Swirl Reactor Geometry for High-Pressure Solid-Liquid Mixing
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Solution Overview
Problem
Existing mixing technologies for solid-liquid mixtures, such as mechanically agitated vessels and magnetically coupled systems, face challenges in high-pressure sealing, high power consumption, shear sensitivity of solids, and non-uniform reaction rates, limiting their effectiveness in industrial-scale applications like Reductive Catalytic Fractionation of lignocellulose (RCF).
Innovation Solution
A continuous flow reactor with a swirl generator and specific vessel geometry that generates a Coanda flow, ensuring uniform mixing and reaction of solid particles with liquids, avoiding the need for rotating parts and enabling operation under high pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanically agitated vessels are used for solid-liquid mixing, then mixing capability is improved, but sealing problems occur at high pressure and power consumption increases
Solution Approach 1:
The patent replaces the mechanical agitation system (shaft-driven or magnetically coupled impellers) with a swirl flow generator that creates mixing through fluid dynamics. The swirl generator introduces tangential flow components that generate vortexes and enhance mixing without requiring mechanical seals or high power input, thus resolving the sealing problems at high pressure while maintaining mixing capability
Solution Approach 2:
The invention uses hydraulic principles by utilizing the fluid flow itself to create mixing through the swirl generator. The tangential inlet nozzles convert axial flow into rotational flow, creating a self-sustaining vortex that mixes solid particles with liquid without external mechanical agitation, thereby eliminating sealing issues and reducing power consumption
2Productivity
If high rotational speed impellers are used for mixing, then mixing efficiency is improved, but shear-sensitive solids are damaged
Solution Approach 1:
The patent eliminates mechanical impellers that cause high shear forces by using a swirl flow generator that mixes through fluid dynamics. The swirl generator creates gentle vortexes and recirculation patterns that mix solid particles without subjecting them to high shear stresses, thus protecting shear-sensitive solids while maintaining mixing efficiency
Solution Approach 2:
The invention changes the flow parameters by introducing tangential velocity components through the swirl generator. This creates a complex flow pattern with multiple vortices and recirculation zones that enhance mixing through fluid motion rather than mechanical agitation, achieving efficient mixing with minimal shear forces on the solid particles
3Ease of operation
If mechanically agitated vessels are used, then mixing is achieved, but high power input is required especially for high-viscosity substances
Solution Approach 1:
The patent replaces the high-power mechanical agitation system with a low-power swirl flow generator that utilizes fluid dynamics for mixing. The swirl generator creates mixing effects through tangential flow and vortex formation, achieving effective mixing with significantly reduced power input, especially for high-viscosity substances that would require excessive power from mechanical impellers
Solution Approach 2:
The invention uses hydraulic energy from the fluid flow itself to drive the mixing process. The swirl generator converts a portion of the axial flow energy into rotational motion, creating self-sustaining vortexes that mix the contents without requiring external mechanical power, thus achieving mixing with minimal energy input
4Stability of the object's composition
If impeller rotation is increased for better mixing, then mixing uniformity is improved, but gas entrainment increases resulting in non-optimal mixing
Solution Approach 1:
The patent replaces the mechanical impeller system that entrains gas with a swirl flow generator that mixes through controlled fluid dynamics. The swirl generator creates vortexes and recirculation patterns that enhance mixing uniformity without the violent turbulence and gas entrainment characteristic of high-speed impeller rotation, thus achieving uniform mixing without excessive gas incorporation
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 reactor achieves over 96% homogeneous suspension and 97% volume concentration, enhancing mixing efficiency and yield while handling shear-sensitive solids and maintaining uniform reaction conditions.
Implementation Method 1
the dimensions of the mixing vessel are configured to generate a Coanda flow of liquid, preferably an upward Coanda flow of liquid, along the wall of the tapered part and the wall of the upper cylindrical part
Implementation Method 2
Recent research has shown that swirl flow effectively enhances the mixing in both turbulent combustion systems and laminar microscale reactors
Data Source
AI summary
A continuous flow reactor includes a swirl flow generator and a mixing vessel including (i) a lower cylindrical part in direct fluid communication with the outlet of the swirl generator; (ii) an upper cylindrical part of diameter larger than the diameter of the lower cylindrical part; (iii) a tapered part located between the lower cylindrical part and the upper cylindrical part; and, (iv) an outlet located on the upper base of the upper cylindrical part and outside of the central part of said upper base. A swirl number that the swirl generator is adapted to provide, and the dimensions of the mixing vessel, are adapted to generate a Coanda flow of liquid, such as an upward Coanda flow of liquid, along the wall of the tapered part and the wall of the upper cylindrical part, when liquid is flowing through the reactor.