Vertical Screw Mixer With Sleeve for Viscous Media Defibrating
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Solution Overview
Problem
Existing mixing devices for biogas plants struggle with inefficient mixing times and often fail to effectively separate solids from highly viscous media, leading to clogging and inadequate homogeneity.
Innovation Solution
A mixing device featuring a vertical screw mixer with a freely suspended sleeve and adjustable rotation direction, combined with a minimal gap between the agitator screw and sleeve, and additional features like teeth or cams to break up clumps, along with a silo-like container and screen for solid separation, and temperature control channels for sanitization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional agitators are used for mixing highly viscous media, then mixing is possible, but mixing time is excessive and homogeneity is insufficient
Solution Approach 1:
The mixing device segments the mixing action into two distinct components: a vertical screw mixer for rapid initial mixing and circulation, and a horizontal ribbon mixer for gentle final homogenization. This segmentation allows each mixer to perform its optimal function, reducing overall mixing time while achieving superior homogeneity
Solution Approach 2:
The device employs dynamic control by enabling independent operation of the vertical screw mixer and horizontal ribbon mixer. The vertical screw can operate alone for rapid mixing, the ribbon mixer can operate alone for gentle homogenization, or both can operate simultaneously, providing dynamic adaptability to different mixing requirements and significantly reducing mixing time
2Reliability
If solids are present in highly viscous media, then clogging occurs with conventional mixers, but effective solid separation is needed
Solution Approach 1:
The device extracts the solid separation function from the mixing process by incorporating a separate screening system with a screen at the discharge end of the vertical screw mixer. Solids are separated from the viscous media before discharge, preventing clogging in downstream equipment while maintaining continuous operation and productivity
Solution Approach 2:
The vertical screw mixer acts as an intermediary device that both mixes the viscous media and prepares it for separation by conveying it to the screen. The screen then mediates the separation between solids and liquid, with the separated liquid returning to the mixing chamber and solids being discharged separately, thus preventing clogging while maintaining productivity
3Reliability
If sanitization is required for highly viscous media, then conventional heating methods are insufficient, but effective temperature control is needed
Solution Approach 1:
The vertical screw mixer serves multiple functions: it mixes the viscous media, conveys it for separation, and simultaneously acts as a heating element through its heated jacket. This multi-functionality enables effective sanitization through direct contact heating while reducing overall energy consumption compared to separate heating systems
Solution Approach 2:
The vertical screw mixer performs self-heating through its integrated heated jacket, eliminating the need for separate external heating equipment. The media is heated directly during the mixing and conveying process, making the system self-sufficient for sanitization while minimizing energy consumption
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
Achieves faster and more homogeneous mixing, effective solid separation, and enhanced sanitization, reducing clogging risks and improving overall process efficiency.
Implementation Method 1
the agitator is arranged as a vertical screw mixer in the container, wherein the screw mixer has a stirring screw and a sleeve enclosing the stirring screw
Implementation Method 2
The screw mixer itself can be heated by a heated jacket, which offers significant advantages. This enables a sanitization process to take place in the mixing device
Implementation Method 3
Furthermore, it is also possible to arrange a screen at the discharge end of the screw mixer, which has the advantage that solids are separated out in the mixing device itself
Implementation Method 4
Clumps, thickened portions, or similar materials can be forced into the sleeve due to the minimal gap between the outer surface of the agitator screw and the inner surface of the sleeve due to the centrifugal force when the agitator screw is driven
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a mixing device (1) for mixing highly viscous media, in particular for a biogas plant, comprising a large-volume outer container (2) and an agitator arranged therein, wherein the container (2) has a medium inlet and a discharge line (6) for discharging the mixed medium. The agitator is designed as a vertical screw mixer (8), comprising a stirring screw (12) and a sleeve (9) enclosing the stirring screw (12).