Static Mixer Webs With Tapered Geometry For Low Pressure Drop
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Solution Overview
Problem
Existing static mixers face challenges in achieving effective mixing with low pressure drop and defined residence time behavior, particularly in laminar and transitional flow areas, while also being cost-effective and easy to assemble, with issues such as dead zones and high pressure loss in current designs.
Innovation Solution
The design features tailored webs with minimal width in the middle and maximum spacing between adjacent crossing points, ensuring a recessed inner wall contact to minimize edge movement and pressure loss, and the use of partially tapered webs to prevent laminar flow, resulting in improved mixing performance and residence time distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional static mixers with intersecting webs are used to achieve mixing in laminar flow areas, then mixing is accomplished, but dead zones are formed that increase residence time and cause high pressure loss
Solution Approach 1:
The web geometry is optimized locally by varying the web width along its length. The webs have maximum width at the crossing points to maintain structural integrity and mixing effectiveness, while having reduced width in the middle sections to minimize dead zones and reduce pressure loss. This local variation in web quality resolves the contradiction between achieving thorough mixing and minimizing energy loss.
Solution Approach 2:
Instead of having uniform web width throughout, the invention inverts the conventional approach by making the webs narrower in the middle sections where dead zones typically form, while maintaining adequate width at the crossing points. This inverted geometry pattern eliminates the harmful dead zones without compromising the mixing function.
2Productivity
If multiple web layers are added to improve mixing performance, then mixing quality increases, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention achieves improved mixing quality by changing the geometric parameters of the webs rather than simply adding more web layers. By optimizing web width distribution, angle of inclination, and spacing, the patent accomplishes effective mixing with fewer web layers, thereby reducing device complexity and manufacturing cost while maintaining or improving mixing quality.
3Productivity
If webs are positioned close to the inner wall to maximize mixing contact, then mixing effectiveness improves, but edge movement increases and pressure loss increases
Solution Approach 1:
The web geometry is locally optimized by positioning the narrower middle sections of the webs closer to the inner wall to maximize mixing contact in the bulk flow region, while the wider crossing points maintain structural stability. This local differentiation allows effective mixing without excessive edge movement or pressure loss.
Data Source
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AI summary
A static mixing device comprises a flow channel with at least one mixing element arranged in the flow channel. Each mixing element has a plurality of crosswise arranged webs (14A, 14B) forming an angle greater than 0° with the longitudinal axis of the flow channel. At least one of the webs (14A, 14B) between adjacent intersections is tapered. At the midpoint between adjacent intersections (16), the webs (14A, 14B) have their smallest width (b), and adjacent webs (14A, 14B) have their largest spacing (a). The edge regions of the webs (14A, 14B) adjacent to the inner wall of the flow channel (10) have a recess (122) opposite the inner wall of the flow channel (10).