Spiral Mixing Apparatus for Compact Liquid-Liquid Extraction Columns
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Solution Overview
Problem
Existing liquid-liquid extraction technologies face inefficiencies in solute transfer between phases, leading to low process efficiency, high energy consumption, and installation challenges due to column height, particularly in forming stable emulsions and requiring additional separation techniques.
Innovation Solution
A mixing apparatus with spiral-shaped modular elements, such as finned tubes, integrated into a countercurrent extraction column, provides a continuous and efficient mixing mechanism that minimizes emulsion formation by using a combination of gravitational and rotational forces, enhancing the contact surface area and solute exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixing technologies are used in liquid-liquid extraction, then solute transfer between phases occurs, but process efficiency is low and energy consumption is high
Solution Approach 1:
The patent employs a rotating mixing element that dynamically interacts with the liquid phases. The rotation creates varying flow patterns and shear forces that enhance mass transfer between phases while maintaining efficient mixing with reduced energy input compared to conventional static or high-speed agitation systems.
Solution Approach 2:
The mixing apparatus is divided into modular spiral-shaped elements with fins that segment the liquid flow into multiple pathways. This segmentation increases the interfacial contact area between phases and improves solute transfer efficiency while distributing energy consumption across multiple small-scale mixing zones rather than requiring high overall energy input.
2Productivity
If conventional extraction columns are used, then extraction process occurs, but column height is large causing installation challenges
Solution Approach 1:
The rotating mixing element creates dynamic mixing zones that intensify mass transfer within a compact volume. This dynamic action allows achieving high extraction efficiency in a shorter column height by concentrating the mixing and mass transfer activity in specific rotational zones rather than requiring long continuous contact sections.
Solution Approach 2:
The patent introduces rotation as a new dimension of mixing, transforming the traditional vertical or horizontal linear flow pattern into a three-dimensional rotational flow field. This dimensional change enables efficient mass transfer to occur within a compact axial space, reducing the required column height while maintaining or improving extraction efficiency.
3Productivity
If mechanical mixing systems are used to increase contact surface area, then solute transfer improves, but emulsion formation increases requiring additional separation techniques
Solution Approach 1:
The rotating mixing element provides controlled dynamic mixing that enhances mass transfer while allowing phases to separate between rotation cycles. The continuous rotation and reversal create brief intense mixing periods followed by separation periods, preventing stable emulsion formation while maintaining high solute transfer efficiency during the mixing phases.
Solution Approach 2:
The rotation of the mixing element creates periodic mixing and separation cycles. During rotation, intense mixing occurs to enhance solute transfer; during reversal or between rotations, phases have opportunity to separate. This periodic action pattern prevents continuous emulsion stabilization while maintaining effective mass transfer during the active mixing phases.
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 approach significantly improves extraction efficiency, reduces operational costs, and allows for compact column design suitable for installation near process areas, while maintaining high yields and minimizing emulsion stability issues.
Implementation Method 1
Such reciprocal intimate contact, which is helped by the dispersion of the phases, can be obtained by using a unique gravitational potential energy
Implementation Method 2
The phases, both modified in composition, provided there is still a residual difference in their densities, can subsequently be separated using a gravitational potential energy, alone or associated with devices that exploit a centrifugal force
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
An apparatus (30) for mixing two countercurrent liquid phases as well as extraction column (4) for carrying out continuous countercurrent liquid-liquid extraction processes, which comprises said mixing apparatus are described.