Static Mixer Insert With Internal Channels For Viscous Fluid Heat Exchange
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Solution Overview
Problem
Existing static mixers and heat exchangers face limitations in efficiently mixing and cooling or heating viscous fluids, leading to non-homogeneous fluid flow, residence time differences, and potential decomposition of sensitive polymers, due to inadequate mixing performance and high production costs.
Innovation Solution
A device comprising a cladding element and a mixer insert with intersecting groups of web elements, where the web elements have channels extending from one end to the other, allowing for efficient cross-mixing and heat exchange without gaps, manufactured using a casting method for economic production and high fluid pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shell and tube heat exchangers with static mixers are used for larger throughput quantities, then heat exchange capacity is improved, but fluid flow distribution becomes non-homogeneous leading to different residence times and potential fluid decomposition
Solution Approach 1:
The mixing chamber is divided into multiple segments by a plurality of mixer inserts arranged in series, each insert creating additional flow paths that distribute fluid more uniformly across all tubes, reducing residence time differences
Solution Approach 2:
Static mixer inserts are nested inside the tubes of the shell and tube heat exchanger, combining mixing functionality within the heat exchange structure to achieve both heat transfer and homogeneous mixing simultaneously
2Productivity
If bundle heat exchangers with tubes arranged in the fluid flow are used, then heat transfer surface utilization is improved, but mixing performance is reduced due to insufficient cross-flow generation
Solution Approach 1:
The mixer inserts are designed with web elements of varying geometries and arrangements in different sections of the mixing chamber, creating locally optimized flow patterns that generate sufficient cross-flow while maintaining high heat transfer surface utilization
Solution Approach 2:
Web elements extend in multiple dimensions including radial and axial directions, creating three-dimensional flow disruption that enhances cross-mixing without compromising the compact tube bundle configuration
3Adaptability or versatility
If static mixers are cooled or heated from the outside with a jacket, then heat transfer function is added, but the tube surface area for heat exchange is limited and cooling/heating capacity is severely limited for larger throughputs
Solution Approach 1:
The mixer inserts serve dual functions as both mixing elements and heat transfer surfaces, with channels through the web elements allowing heat exchange fluid to flow directly within the mixing chamber, combining mixing and heat transfer functions in a single component
Solution Approach 2:
Heat exchange channels are nested within the web elements of the mixer inserts, allowing heat transfer fluid to flow through the mixing chamber interior and maximize heat transfer surface area without increasing external dimensions
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 device achieves optimal mixing and heat exchange with minimal residence time distribution, preventing fluid decomposition and allowing for efficient cooling or heating of viscous fluids, while maintaining a compact and cost-effective design.
Implementation Method 1
the web elements are provided with channels (11, 12) for a heat transfer fluid in operative condition. The channels are in operative condition not in connection with the flowable medium
Implementation Method 2
The boundary layer between the fluid and the tube wall are replaced continuously by the mixer inserts arranged in the interior of the double jacket
Implementation Method 3
The pressure gradient may be generated for example by the use of pumps
Implementation Method 4
The mixer insert used typically contains built-in elements, which cause a deflection of the fluid stream or of the flowable medium, which is guided through the mixing chamber
Data Source
AI summary
A device (1) for static mixing and heat exchange comprises a cladding element (2) and a mixer insert (3), whereby the mixer insert (3) is in the operative state arranged inside the cladding element (2). The mixer insert has a longitudinal axis and comprises a first group (5) of web elements and a second group (6) of web elements. The first group (5) of web elements extends along a first common group plane (7) and the second group (6) of web elements extends along a second common group plane (8). At least a portion of the web elements (9, 10) is provided with channels (11, 12). The channels extend from a first end (13) of the web element (11) to a second end (14) of the web element (11). The cladding element (2) comprises a corresponding channel, which is in fluid connection with the first end (13) and the second end (14) of the web element whereby the transition from at least one of the first (13) and second ends (14) of the web element to the corresponding channel in the cladding element (2) is free from gaps.