Static Mixer Element Layout for High-Pressure Bubble Breakup
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Solution Overview
Problem
Existing static mixers are inefficient in reducing bubble size and require high energy consumption under high pressure conditions, limiting their effectiveness in gas/liquid mixing processes.
Innovation Solution
A static mixer element with evenly distributed through openings and mixer units that force fluid flow changes, combined with a frame and position lockers, allowing for compact and efficient gas/liquid mixing under high pressure by minimizing bubble size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional static mixers are used under high pressure conditions, then the mixing process can be maintained, but bubble size reduction is inefficient and gas/mass transfer is suboptimal
Solution Approach 1:
The static mixer is divided into multiple mixer units (at least two) arranged in series, where each unit contains multiple through-openings. This segmentation allows the fluid stream to be divided into multiple smaller streams that pass through different openings, creating numerous smaller bubbles rather than fewer larger bubbles, thereby improving gas/mass transfer efficiency under high pressure conditions
Solution Approach 2:
Each mixer unit is designed with specific local characteristics - the through-openings are distributed across the surface of each unit, and the units have different orientations relative to the flow direction. This local quality variation ensures that different regions of the mixer contribute differently to bubble fragmentation, optimizing the overall gas/mass transfer process
2Device complexity
If conventional static mixers are used, then no moving parts are required, but energy consumption increases under high pressure conditions
Solution Approach 1:
While maintaining the static mixer configuration with no moving parts, the invention introduces dynamic flow patterns through the strategic arrangement of multiple mixer units with through-openings at different orientations. The fluid flow creates dynamic mixing action and bubble fragmentation without requiring mechanical movement, thereby reducing energy consumption while maintaining mixing effectiveness under high pressure
3Productivity
If mixer units are arranged to force flow changes, then mixing efficiency improves, but device complexity increases
Solution Approach 1:
Multiple mixer units are nested or stacked in series within the same mixer element housing, with each unit containing multiple through-openings. This nested arrangement allows multiple mixing stages to be compactly integrated into a single device, improving mixing efficiency through repeated flow redirection while avoiding the complexity of multiple separate devices
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 achieves enhanced gas/mass transfer and homogenization with reduced pressure loss, making it more efficient and cost-effective for high-pressure applications.
Implementation Method 1
A static mixer element with evenly distributed through openings across its surface, comprising multiple mixer units that force fluid flow changes
Data Source
Figure 1
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Figure 3A~3B
AI summary
The present invention relates to a static mixer or a flow reactor comprising a static mixer for mixing streams of fluid transported through or circulated in a flow reactor, and in particular a static mixer according to the invention may improve gas/mass transfer by reducing the size of gas bubbles. A flow reactor according to the invention may have any cross-section, e.g. circular, and one or more mixing units may be inserted in the flow reactor. More particularly, the invention relates to a static mixer element configured to reduce the size of gas bubbles in a liquid for installation in a flow channel which static mixer element comprises a mixer unit (1) extending over a cross-section area of the flow channel which mixer unit (1) comprises a plurality of through openings (3), the static mixer element comprises or is constituted of at least two mixer units (1), a first or previous mixer unit (1) and a second and adjacent mixer unit (1), which first and second mixer units are displaced relative to each other in the direction of flow, in such a way that a through opening (3) in the first or previous mixer unit (1) at least partly faces a surface of the second and adjacent mixer unit (1) thereby forcing the fluid flow to change direction, wherein adjacent mixer units (1) have substantially the same height or thickness h, and are substantially parallel having a distance d between them, which distance d may be approximately 0 as two adjacent mixer units (1) may be in contact with each other at one or more points, or the distance d may be larger than 0 and may be at least 0.5 the thickness of a mixer unit (1) i.e. 0.5xh, or the distance d may be at least the thickness of a mixer unit i.e. 1xh, or the distance d may be at maximum 10 times the thickness of a mixer unit (1) i.e. 10xh, or at maximum 5 times the thickness of a mixer unit i.e. 5xh, or at maximum 3 times the thickness of a mixer unit i.e. 3xh.