity by keeping polymers in motion while ensuring complete hydration through cumulative mixing effects.
Solution Approach 2:
The continuous flow through multiple chambers creates periodic mixing zones where the polymer-liquid mixture undergoes repeated cycles of mixing and flow. Each chamber represents a periodic action zone that contributes to overall hydration, maintaining high productivity through continuous operation while achieving precision through repeated mixing cycles.
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 configuration effectively mitigates the slipstream issue, ensuring consistent hydration of polymers by allowing controlled flow and mixing, resulting in a more uniform polymer solution.
Implementation Method 1
Adjacent mixing chambers may be coupled using an under-over baffle... This configuration effectively mitigates the slipstream issue, ensuring consistent hydration of polymers by allowing controlled flow and mixing
Implementation Method 2
at least one mixing device disposed within at least one of the plurality of mixing chambers... at least one mixing device comprises at least one impeller
Data Source
AI summary
Embodiments of the present disclosure involve methods, devices, and systems for hydrating polymers using multiple mixing chambers. Adjacent mixing chambers may be coupled using an under-over baffle, and each mixing chamber may be generally rectangular with rounded corners.