Tube Bundle Mixing Device for Low-Pressure Gas Distribution
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Solution Overview
Problem
Existing mixing devices for gases in styrene production units fail to achieve uniform distribution and high mixing efficiency at low pressure drops, leading to reduced yield and catalyst aging due to inhomogeneous gas concentration and temperature, and increased energy consumption.
Innovation Solution
A mixing device comprising a bundle of tubes with side holes and directional fins within tubular bodies ensures uniform gas distribution, using a closed casing to maintain pressure and facilitate turbulent mixing within reduced chamber dimensions, eliminating the need for a static mixer and allowing for low-pressure-drop operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mixing devices with turbulent diffusion and static mixers are used, then mixing homogeneity is improved, but pressure drop increases and device complexity increases
Solution Approach 1:
The mixing device is segmented into multiple tubes arranged in a bundle, each tube contributing to the overall mixing process. This segmentation allows the system to achieve high mixing homogeneity through the combined effect of multiple parallel mixing channels while maintaining low pressure drop in each individual channel, thus resolving the contradiction between mixing quality and pressure loss
Solution Approach 2:
Each tube in the bundle has side holes positioned at specific locations to create local turbulence and mixing zones. This local quality approach enables effective mixing within each tube while keeping the overall pressure drop low, as each tube operates independently with optimized local mixing characteristics rather than requiring high pressure drop across the entire mixing chamber
2Manufacturing precision
If traditional mixing devices with turbulent diffusion and static mixers are used, then mixing homogeneity is improved, but device complexity and investment costs increase
Solution Approach 1:
The device merges the functions of multiple tubes into a single integrated bundle structure, eliminating the need for separate static mixers downstream. The tube bundle itself performs both distribution and mixing functions, simplifying the overall device structure while maintaining high mixing homogeneity, thus resolving the contradiction between mixing quality and device complexity
Solution Approach 2:
Each tube in the bundle serves multiple functions: it distributes the gas stream, creates turbulence through side holes, and contributes to overall mixing. This multi-functionality eliminates the need for additional dedicated mixing components like static mixers, reducing device complexity while maintaining effective mixing performance
3Volume of stationary object
If mixing chamber volume is reduced, then equipment investment costs are reduced, but mixing homogeneity deteriorates
Solution Approach 1:
The invention transitions from a single large mixing chamber to multiple parallel tube channels, effectively adding a dimensional aspect to the mixing process. This allows the system to achieve high mixing homogeneity within a compact total volume by utilizing the parallel architecture of multiple tubes, thus resolving the contradiction between chamber volume and mixing quality
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 solution achieves complete gas mixing with reduced pressure drops, enhancing styrene production yield and selectivity while minimizing energy consumption and equipment costs, making it adaptable to existing plants without space constraints.
Implementation Method 1
The first feeding system of one of the two gases comprises a plurality of fins, inside the first tubular body, which allow a uniform distribution of the feeding gas to the single tube
Implementation Method 2
The turbulence (often increased by means of suitable promoters) and the elongated form of the chamber allow the two gases to mix
Data Source
AI summary
Mixing device for two gases/vapours (hereinafter gases) comprising: a) a plurality of tubes arranged in a bundle (1), each provided, in its initial portion, with a plurality of side holes (5); b) a first feeding system of one of the two gases, comprising a first tubular body (6) situated on the inlet side of the tubes, and c) a second feeding system of the other gas comprising a second tubular body (7) that envelopes in a gas-proof way the tube bundle (1) and at least a portion of the first tubular body (6); characterized in that: d) the first feeding system of one of the gases comprises a plurality of fins (8), inside the first tubular body (6), which allow a uniform distribution of the feeding gas to the single tubes.