Static Mixing Device Radial Flow Passages Pressure Drop
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Solution Overview
Problem
Conventional dynamic mixing devices for fluid or gas streams are inefficient, require energy, have a large packaging size, and can contaminate fluids due to moving parts and potential leaks, especially in applications requiring high purity and corrosive fluids.
Innovation Solution
A static mixing device with a one-piece mixing body featuring radially extending fluid inlet and outlet passages, a reduced diameter section, and a housing with an annular volume, which generates a mixing vortex motion without dynamic elements, minimizing internal hold-up volume and pressure loss, and can be constructed from chemically inert materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dynamic mixing device with moving elements is used, then mixing effectiveness is improved, but device complexity and reliability worsen due to moving parts that can fail
Solution Approach 1:
The patent replaces the dynamic mechanical mixing system (rotating turbine blades) with a static mixing system that uses carefully designed flow passages and geometric features to generate mixing vortex motion. The mixing body contains radially extending flow passages that create turbulent flow patterns and vortex motion, achieving effective mixing without any moving parts, thereby eliminating wear, friction, and mechanical failure modes.
Solution Approach 2:
The patent extracts and removes all moving elements from the mixing device. By taking out the turbine blades and rotating components, the design achieves a completely static mixing structure that relies solely on fluid dynamics and geometric configuration to accomplish mixing, thus improving reliability by eliminating components that can fail.
2Productivity
If a dynamic mixing device with turbine blade is used, then mixing is achieved, but energy consumption increases
Solution Approach 1:
The patent eliminates the need for mechanical energy input by replacing the driven turbine blade system with a passive static mixing structure. The mixing body uses strategically positioned flow passages, radially extending features, and geometric configurations that naturally generate turbulent flow and vortex motion from the fluid's own kinetic energy, removing the requirement for external energy input to drive moving components.
3Productivity
If a dynamic mixing device is used, then mixing function is provided, but packaging size becomes large
Solution Approach 1:
The patent employs a compact cylindrical mixing body with radially extending flow passages that utilize the radial dimension to create efficient mixing. The flow passages extend from the central axis outward to the cylindrical wall, creating short, direct flow paths that generate vortex motion within a compact volume. This three-dimensional arrangement of flow passages achieves effective mixing in a much smaller packaging size compared to traditional dynamic mixers.
Solution Approach 2:
The mixing body is segmented into multiple radial flow passages that divide the fluid stream into separate channels. These segmented passages create multiple smaller vortex zones throughout the mixing body, achieving comprehensive mixing in a compact structure. The segmentation of flow paths allows efficient mixing to occur in a reduced overall device volume.
4Productivity
If conventional dynamic mixing device is used, then mixing is achieved, but internal hold up volume increases
Solution Approach 1:
The patent uses a cylindrical mixing body with radially extending flow passages that create direct, short flow paths from inlet to outlet. The radial geometry ensures that fluid flows outward from the center along the radial dimension with minimal dead zones, significantly reducing internal hold-up volume compared to conventional dynamic mixers with complex internal geometries.
Solution Approach 2:
The static mixing structure eliminates the need for large mixing cavities required by dynamic elements. The flow passages are designed to be fully swept by the flowing fluid, with no stagnant regions, achieving minimal hold-up volume by replacing the mechanical mixing approach with streamlined fluid dynamic paths.
5Productivity
If dynamic mixing elements are used, then mixing is provided, but leak paths increase
Solution Approach 1:
The patent extracts and removes all moving elements that create seal interfaces and potential leak paths. The completely static mixing structure eliminates shafts, bearings, and dynamic seals, providing a leak-free design that maintains fluid purity, especially important for corrosive or high-purity applications.
Solution Approach 2:
The static mixing system replaces the mechanical system with moving parts that require sealing with a purely static structure. The mixing body contains all mixing functions within sealed flow passages, eliminating the need for dynamic seals and reducing leak paths to virtually zero, thereby maintaining fluid integrity and purity.
6Productivity
If dynamic mixing device is used, then mixing is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts and removes all moving components, bearings, shafts, and drive mechanisms from the design. This simplification to a purely static structure dramatically reduces manufacturing complexity, as the mixing body can be manufactured as a single piece or simple assembly of static components without the need for precision mechanical assemblies.
Solution Approach 2:
The mixing body is designed with segmented radial flow passages that can be manufactured using standard machining or molding processes. The segmentation of flow paths into radial channels simplifies the manufacturing process compared to creating complex dynamic mechanisms, allowing the structure to be produced with conventional manufacturing techniques.
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 static mixing device effectively mixes fluids without dynamic elements, is compact, reduces pressure drop, and maintains fluid purity, making it suitable for high-purity and corrosive fluid applications.
Implementation Method 1
generates a mixing vortex motion without dynamic elements
Data Source
AI summary
Mixing devices comprise a mixing element having a body with a fluid inlet port, and a fluid outlet port that is separated from the fluid inlet port. Fluid outlet passages extend through a body wall section defining the fluid inlet port, and fluid inlet passages extend through a body wall section defining the fluid outlet port. The body includes an outside surface having a reduced diameter section, and the fluid inlet and outlet passages are positioned axially along the reduced diameter section. The mixing element is statically disposed within an internal chamber of a housing, and an annular volume is defined between an inside surface of the internal chamber and the mixing element reduced diameter section to facilitate passage and mixing of fluid within the annular volume. The mixing element total inlet area is approximately equal to its total outlet area to minimize unwanted pressure drop.