Mixer Stator Flush Line for Powder Pre-wetting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mixers for dispersing powdered chemicals into fluids, such as those used in wellbore operations, face challenges with powder agglomeration leading to suboptimal mixing and potential clogging, which are not adequately addressed by traditional pre-wetters that require additional pumping equipment, limiting system flexibility and increasing costs.
Innovation Solution
A mixer design incorporating an impeller/slinger assembly and a stator with a flush line that taps high-pressure, low-additive-content fluid from the mixing chamber to pre-wet additives within the mixer, eliminating the need for separate pumping equipment and promoting uniform dispersion by creating a two-stage high-shearing and cavitation mixing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pre-wetter is employed to prevent powder agglomeration, then powder dispersion quality is improved, but device complexity increases due to additional pumping equipment
Solution Approach 1:
The pre-wetting function is merged with the main mixing apparatus by integrating a flush line that delivers fluid directly to the powder inlet region. This eliminates the need for separate pre-wetting equipment and pumps, reducing system complexity while maintaining effective powder dispersion prevention
Solution Approach 2:
A flush line acts as an intermediary fluid delivery mechanism between the main pump and the powder inlet. It provides a dedicated fluid pathway that pre-wets powder before it enters the mixing chamber, improving dispersion quality without requiring additional pumping equipment
2Manufacturing precision
If separate pumping equipment is added for pre-wetting, then powder wetting effectiveness is improved, but cost increases
Solution Approach 1:
The main pump serves multiple functions: it provides both the primary fluid flow for mixing and the pressurized fluid for pre-wetting the powder through the flush line. This multi-functionality eliminates the need for separate pumping equipment, reducing system cost while maintaining effective powder wetting
Solution Approach 2:
The system uses its own internal fluid flow to perform the pre-wetting function. The flush line taps into the pressurized fluid already being supplied by the main pump, allowing the system to self-service the pre-wetting requirement without external or additional equipment
3Manufacturing precision
If additional equipment is added to the system, then powder dispersion capability is improved, but maintenance requirements increase
Solution Approach 1:
The pre-wetting function is combined with the main mixing system through an integrated flush line. This reduces the total number of equipment components that require maintenance, while still providing effective powder dispersion capability through the unified system
4Manufacturing precision
If the system uses traditional pre-wetting methods, then powder clumping is reduced, but system flexibility is limited
Solution Approach 1:
The flush line configuration and flow rate can be dynamically adjusted to optimize pre-wetting effectiveness for different powder types and operating conditions. This dynamic adjustability enhances system flexibility while maintaining effective clumping prevention across various 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 ensures effective prevention of powder clumping, achieves uniform dispersion of additives, and reduces the risk of clogging, while simplifying the system by eliminating the need for additional pumping equipment, thus enhancing operational efficiency and flexibility.
Implementation Method 1
A mixer design incorporating an impeller/slinger assembly and a stator with a flush line that taps high-pressure, low-additive-content fluid from the mixing chamber to pre-wet additives within the mixer
Implementation Method 2
promoting uniform dispersion by creating a two-stage high-shearing and cavitation mixing process
Implementation Method 3
promoting uniform dispersion by creating a two-stage high-shearing and cavitation mixing process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A mixer and method for mixing are provided. The mixer includes a housing having a fluid inlet, an additive inlet, and an outlet, with the housing defining a mixing chamber in fluid communication with the fluid inlet, the additive inlet, and the outlet. The mixer also includes an impeller disposed in the mixing chamber, wherein, when rotated, the impeller draws fluid through the fluid inlet. The mixer also includes a slinger disposed in the mixing chamber and configured to receive the fluid from the impeller and to receive an additive from the additive inlet. When rotated, the slinger slings the fluid and the additive radially outwards. The mixer further includes a stator disposed at least partially around the slinger, with the stator including vanes spaced circumferentially apart so as to define flowpaths therebetween.