Protruding Plate Static Mixer for Low Pressure Loss Fluid Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mixing devices for fluid streams in ducts, particularly static mixers, incur significant pressure losses, leading to inefficient mixing and higher energy costs, while regular shaped mixers struggle with poor mixing at duct corners and high pressure losses, necessitating a solution that enhances mixing efficiency with reduced pressure loss.
Innovation Solution
The use of a solid plate with protrusions extending outward from a main solid plate body, positioned transversally to the fluid stream, creates turbulent regions and aids mixing by diverting the flow, reducing obstruction and pressure loss, and allowing for better interaction of fluid streams within a shorter mixing distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional static mixers are used to achieve proper mixing of fluid streams, then mixing efficiency is improved, but pressure loss increases significantly
Solution Approach 1:
The mixing device is segmented into multiple discrete elements (baffles, protrusions, deflectors) positioned at specific intervals within the duct, rather than using a single continuous static mixer. This segmentation allows mixing to occur in distributed stages, reducing the pressure loss associated with any single mixing element while maintaining overall mixing efficiency
Solution Approach 2:
The invention introduces local turbulence-generating features (protrusions, baffles, deflectors) at specific locations within the duct where mixing is needed, rather than using a full-length static mixer. The local quality of the flow is modified only in the regions where mixing elements are present, allowing laminar flow to be maintained in other regions and thus reducing overall pressure loss
2Ease of manufacture
If regular shaped mixing devices are used in ducts, then manufacturing is simplified, but mixing performance at duct corners deteriorates
Solution Approach 1:
The mixing device incorporates asymmetric features including protrusions extending from the duct walls at different positions and angles, and deflectors oriented to create specific flow patterns. These asymmetric elements are specifically designed to address the poor mixing that occurs at duct corners, improving mixing performance while maintaining relatively simple manufacturing
Solution Approach 2:
The invention transitions from two-dimensional flat mixing surfaces to three-dimensional protruding elements (baffles, protrusions, deflectors) that extend into the duct flow. This dimensional change creates more effective flow disruption and turbulence generation, particularly in the corner regions of the duct, while the elements themselves can be manufactured using standard fabrication techniques
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 configuration improves mixing efficiency within a commercially acceptable pressure loss range, reducing mixing distances and energy costs, while minimizing pressure losses and enhancing homogeneity of fluid streams, particularly effective in applications like flue gas cleaning and acid mist reduction.
Implementation Method 1
creates turbulent regions and aids mixing by diverting the flow
Data Source
AI summary
A method for the mixing of fluid streams in a duct comprising positioning at least one mixing device having a front side and a back side within said duct through which a first major stream travels, the at least one mixing device determining a total cross-sectional area which is significantly lower than that of the duct so as to allow for the passage of said first major stream, whereby the at least one mixing device is a solid plate provided with one or more protrusions extending outward from the main solid plate body.