Polytope Static Mixer Geometry for CFD-Led Mixing Optimization
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Solution Overview
Problem
Existing static mixer designs require extensive experimental testing and re-designs to achieve optimal performance, leading to high costs and limited exploration of design space.
Innovation Solution
A computational workflow combining an evolutionary design algorithm and computational fluid dynamics to predict optimal static mixer geometries, utilizing an elongated integral scaffold with radially or axially arranged polytope projections for enhanced mixing and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional static mixer design methods are used with extensive experimental testing and re-designs, then optimal performance can be achieved, but manufacturing costs and time consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by using computational fluid dynamics (CFD) simulations and evolutionary algorithms to predict and optimize mixer geometry before physical manufacturing. This allows multiple design iterations to be tested virtually, identifying the optimal geometry upfront and avoiding costly experimental re-designs later in the manufacturing process.
2Manufacturing precision
If multiple candidate static mixer designs are manufactured and tested experimentally, then the most suitable design can be identified, but time and resource consumption increase
Solution Approach 1:
The patent uses computational models as virtual copies of physical mixers to evaluate performance. The CFD simulations create digital twins of candidate designs, allowing thorough evaluation of mixing characteristics without building physical prototypes. This virtual copying approach maintains design optimization capability while dramatically reducing the time and resources needed for testing multiple candidates.
3Productivity
If complex geometries are designed for high performing static mixers, then mixing efficiency improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs parameter changes by systematically varying geometric parameters (such as projection angles, heights, and spacing) within the evolutionary algorithm. This allows the optimization of mixing efficiency through precise parameter adjustment rather than fundamentally changing the overall geometry structure, thereby achieving high performance while controlling manufacturing complexity.
4Reliability
If extensive experimental testing is conducted to validate mixer designs, then performance reliability is confirmed, but resource consumption and manufacturing costs increase
Solution Approach 1:
The patent replaces the mechanical experimental testing system with a computational simulation system. Instead of physically manufacturing and testing mixers to validate performance, CFD simulations and evolutionary algorithms provide virtual validation. This substitution maintains performance reliability assessment capability while dramatically reducing energy and resource consumption associated with physical prototyping and testing.
Data Source
AI summary
This disclosure relates to a static mixer element comprising an elongated integral scaffold, wherein the scaffold comprises plurality of polytope projections in (i) a radially or axially arranged network or (ii) a spiral ribbon of polytope projections to define a plurality of passages configured for mixing one or more fluidic reactants during flow and reaction thereof through the mixer, wherein the static mixer element comprises at least one elongated support member, wherein at least a portion of the plurality of projections are in connection with the elongated support member.