Static Mixer Pipe Assembly for Accurate Inline Fluid Sampling
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Solution Overview
Problem
Existing static mixers in pipelines are large, difficult to construct and install, and require complex welding, making them inefficient for accurate fluid mixing and measurement in industries like chemical, oil, and gas transportation.
Innovation Solution
A pipe assembly featuring a static mixer with angled slots and arms forming concentric rings, designed for easy installation and space-efficient operation, combined with a flow conditioner and optional pre-mixer, to ensure proper fluid mixing and sampling within pipelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional static mixers are used in pipelines, then fluid mixing function is provided, but device size becomes large and installation complexity increases
Solution Approach 1:
The static mixer is divided into multiple individual elements that can be easily connected together in series. Each element contains a specific pattern of baffles and openings, and multiple elements work together to achieve thorough mixing. This segmentation allows the mixer to be manufactured and installed in manageable sections rather than as a single large complex unit.
Solution Approach 2:
The static mixer elements are designed to be nested or stacked within the pipeline interior space. Each element fits within the pipe diameter, and multiple elements are arranged axially along the pipeline. This nesting approach maximizes the use of available pipeline volume while keeping each individual mixer element compact and space-efficient.
2Ease of manufacture
If traditional static mixers are used in pipelines, then fluid mixing function is provided, but welding requirements become complex
Solution Approach 1:
Multiple static mixer elements are combined into a single integrated assembly that functions as one unit. The elements are connected using simple mechanical coupling methods such as threading, clamping, or snap-fits, eliminating the need for complex welding procedures. This merging approach maintains mixing effectiveness while dramatically simplifying installation and construction.
Solution Approach 2:
The static mixer elements are designed with self-aligning features and inherent structural stability that allow them to be installed without requiring complex welding or specialized construction expertise. The elements may include features such as alignment pins, self-centering mechanisms, or interference-fit connections that enable workers to install the mixer using basic tools and skills.
3Measurement precision
If multiple fluids are mixed in pipelines, then accurate measurement can be achieved, but mixing efficiency is insufficient with existing devices
Solution Approach 1:
Different regions of the static mixer elements are designed with locally optimized features to address specific mixing requirements. For example, certain sections may have higher baffle density for intense local mixing, while other sections have larger openings for bulk flow through. The baffle angles, opening sizes, and patterns are locally tailored to create progressive mixing zones that efficiently blend multiple fluids together.
Solution Approach 2:
The static mixer elements are designed to dynamically interact with the flowing fluid, creating turbulent eddies and varying flow patterns as the fluid passes through each element. The angled baffles and strategic openings generate swirling motions and pressure variations that enhance mixing efficiency. This dynamic fluid-structure interaction ensures rapid and thorough mixing of multiple fluids, enabling accurate downstream measurement of fluid composition.
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 enables efficient fluid mixing and accurate sampling by imparting rotating and turbulent flow, reducing installation complexity and space requirements, while ensuring representative fluid composition sampling.
Implementation Method 1
The solution enables efficient fluid mixing and accurate sampling by imparting rotating and turbulent flow
Implementation Method 2
The solution enables efficient fluid mixing and accurate sampling by imparting rotating and turbulent flow
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B~2C
AI summary
A pipe assembly for flow measurement is characterized by a fluid flow pipeline; at least one flow conditioner; and at least one static mixer. The at least one flow conditioner and the at least one static mixer are disposed in the fluid flow pipeline in an orientation substantially perpendicular to a longitudinal axis of the fluid flow pipeline.