Static Emulsification Device for Intrinsic Safety
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Solution Overview
Problem
Current emulsion matrix preparation technologies in the civil explosive industry face issues such as outdated processing methods, poor safety, and high energy consumption due to the use of high-speed shear and screw pumps, leading to safety risks and inefficient energy use.
Innovation Solution
An emulsion matrix ground station with intrinsic safety is developed, utilizing a static emulsification device that mixes jetted water and oil phases without mechanical stirring or shear, allowing direct loading of the emulsion matrix into a truck for on-site use, thereby reducing energy consumption and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed shear is used to produce emulsion matrix, then production efficiency is improved, but safety level deteriorates due to mechanical friction risks
Solution Approach 1:
The patent replaces the high-speed shear mechanical mixing system with a static emulsification device that uses fluid dynamics (jet streams and vortex flow) to create emulsion matrix. This substitution eliminates mechanical friction and the associated safety risks while maintaining production efficiency through the high-velocity fluid interaction in the static mixing chambers.
2Ease of operation
If screw pump is used for transporting emulsion matrix, then transportation capability is improved, but energy consumption increases and safety level deteriorates
Solution Approach 1:
The patent extracts and eliminates the screw pump component from the system by designing the emulsion matrix production and delivery process to rely on fluid pressure and gravity flow through the static emulsification device and loading system. This removal of the mechanical pumping component directly reduces energy consumption and eliminates the safety risks associated with mechanical friction in pump components.
3Productivity
If mechanical stirring is used in emulsion matrix production, then mixing efficiency is improved, but safety level deteriorates due to friction heat generation
Solution Approach 1:
The patent substitutes mechanical stirring with a static emulsification process where jet streams of water and oil phases interact in controlled chambers with vortex flow patterns. This fluid-dynamic approach achieves thorough mixing without mechanical contact, thereby eliminating friction heat generation while maintaining high mixing efficiency through the turbulent flow and vortex mechanisms.
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 solution eliminates mechanical friction risks and reduces overall energy consumption by approximately 50% compared to prior art, ensuring safer and more efficient emulsion matrix production and transportation.
Implementation Method 1
a water phase pump, an oil phase pump and a static emulsification device, wherein, the water phase pump has an inlet connected to an outlet of the water phase tank by a pipeline, and an outlet connected to a water phase inlet of the static emulsification device by a pipeline
Implementation Method 2
The static emulsification device is designed by utilizing a principle of jetting vortex flow emulsification
Data Source
Figure 1~2
Figure 3
AI summary
An emulsion matrix ground station with intrinsic safety, which relates to the technical field of emulsion matrix preparation process and apparatus of mobile ground auxiliary equipment in civil explosive industry, comprises a water phase tank (2), an oil phase tank (11), a water phase pump (5), an oil phase pump (9) and a static emulsification device (7), wherein, the water phase pump (5) has an inlet connected to an outlet of the water phase tank (2) by a pipeline, and an outlet connected to a water phase inlet (13) of the static emulsification device (7) by a pipeline; the oil phase pump (9) has an inlet connected to an outlet of the oil phase tank (11) by a pipeline, and an outlet connected to an oil phase inlet (12) of the static emulsification device (7) by a pipeline. It uses a fully static emulsification device as the emulsification apparatus, and is an emulsion matrix preparation and transportation apparatus with no stirring, no mechanical shear, no emulsion delivering matrix pump in the preparation process of emulsion matrix. The static emulsification device is designed by utilizing a principle of jetting vortex flow emulsification, and the prepared emulsion matrix is directly loaded by means of a hose from the outlet of the static emulsification device into an emulsion tank of an emulsion loading truck, so that the heat explosion possibility due to mechanical friction is eliminated, and the overall energy consumption of the entire production line is also reduced.