Two-Shaft Reactor Mixing Elements and Modular End Cap
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Solution Overview
Problem
Existing two-shaft reactors/mixers face challenges in achieving effective cleaning of the housing inner wall and efficient mixing, particularly with highly viscose and solid-containing substances, leading to potential side reactions and product inhomogeneity, and require expensive production methods for discharge screw integration.
Innovation Solution
A two-shaft reactor/mixer design with rotatably supported shafts and disc-shaped elements with scrapers for kinematic cleaning, combined with static mixing elements that create shear forces for enhanced mixing and cleaning, and a modular system for detachable end cap and discharge screw connector block for cost-effective and flexible operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disc-shaped elements with scrapers are used for kinematic cleaning, then cleaning effect is improved, but housing inner wall areas with small product mixing remain uncleaned
Solution Approach 1:
The housing inner wall is segmented into different functional zones: some areas are equipped with static mixing elements for enhanced mixing, while other areas maintain only scrapers for cleaning. This segmentation allows each zone to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different qualities are applied to different parts of the housing inner wall: areas requiring intense mixing receive static mixing elements, while areas prioritized for cleaning have only scrapers. This local differentiation resolves the contradiction by allowing both mixing and cleaning to excel in their respective zones.
2Reliability
If two shafts with disc-shaped elements and scrapers are used, then kinematic cleaning is achieved, but housing inner wall is not fully cleaned
Solution Approach 1:
The housing circumference is segmented into cleaning zones and mixing zones. Cleaning zones are positioned where scrapers from both shafts can effectively contact the wall, while mixing zones incorporate static elements. This segmentation enables comprehensive coverage of both cleaning and mixing functions.
Solution Approach 2:
Static mixing elements serve as intermediaries between the rotating scrapers and the housing wall in certain zones, creating additional flow disturbances that enhance both mixing and indirect cleaning effects in areas where direct scraper contact is limited.
3Strength
If discharge screw apparatus is fixedly integrated into end cap, then structural integrity is improved, but production costs increase
Solution Approach 1:
The discharge screw apparatus is segmented from the end cap structure, allowing them to be manufactured separately as standard components. The end cap and discharge screw are then connected through a standardized interface (flange connection), maintaining structural integrity while enabling cost-effective separate production and assembly.
Solution Approach 2:
The standardized flange connection interface serves multiple functions: it provides structural connection between end cap and discharge screw, enables easy assembly and disassembly, and allows for standardized manufacturing of both components. This universal interface resolves the contradiction between strength and manufacturing cost.
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 enhances mixing efficiency, reduces processing time, and improves cleaning, allowing for better operational control and adaptability, while the modular system simplifies mounting and reduces costs, enabling effective degassing and reaction of highly viscose products.
Implementation Method 1
the disc-shaped elements and/or the scrapers of a shaft respectively carry out with the disc-shaped elements and/or the scrapers of an adjacent shaft as well as with the housing a mutual, kinematic cleaning
Implementation Method 2
in the area of the spaces between the scrapers, the static mixing elements and the housing inner wall, sheer forces, in particular a flow disturbance, are created in an enhanced manner
Implementation Method 3
all surfaces of the scrapers may be cleaned kinematically and that all surfaces of the scrapers of a shaft being directed outwardly are convex in an arbitrary radial section through the mixer and are cleaned by an adjacent shaft or its scrapers or by the housing
Data Source
AI summary
An at least two shaft reactor/mixer, in particular for process engineering treatment of highly viscose, elastic and/or solid containing reaction substance and mixture, in which at the housing inner wall inwardly directed static mixing elements are arranged, which interact with scrapers of the at least two shafts in such a way, that in the area of the spaces between the scrapers the static mixing elements and the housing inner wall sheer forces, in particular a flow disturbance, are generated in an enhanced manner. In addition, there is a system including an end cap for a one or multiple shaft reactor/mixer and a discharge screw connector block being connectable with the end cap in a detachable manner.