Spherical Mixing Assembly for Uniform Shear and Low Pressure Drop
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Solution Overview
Problem
Conventional mixers in the oil refining process suffer from uneven shear force distribution, leading to inefficient mixing, high pressure drop, high power consumption, and the formation of inseparable emulsions, which can cause corrosion and equipment damage due to residual salts in crude oil.
Innovation Solution
A mixing assembly comprising a tubular member with a spherical body that includes channels oriented towards the center, allowing for efficient mixing with uniform shear force and reduced pressure drop, featuring a Y-shaped injection nozzle and flush windows for solid accumulation removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixers are used to create water-oil emulsion, then mixing function is achieved, but uneven shear force distribution occurs leading to dead-spots and minimal turbulent flow which reduces mixing efficiency
Solution Approach 1:
The spherical body is segmented into multiple channels (first plurality of channels in inlet side, second plurality of channels in outlet side) that divide the fluid flow into multiple streams. This segmentation creates more uniform shear force distribution across the mixing zone and eliminates dead-spots by ensuring all areas receive turbulent flow coverage.
Solution Approach 2:
The patent introduces a third dimension by orienting channels toward a center point within the spherical body, creating radial flow patterns. This dimensional change from linear to radial flow distribution enhances turbulence uniformity and eliminates minimal flow areas that occur in conventional linear mixer designs.
2Productivity
If conventional mixers are used to create water-oil emulsion, then mixing function is achieved, but extreme local turbulence occurs which promotes highly inseparable emulsion
Solution Approach 1:
The channel orientations toward the center create localized high-turbulence zones at the center point while maintaining controlled shear forces in peripheral areas. This local quality differentiation ensures efficient mixing at the core while preventing excessive turbulence that would create inseparable emulsions in surrounding regions.
Solution Approach 2:
The patent changes the flow parameters by directing channels toward a central point, which modifies the velocity distribution and shear rate profiles. This parameter change creates a more balanced turbulence intensity distribution that achieves mixing efficiency without generating the extreme local turbulence that leads to stable, inseparable emulsions.
3Productivity
If conventional mixers are used to create water-oil emulsion, then mixing function is achieved, but high pressure drop occurs
Solution Approach 1:
By segmenting the flow into multiple channels within the spherical body, the pressure drop is distributed across parallel flow paths rather than concentrated in a single path. This segmentation reduces the overall pressure drop while maintaining the turbulence intensity needed for effective mixing.
4Productivity
If conventional mixers are used to create water-oil emulsion, then mixing function is achieved, but high power consumption occurs
Solution Approach 1:
The segmented channel structure allows energy to be distributed more efficiently across multiple flow paths, reducing the peak energy requirements. The radial orientation of channels toward the center creates more uniform energy distribution, reducing overall power consumption while maintaining mixing effectiveness.
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 assembly achieves efficient mixing with reduced power consumption, lower chemical and water usage, and improved droplet uniformity, minimizing corrosion risks and operational costs while allowing for flexible installation orientations.
Implementation Method 1
Conventional mixers however have uneven shear force exerted to the process flow, leading to either dead-spots and/or other areas having minimal turbulent flow
Implementation Method 2
Conventional mixers however have uneven shear force exerted to the process flow, leading to either dead-spots and/or other areas having minimal turbulent flow
Data Source
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AI summary
A mixing assembly (100) comprises a tubular member (105) and a spherical body (125) disposed within a portion of the tubular member (105). The spherical body (125) has a central volume (810), and a wall (800) defined by an outside diameter (805) and an inside diameter (900). The spherical body (125) includes an inlet side (200) and an outlet side (400), and a plurality of channels (205) formed in each of inlet side (200) and outlet side (400). The channels (205) are oriented toward a center of the central volume (810). A mixing assembly (100) comprises a tubular member (105) and a spherical body (125) disposed within a portion of the tubular member (105). The spherical body (125) has a central volume (810), and a wall (800) defined by an outside diameter (805) and an inside diameter (900). The spherical body (125) includes an inlet side (200) and an outlet side (400), and a plurality of channels (205) formed in each of inlet side (200) and outlet side (400). The channels (205) are oriented toward a center of the central volume (810).