Multi-channel Variable-flow Pipeline Mixer Design
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Solution Overview
Problem
Existing fluid mixing systems in pipelines face challenges in achieving adequate dispersion and mixing of injected fluids across a wide range of flow rates, particularly when the pipe fluid flow rate decreases below a critical level, limiting the injection rate and preventing turbulent mixing.
Innovation Solution
The implementation of a multi-channel, variable-flow pipeline mixer apparatus with multiple mixers, each comprising a reducer conduit for acceleration and an expander conduit for turbulent mixing, along with a shut-off valve to adjust flow rates, ensuring efficient mixing by increasing the surface area for fluid entrainment and facilitating turbulent mixing across varying flow conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single converging pipe section is used to accelerate pipe fluid, then mixing is improved, but the injection rate is limited below the required level
Solution Approach 1:
The patent divides the mixing system into multiple separate mixers (first mixer, second mixer, etc.) instead of using a single mixer. Each mixer has its own converging section and expander section, allowing the pipe fluid to be split and mixed with injected fluid in parallel channels, thereby increasing the total injection rate while maintaining mixing quality.
Solution Approach 2:
The patent transitions from a single-channel mixing approach to a multi-channel parallel mixing approach. By adding the dimension of multiple parallel mixers, the system can handle higher injection rates while maintaining the mixing effectiveness of individual channels.
2Manufacturing precision
If a single diverging pipe section is used to facilitate turbulent mixing, then mixing is improved, but the system cannot achieve turbulent mixing when pipe fluid flow rate decreases below a critical level
Solution Approach 1:
By segmenting the mixing system into multiple parallel mixers, each mixer can be optimized to maintain turbulent flow conditions within a broader overall flow rate range. When total flow rate decreases, the system can still maintain turbulence in individual mixer channels.
Solution Approach 2:
The patent uses variable geometry in the converging and expander sections to optimize flow conditions. The specific geometric parameters of each mixer can be adjusted or designed to maintain turbulent mixing across varying flow rates, improving adaptability.
3Productivity
If multiple mixers are incorporated to increase surface area for fluid entrainment, then mixing efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple mixers into a single integrated assembly where the mixers are arranged in parallel and connected to common inlet and outlet conduits. This merging approach increases mixing efficiency through multiple channels while minimizing the increase in overall device complexity by using a modular, systematic arrangement.
4Manufacturing precision
If the pipe fluid flow rate is insufficient to support turbulent mixing in all mixers, then mixing in some mixers is compromised, but reducing flow to single mixer loses the benefit of multiple channels
Solution Approach 1:
The patent incorporates flow control valves in each mixer channel that allow dynamic adjustment of flow distribution. When total flow rate is insufficient, the valves can be adjusted to concentrate flow in fewer active mixers, ensuring turbulent mixing conditions are maintained where needed while keeping other channels inactive or at lower flow.
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 solution enhances mixing efficiency by increasing the surface area for fluid entrainment and allowing adequate injection rates, ensuring turbulent mixing even at lower pipe fluid flow rates, thereby improving the quality and consistency of fluid processing across a wide range of flow conditions.
Implementation Method 1
a reducer conduit that converges to accelerate pipe fluid
Implementation Method 2
an expander conduit in which the pipe fluid and injected fluid(s) can turbulently mix
Implementation Method 3
increase the surface area along which the injected fluid(s) can be entrained by the pipe fluid
Data Source
AI summary
The present disclosure includes mixing apparatuses comprising a first conduit defining an inlet channel, a second conduit defining an outlet channel, and an injection assembly that is disposed between the first and second conduits. The injection assembly can comprise two or more mixers, each having a reducer conduit that defines a mixing channel and an expander conduit that defines an expanding channel. The injection assembly can also comprise a first injection conduit configured to inject fluid into the mixing channel. At least one of the mixers can comprise a shut-off valve movable from an open position to a closed position in which the shut-off valve prevents fluid from flowing from the mixer to the second conduit. Closing the shut-off valve can increase the fluid flow rate in at least one other of the mixing channels.