Tangential Slurry Mixer Layout Without Gearbox Flow Control
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Solution Overview
Problem
Existing mixers and agitators are inefficient in achieving thorough mixing of liquids and solids, particularly in applications like leaching and absorption processes, and require complex gearboxes for flow control, with maintenance being a challenge.
Innovation Solution
A mixer design featuring a variable speed motor, a helical impeller, and shoulder rings within a vessel that promotes tangential and counter-current flow, combined with a stator to minimize swirl, allowing efficient mixing and suspension of materials without the need for gearboxes, and enabling easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixers and agitators are used, then mixing of liquids and solids can be achieved, but mixing efficiency is insufficient and complex gearboxes are required for flow control
Solution Approach 1:
The patent replaces the conventional mechanical gearbox system with a hydrodynamic pump system. The pump uses a rotating impeller to create controlled fluid flow patterns that achieve both mixing and suspension functions, eliminating the need for complex mechanical gearboxes while improving mixing efficiency through fluid dynamic forces.
Solution Approach 2:
The invention employs hydraulic principles by using a pump with an impeller to generate controlled liquid flow. The pump creates upward and downward currents that circulate through the vessel, providing efficient mixing and suspension of solids without mechanical contact, thereby simplifying the overall system design.
2Ease of repair
If conventional mixers are used, then mixing can be performed, but maintenance is challenging
Solution Approach 1:
The mixing system is segmented into modular components: the pump assembly with impeller, the vessel, and the support structure. This segmentation allows the pump to be easily removed and replaced independently from the vessel, significantly simplifying maintenance operations and reducing downtime.
Solution Approach 2:
The pump assembly is designed to be extractable from the vessel through a removable connection at the base. This extraction capability enables easy access to the impeller for cleaning, repair, or replacement without draining the vessel or disassembling the entire mixing system.
3Productivity
If simple flow control is used, then device complexity is reduced, but mixing thoroughness is insufficient
Solution Approach 1:
The vessel incorporates localized flow control features including baffles positioned at specific locations and a multi-hole outlet at the base. These local structural modifications create targeted turbulence and circulation patterns that enhance mixing thoroughness without requiring complex overall flow control mechanisms.
Solution Approach 2:
The system achieves dynamic mixing through the rotating impeller that creates continuously changing flow patterns. The rotation speed can be varied to adjust the intensity of mixing, providing adaptive control that maintains thorough mixing across different operating conditions without complex mechanical control systems.
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 design achieves enhanced mixing efficiency and better material suspension, facilitating maintenance and reducing complexity by eliminating the need for gearboxes, while allowing flexible flow control and improved performance in processes like leaching and absorption.
Implementation Method 1
a pump within the vertical pipe and connected to the motor to be driven through a drive shaft
Implementation Method 2
the two feed pipes in the bottom chamber of the vessel which directs the flow tangentially in opposite directions, causing very good mixing
Implementation Method 3
Means are provided projecting into the lower portion of the vessel and inhibiting the upward movement of the liquid/slurry before moving inwardly beyond the said means whereafter the liquid/slurry is permitted to pass upwardly above the said means
Implementation Method 4
The pump preferably comprises a helical impeller mounted on the motor drive shaft
Implementation Method 5
A stator surrounds the shaft preferably below the helical impeller to provide support for the shaft and to break the swirl effect
Data Source
AI summary
A mixing vessel comprises a top portion (12) on an inverted conical middle portion (14) and a mixing chamber (16) below the middle portion. A launder (28) surrounds the upper part of the top portion. Solution from the launder is led to a vertical pipe (46) including a motor driven impeller (42) down to the level of the mixing chamber. Two feed pipes (47, 48) lead from the vertical pipe to enter the mixing chamber tangentially in opposite directions.