Tube Bundle Mixer with Inclined Bars for Heat Transfer
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Solution Overview
Problem
Existing static mixers with X-structure face challenges in scalability due to high pressure loss, mechanical weakness, and maldistribution issues when handling viscous products, especially at industrial throughputs, which affects heat transfer and product quality.
Innovation Solution
A tube bundle heat exchanger with a novel arrangement of bars and tubes, where bars are inclined at 30-60° and have a square spacing, allowing for efficient cross-mixing and heat transfer with reduced pressure loss and increased stability, enabling scalable and cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional X-structure static mixers are used for laminar flow mixing, then mixing efficiency and heat transfer are improved, but pressure loss increases and scalability to industrial throughputs becomes impossible
Solution Approach 1:
The housing is divided into multiple sections with tube bundles arranged in parallel, allowing the system to handle industrial throughputs while maintaining efficient mixing and heat transfer in each section. The tube bundle configuration segments the flow path to prevent excessive pressure loss while achieving required productivity
Solution Approach 2:
The bars are arranged in multiple layers at different angles (including 45° and other orientations) rather than a single plane, creating a three-dimensional mixing structure that enhances mixing efficiency and heat transfer without proportionally increasing pressure loss
2Productivity
If tube diameter is increased to handle industrial throughputs, then productivity is improved, but heat transfer surface area to volume ratio decreases and heat transfer becomes insufficient
Solution Approach 1:
Instead of using a single large-diameter tube, the system employs multiple smaller-diameter tubes arranged in parallel bundles. This segmentation maintains a high surface area to volume ratio for efficient heat transfer while collectively handling industrial throughput levels
Solution Approach 2:
The tube bundle serves multiple functions simultaneously: it provides heat transfer surface area, acts as a structural support for the bar mixing elements, and distributes the flow across multiple parallel paths to handle industrial throughputs while maintaining efficient heat transfer
3Strength
If bar width is increased to improve mechanical stability against flow forces, then structural strength is improved, but pressure loss increases
Solution Approach 1:
The bars are arranged in multiple layers at different angles (45° and other orientations) creating a three-dimensional interwoven structure. This multi-layer arrangement provides enhanced mechanical stability and resistance to flow forces without requiring individual bars to be excessively wide, thereby limiting pressure loss increase
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 apparatus achieves efficient heat transfer and mixing with a narrow residence time distribution, high stability, and reduced pressure loss, making it suitable for viscous products and scalable to industrial throughputs without compromising product quality.
Implementation Method 1
A heat transfer medium can flow in the tubes in co-current or counter-current to the product
Implementation Method 2
The apparatus is preferably suitable for laminar flowing media, but can also be used with turbulent flow
Implementation Method 3
The disclosure is preferably suitable for laminar flowing media, but can also be used with turbulent flow
Implementation Method 4
the flowing medium is forced to flow crosswise around the tubes and is constantly cross-mixed at the same time
Data Source
AI summary
An apparatus for supplying and dissipating heat, for carrying out reactions and for mixing and dispersing flowing media in a housing with an internal diameter for a medium and comprising internal fittings made up of a bundle of tubes with an external diameter or made up of other elongate elements oriented parallel to the longitudinal axis of the housing is provided. The apparatus includes crosspieces or crosspiece layers installed crosswise between the elongate elements. The crosspieces are inclined in relation to the longitudinal axis of the housing and are not in contact. After axially successive crosspieces, or a length, the crosspieces are installed between the tubes and turned by preferably 90°. A heat-transfer medium can flow in a co-current or counter-current mode. This results in a mixer/heat exchanger or reactor with an extremely large heat-transfer capacity and almost plug flow.