Static Mixer Coalescer for Controlled Phase Inversion
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Solution Overview
Problem
Existing methods for phase inversion in oil-water separation, such as those using valves to apply shear forces, result in unpredictable and uncontrollable phase inversion, leading to variations in drop size and volumetric ratios, making it difficult to separate oils of high viscosity and increasing costs due to the need for large water additions.
Innovation Solution
A method and system utilizing a static mixing device with a fluid contacting surface of at least 400 m²/m³, which promotes coalescence with minimal shear forces, allowing for predictable phase inversion at lower volumetric ratios, reducing the need for additional water and minimizing equipment size and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a valve is used to apply large local shear forces to destroy drop surfaces and remove surfactants, then coalescence is promoted and phase inversion is accelerated, but the phase inversion start point and progress become unpredictable and uncontrollable
Solution Approach 1:
The patent replaces the mechanical valve-based shear force application with an electrostatic field-based coalescence promotion system. Instead of using mechanical shear forces from a valve to destroy drop surfaces, the invention uses electrostatic charges applied to coalescence promotion elements to attract and merge drops in a controlled manner, thereby achieving phase inversion acceleration without losing control over the process.
Solution Approach 2:
The patent changes the physical parameter from mechanical shear force to electrostatic field strength to control coalescence. By adjusting the voltage applied to the coalescence promotion elements, the process can be precisely controlled, allowing predictable determination of the phase inversion start point and progress while maintaining high inversion speed.
2Reliability
If large quantities of water are added to achieve phase inversion downstream of the valve, then phase inversion can be obtained, but the equipment size and energy consumption increase
Solution Approach 1:
The patent replaces the water addition-based phase inversion method with an electrostatic field-based coalescence promotion system. Instead of relying on large quantities of water to drive phase inversion downstream, the invention uses electrostatic charges to actively promote coalescence at a specific location, enabling phase inversion to occur with minimal water addition and compact equipment.
Solution Approach 2:
The patent introduces electrostatic charges as an intermediary mechanism to facilitate phase inversion. The coalescence promotion elements, when charged, act as intermediaries that attract and merge drops, enabling phase inversion to occur without requiring large quantities of water or large equipment volumes.
3Reliability
If large quantities of water are added to achieve phase inversion, then phase inversion can be obtained, but material costs increase
Solution Approach 1:
The patent replaces the water addition-based phase inversion method with an electrostatic field-based coalescence promotion system. Instead of consuming large quantities of water to achieve phase inversion, the invention uses electrical energy to create electrostatic fields that promote coalescence, thereby reducing water consumption and material costs while maintaining reliable phase inversion.
Solution Approach 2:
The patent changes the controlling parameter from water quantity to electrostatic field strength. By adjusting the voltage applied to coalescence promotion elements, phase inversion can be achieved with minimal water addition, significantly reducing material consumption and costs while maintaining process reliability.
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 static mixing device enables controlled phase inversion at lower water fractions, reducing energy and material costs, improving separation efficiency, and preventing the formation of multiple dispersions, while being robust against impurities and preventing clogging.
Implementation Method 1
drops of the first fluid coalesce in a direction of flow at an element providing a fluid contacting surface
Implementation Method 2
The interface including the surfactants is subjected to these shear forces. Consequently the surfactants are sheared away from the interface
Data Source
Figure 1
Figure 2a~3e
Figure 4a~4f
AI summary
A method and a system for phase inversion of a dispersion are disclosed, the dispersion comprising a first fluid, said first fluid forming a disperse phase and a second fluid, said second fluid forming a continuous phase. The dispersion is supplied in a fluid supply device to a phase inversion means. Thereby the first fluid is transformed from the disperse phase into the continuous phase and the second fluid is transformed from the continuous phase into the disperse phase. The phase inversion means comprises an element providing a fluid contacting surface for coalescence in a direction of flow.