Homogeneous Mixing Apparatus With Variable Speed Stator Rotor Gaps
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Solution Overview
Problem
Existing mixing technologies lack flexibility and efficiency in handling different mixing requirements, such as gas-liquid, liquid-liquid, and liquid-solid mixtures, and struggle to achieve uniform dispersion and emulsification effectively.
Innovation Solution
A homogenous mixing apparatus with a series of dynamic mixing devices, each with adjustable rotating speeds and gap distances between stators and rotors, along with a control unit for independent operation, temperature regulation, and pressure control, allowing for flexible operating modes to meet various mixing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single dynamic mixer is used for mixing, then the device structure is simple, but the adaptability to different mixing requirements (gas-liquid, liquid-liquid, liquid-solid) is insufficient
Solution Approach 1:
The mixing system is divided into multiple independent dynamic mixers (first, second, and third dynamic mixers) that can be selectively activated. Each mixer has its own rotor-stator assembly with adjustable parameters, allowing the system to adapt to different mixing requirements (gas-liquid, liquid-liquid, liquid-solid) by engaging only the necessary mixers for each specific application.
Solution Approach 2:
The patent implements dynamic adjustability in rotor speed, stator-rotor gap distance, and the selection of which mixers to operate. The control unit enables real-time modification of mixing parameters during operation, allowing the same apparatus to handle various mixing tasks with different viscosity, density, and phase composition requirements.
2Productivity
If fixed rotating speed and gap distance are used in dynamic mixers, then the control system is simple, but the mixing efficiency and uniformity for different materials cannot be optimized
Solution Approach 1:
The system employs variable speed drives for each rotor and adjustable mechanisms for stator-rotor gap control. The control unit receives feedback and automatically adjusts rotating speeds and gap distances to optimize mixing efficiency for different material properties, transforming the static mixer into a dynamically adaptable system.
Solution Approach 2:
The patent changes key operating parameters (rotating speed, gap distance, operational stage selection) based on the specific mixing requirements. By adjusting these parameters, the system optimizes the energy input and shear forces applied to different materials, thereby improving mixing efficiency and uniformity for gas-liquid, liquid-liquid, and liquid-solid systems.
3Productivity
If multiple dynamic mixers are operated simultaneously at high speed, then the mixing efficiency is high, but the energy consumption increases significantly
Solution Approach 1:
The system allows selective operation of individual dynamic mixers based on the specific mixing task requirements. Not all mixers need to operate at high speed simultaneously - the control unit can activate only the necessary number and combination of mixers, applying partial action to reduce energy consumption while maintaining adequate mixing efficiency.
Solution Approach 2:
The multi-stage mixing system can operate in sequential or periodic fashion, where different mixers are activated at different times or cycles. This periodic operation allows the system to achieve thorough mixing through multiple passes at moderate speeds rather than continuous high-speed operation of all mixers, thereby reducing overall energy consumption.
4Manufacturing precision
If the stator and rotor are fixed in position, then the mechanical structure is simple, but the mixing uniformity and dispersion quality cannot be optimized
Solution Approach 1:
The patent introduces adjustability in the radial and axial positions of rotors and stators. The gap distance between stator and rotor surfaces can be modified, and the angular orientation of teeth can be adjusted. These dynamic positioning capabilities allow optimization of flow patterns and shear distribution to achieve superior mixing uniformity and dispersion quality.
Solution Approach 2:
The system allows different local configurations of rotor-stator assemblies with varying gap distances and tooth arrangements in different spatial locations. This enables tailored mixing intensity and flow patterns in specific regions of the mixing chamber, optimizing local mixing quality for heterogeneous materials with varying properties throughout the batch.
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 apparatus simplifies operation, significantly improves mixing efficiency, and achieves high-quality mixing results by allowing for precise control of mixing parameters, reducing mixing time, and enhancing the uniformity of mixtures.
Implementation Method 1
The rotor is located on an inner side of the stator, and is arranged to be rotatable relative to the stator by means of a rotating shaft. An axial gap and a radial gap are provided between each row of stator teeth and rotor teeth.
Implementation Method 2
uses a rotor or a combination of a rotor and a stator to make the pressurized ozone gas fully transfer mass with the liquid with a certain pressure under a pressure condition, so as to increase a rate of dissolving the ozone gas into the liquid, improve the mixing efficiency
Implementation Method 3
make the pressurized ozone gas fully transfer mass with the liquid with a certain pressure under a pressure condition
Implementation Method 4
increase a rate of dissolving the ozone gas into the liquid
Data Source
AI summary
A homogenous mixing apparatus is provided that includes a circulation unit, a dynamic mixing unit, wherein a feeding port of the first-stage dynamic mixing device communicates with the discharging end of the circulation unit, a discharging port of the third-stage dynamic mixing device communicates with the feeding end of the circulation unit, and each of the dynamic mixing devices includes a dynamic mixer; and a control unit, configured to be capable of controlling the dynamic mixing unit, so that the dynamic mixers of the first-stage, second-stage, and third-stage dynamic mixing device are capable of being independently started and shut down and operated at independent rotating speeds, wherein the dynamic mixers each includes a stator and a rotor, rotating speed ranges of the dynamic mixers of the first-stage, second-stage, and third-stage dynamic mixing device increase in sequence, and distances between the rotors and the stators decrease in sequence.