Static Mixer Injector for Extrusion Steam Water Injection
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Solution Overview
Problem
Conventional extrusion systems face issues with contamination and inefficiency due to the injection of steam and water, leading to plugging and microbiological contamination problems, as well as wasteful thermal energy evolution.
Innovation Solution
A composite fluid injection apparatus comprising a static mixer section and an injector valve with a large diameter and short injection path to minimize plugging, combined with automated control for efficient steam and water injection into extrusion system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional injectors with small diameter and long length are used, then fluid injection is achieved, but plugging occurs and reliability deteriorates
Solution Approach 1:
The patent inverts the conventional injector design by using a short, wide-bore injector instead of a long, narrow-bore injector. The injector has a length of only 0.5 to 2 inches with a large bore diameter of 0.25 to 0.5 inches, reversing the traditional aspect ratio to prevent plugging while maintaining injection effectiveness.
Solution Approach 2:
The patent changes the geometric parameters of the injector by increasing the bore diameter and decreasing the length. This parameter transformation converts the injector from a conventional long-narrow design to a short-wide design, fundamentally altering its behavior to prevent plugging and improve reliability.
2Manufacturing precision
If multiple injectors are used along the preconditioner housing, then moisture distribution is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple injection functions into a single injector assembly that can deliver multiple fluid types (steam, water, oil) simultaneously or sequentially. This consolidation reduces the number of separate injector components while maintaining the ability to provide distributed moisture throughout the preconditioning zone.
Solution Approach 2:
The injector assembly is designed with multi-functionality to handle different fluid types and injection patterns. A single universal injector structure can accommodate steam, water, and oil delivery, as well as provide both centralized and distributed injection patterns, eliminating the need for multiple specialized injectors.
3Productivity
If steam is injected into the extrusion system, then cooking and forming are facilitated, but thermal energy is wasted through steam venting
Solution Approach 1:
The system incorporates feedback control through temperature sensors and pressure transducers that monitor the extrusion process in real-time. This feedback enables automated adjustment of steam and water injection rates to match actual process requirements, preventing over-injection and the subsequent venting of excess steam that would waste thermal energy.
Solution Approach 2:
The patent dynamically changes the injection parameters (temperature, pressure, flow rate) of steam and water based on process conditions. By adjusting these parameters in real-time, the system optimizes cooking efficiency while minimizing excess steam generation and associated energy losses.
4Stress or pressure
If steam vapor is vented from the system, then pressure is relieved, but contamination occurs
Solution Approach 1:
The patent converts the potentially harmful effect of steam vapor into a beneficial one by using it as a cleaning medium. The steam is directed to impinge upon and wash the extrusion components, using the same steam that would otherwise be wasted to prevent contamination, thereby turning a harmful venting operation into a beneficial cleaning process.
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 reduces plugging and contamination, optimizes thermal energy use, and improves product quality by ensuring consistent and efficient injection of fluids, increasing cook values and reducing steam vapor discharge.
Implementation Method 1
a fluid static mixer section including an elongated, tubular casing having a plurality of fluid inlets, a stationary mixing assembly within the casing and operable to mix plural fluids
Implementation Method 2
an injector valve including a fluid inlet operably coupled with the static mixer outlet, a mixed fluid outlet, shiftable control valve structure
Data Source
AI summary
Apparatus (20) for injection of fluid into extrusion system components such as a preconditioner (24) or extruder (100) is provided, preferably as a composite assembly including a fluid injection valve (52) and an interconnected static mixer section (54). Alternately, use may be made of the fluid injection valve (52) or static mixer section (54) alone. The invention greatly simplifies the fluid injection apparatus used in extrusion systems, while giving more efficient absorption of thermal energy with a minimum of environmental contamination, and the ability to inject multiple streams into the extrusion systems.