Mixer Stator and Slinger Assembly for Powder Dispersion
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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 due to cohesive properties of powders, which can be mitigated but require additional pumping equipment and complexity.
Innovation Solution
A mixer design incorporating an impeller and slinger assembly in a back-to-back arrangement, with a flush line tapping high-pressure, clean fluid from the mixing chamber to pre-wet additives, reducing clumping and eliminating the need for separate pumping equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-wetters are employed to mitigate powder clumping, then powder dispersion quality is improved, but system complexity increases due to additional pumping equipment
Solution Approach 1:
The patent combines the pre-wetting function with the existing pump and mixing chamber by adding a flush line that taps into the pump discharge. This integrates the pre-wetting operation into the existing pumping system, eliminating the need for separate pre-wetting equipment while maintaining effective powder dispersion
Solution Approach 2:
The flush line acts as an intermediary conduit that transfers fluid from the pump discharge to the powder feed point. This intermediary structure enables pre-wetting functionality without requiring direct modification of the pump or addition of complex pre-wetting equipment
2Manufacturing precision
If separate pumping equipment is added for pre-wetting, then powder clumping is reduced, but system costs and maintenance requirements increase
Solution Approach 1:
The patent merges the pre-wetting function into the existing pump system by utilizing the pump discharge pressure to drive fluid through the flush line to the powder feed point. This eliminates the need for separate pumping equipment, reducing both manufacturing costs and maintenance requirements while maintaining effective powder dispersion
Solution Approach 2:
The system uses its own pump discharge pressure to provide the pre-wetting function, rather than requiring external pumping equipment. The flush line taps into the existing high-pressure fluid stream and redirects it to pre-wet the powder, making the system self-sufficient
3Manufacturing precision
If separate pumping equipment is added for pre-wetting, then powder clumping is reduced, but system reliability decreases due to additional failure points
Solution Approach 1:
The patent combines the pre-wetting function with the existing pump system, eliminating additional failure points associated with separate pumping equipment. The flush line utilizes the existing pump discharge pressure, so the system maintains powder dispersion quality without adding components that could fail
4Device complexity
If fixed-size mixer equipment is used, then equipment simplicity is maintained, but adaptability to different flowrates is limited
Solution Approach 1:
The patent enables dynamic adjustment of pre-wetting flowrate by controlling the flush line opening, allowing the fixed-size mixer to adapt to different operating conditions and flowrates while maintaining equipment simplicity
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 design ensures effective dispersion of additives, minimizing clumping and clogging risks while simplifying the system by integrating pre-wetting within the mixer, enhancing mixing efficiency and reducing system complexity and costs.
Implementation Method 1
The impeller draws fluid into the mixing chamber via a fluid inlet, pressurizes the fluid, and expels the fluid downward and outward
Implementation Method 2
Using the pressure of the fluid in the mixing chamber, as provided by the impeller, the flush line may channel the relatively clean fluid from the mixing chamber to the additive-channeling structure, so as to pre-wet the additive
Data Source
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.