Mixing Reactor High-Speed Ejection Fluid Collision
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Solution Overview
Problem
Conventional mixing reactors for heterogeneous fluids face issues with non-uniform mixing, leading to side reactions and reduced reaction yield and rate, with by-products often adhering to reactor surfaces, increasing maintenance costs and reducing production efficiency.
Innovation Solution
A mixing reactor design featuring a first inlet and first nozzle for high-speed ejection of a first fluid, a fluid chamber with distinct space portions, a second inlet and second nozzle for radial introduction of a second fluid, and a third nozzle for radial ejection into a mixing chamber, optimizing fluid collision angles and flow paths to enhance mixing uniformity and reduce side reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sparger or disperser is used to mix heterogeneous fluids in a conventional reactor, then the fluids can be mixed, but the mixing is non-uniform leading to side reactions and reduced reaction yield
Solution Approach 1:
The reactor is divided into multiple functional zones: a first reaction zone for initial mixing and reaction, a second reaction zone for continued reaction, and a separation zone. This segmentation allows different stages of the reaction process to occur in optimized environments, improving both mixing uniformity and reaction yield.
Solution Approach 2:
The patent introduces a vertical dimension to the reaction process by incorporating a separation zone above the reaction zones. This three-dimensional configuration allows fluids to mix not only horizontally but also vertically, enhancing mixing uniformity and preventing side reactions that occur in conventional two-dimensional mixing arrangements.
2Object-generated harmful factors
If the temperature is limited to 70-80°C to suppress side reactions, then side reactions are reduced, but reaction yield and reaction rate are considerably reduced
Solution Approach 1:
The reactor is divided into temperature-zoned sections: first reaction zones maintained at lower temperatures (70-80°C) to suppress side reactions, and a second reaction zone that can operate at higher temperatures to maximize reaction rate. This spatial segmentation of temperature conditions allows simultaneous optimization of both side reaction suppression and reaction rate.
Solution Approach 2:
The system dynamically adjusts temperature conditions differentially across different zones and over time. The first reaction zones operate at controlled lower temperatures initially, then the second reaction zone can be activated or heated to higher temperatures when needed, creating a dynamic temperature profile that optimizes both safety and productivity.
3Object-generated harmful factors
If by-products are generated in conventional reactors, then they may attach to reactor surfaces, but cleaning costs increase and production efficiency deteriorates
Solution Approach 1:
The patent incorporates a separation zone that physically extracts and removes by-products from the main reaction mixture before they can attach to reactor surfaces. This extraction mechanism, combined with controlled temperature zones, prevents by-product deposition and eliminates the need for frequent cleaning operations, maintaining ease of operation and production efficiency.
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 design improves mixing uniformity, reduces side reactions, and increases reaction yield and rate, while allowing for simpler maintenance and reuse of the reactor.
Implementation Method 1
a first nozzle coaxially connected to a downstream side of the first inlet part to eject the first fluid
Implementation Method 2
two or more fluids are effectively collided with each other to enhance mixing uniformity
Data Source
AI summary
A mixing reactor for heterogeneous fluids includes a first inlet part for introducing a first fluid, a first nozzle to eject the first fluid, a fluid chamber having a first space portion and a second space portion having a larger inner diameter than that of the first space portion, a second inlet part for introducing a second fluid, a second nozzle to eject the second fluid, a mixing chamber, and a third nozzle part to eject the second fluid. In the mixing reactor for heterogeneous fluids, two or more fluids are effectively collided with each other to enhance mixing uniformity, reduce side reactions, and thus improve reaction yield and reaction rate, and allow for simple maintenance and reuse.