Static Mixer Radial Vanes Exhaust Gas Mixing

The vanes are designed with curved surfaces instead of flat planes, creating a three-dimensional configuration that promotes turbulent flow and mixing while maintaining smoother gas passage. The curved geometry allows the exhaust gases to follow the vane contours, reducing abrupt flow disturbances and pressure losses while still achieving effective mixing through controlled turbulence.

The invention transitions from traditional two-dimensional flat vane arrangements to three-dimensional curved vane structures with multiple bending lines. This dimensional enhancement creates complex flow patterns and multiple impact surfaces that improve mixing efficiency without proportionally increasing pressure drop, as the three-dimensional configuration optimizes flow guidance and reduces dead zones.

The curved surfaces of the vanes prevent liquid condensate from adhering and forming continuous films, as the liquid droplets follow the curved paths and are redistributed along the flow direction. This curvature effect reduces the effective surface area available for condensate accumulation while maintaining or enhancing mixing performance through improved flow turbulence and gas-liquid contact.

The invention converts the potential harmful effect of increased surface area (which would promote condensate formation) into a beneficial effect by using curved surfaces that actively prevent condensate accumulation. The same curved geometry that increases mixing capability also creates flow patterns that shed liquid films and redistribute condensate, turning what would be a disadvantage into an advantage.

The complex three-dimensional vane structure is achieved through segmented manufacturing processes, where each vane is formed by sequential bending operations along multiple defined lines. This segmentation of the manufacturing process into discrete, repeatable steps (first bending line, second bending line, third bending line) allows complex geometries to be produced using standard sheet metal forming equipment, avoiding the need for complex molds or multi-component assemblies.

The invention achieves complex mixing performance through controlled changes in geometric parameters during the forming process. By defining specific bending lines and angular relationships (such as the radial arrangement of vanes and their convergence toward the center), the design translates simple flat sheet material into three-dimensional curved structures with optimized flow characteristics, maintaining manufacturing simplicity while achieving sophisticated mixing behavior.