Continuous Processing Device Spiral Flow Mixing
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Solution Overview
Problem
Current reaction devices face challenges in achieving uniform contact processing and sufficient processing amounts, particularly in the chemical industry, where batch processing is inefficient and continuous production systems struggle with component control and blockages in micro reactors.
Innovation Solution
A continuous processing device with a processing vessel that generates a spiral liquid flow, where the injection liquid is injected at the center-side position, creating a whirlwind-like effect for uniform reaction and preventing reactant adhesion to the inner surface, and includes features like parallel or series vessel arrangements and external reactors for stable operation and particle size control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a large contact processing reactor is used to achieve uniform reactions, then the reaction uniformity is improved, but the device size and complexity increase
Solution Approach 1:
The reactor is divided into multiple processing vessels arranged in parallel or series, with each vessel containing a circulation system that creates spiral flow. This segmentation allows uniform contact processing in smaller units rather than requiring one large reactor.
Solution Approach 2:
The invention uses hydraulic spiral flow generated by circulation pumps to achieve uniform mixing and contact processing. The spiral flow pattern created by injecting liquid at center-side positions and extracting at opposite ends provides intense mixing without requiring large reactor volumes.
2Manufacturing precision
If batch processing is used to control component feeding, then the processing control precision is improved, but the productivity decreases
Solution Approach 1:
The invention implements continuous processing where components are continuously fed into the processing vessels while spiral flow maintains uniform mixing. This continuous operation eliminates the inefficiencies of batch processing while maintaining precise control over component feeding through flow rate regulation.
3Stability of the object's composition
If micro reactors with 1 mm or less flow path are used to improve contact processing, then the contact efficiency is improved, but the processing amount decreases and blockages occur
Solution Approach 1:
Instead of reducing flow path diameter (one-dimensional approach), the invention creates spiral flow patterns that wrap around the reactor interior multiple times. This multi-dimensional flow path achieves intense contact processing without the blockage issues of micro reactors, as the larger overall vessel size prevents clogging while maintaining effective mixing.
4Productivity
If continuous production system is used to improve productivity, then the processing efficiency is improved, but the contact processing control precision decreases
Solution Approach 1:
The circulation system incorporates feedback control where the extracted processed liquid is returned to the processing vessel to maintain optimal contact conditions. This feedback mechanism ensures that continuous operation maintains precise control over reaction conditions, component concentrations, and mixing effectiveness throughout the processing cycle.
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 enables a large processing amount with stable contact processing properties, preventing blockages and maintaining long-term operation by enhancing mass transfer and temperature stability, while reducing particle diameters and facility costs.
Implementation Method 1
a liquid flow is set to a spiral flow
Implementation Method 2
flow in a swirl portion in the center or in an inner peripheral portion in the vicinity of a void portion in the center, like a whirlwind, has large turbulence with high effect of mass transfer and stirring mixing
Implementation Method 3
This portion becomes a field of rapid diffusion of the injection liquid containing an injection gas or reactant, which enables a uniform reaction
Implementation Method 4
the outer peripheral spiral flow becomes a supplier of the reactant so as to moderate rapid fluctuation of substances/heat. The outer peripheral spiral flow functions as a barrier against the reactant of the injected substances (liquid, gas, solid). Therefore, adhesion of the reactant to the inner surface of the flow path may be prevented
Data Source
AI summary
To provide a processing device which is small but which can exhibits a sufficient processing amount and a uniform contact processing property. In the processing vessel 10, a liquid flow is set to a spiral flow, and in a contact processing field, the injection liquid A, B are injected at a center-side position with respect to an inner surface of the processing vessel so as to perform contact processing.