Vortex Mixing Apparatus for Chemical Reaction Heat Transfer
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Solution Overview
Problem
Current mixing technologies, such as T-tube mixers and active mixing elements, are inadequate for instantaneous chemical reactions as they lead to side product buildup, reduced yields, and inefficiencies in heat transfer, especially at higher flow rates, and require expensive seals and complex engineering.
Innovation Solution
A vortex mixing apparatus that generates vortical movement of chemical components within a flow vessel using an external off-center rotation component, allowing for efficient mixing and product removal without the need for expensive seals or extensive engineering, while maintaining a stationary reactor and enhancing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If T-tube mixer with static mixing elements is used, then mixing occurs through flow rate, but heat transfer is insufficient at higher flow rates
Solution Approach 1:
The patent employs a dynamic vortex-generating element that rotates within the reaction chamber to create intense vortical flow patterns. This dynamic mixing mechanism maintains effective heat transfer and mixing performance across a wide range of flow rates, unlike static mixers that rely solely on flow rate for mixing. The rotating vortex generator actively creates turbulence and enhances convective heat transfer coefficients, allowing the system to maintain temperature control even at high productivity levels.
2Temperature
If tube size is reduced for diffusion mixing, then heat transfer improves, but throughput is limited
Solution Approach 1:
The patent introduces a third dimension of mixing by implementing a rotating vortex-generating element within the reaction chamber. Instead of relying solely on radial diffusion in a small tube, the system creates axial and tangential flow components through vortical motion. This dimensional enhancement allows for effective mixing and heat transfer in a larger volume, thereby increasing throughput while maintaining temperature control through enhanced convective heat transfer surfaces.
3Productivity
If active mixing elements are used, then mixing occurs independently of flow rate, but expensive seals and extensive engineering are required
Solution Approach 1:
The vortex-generating element is designed to be driven by the flow itself rather than requiring external motors or complex drive mechanisms. The flowing reactants pass through a specially configured chamber that converts flow energy into rotational motion of the vortex generator, which in turn creates the intense mixing. This self-driven mechanism eliminates the need for expensive seals, external power sources, and complex engineering while maintaining flow-rate-independent mixing performance.
4Productivity
If active mixing elements with shearing elements are used, then mixing is achieved, but solid feeds are limited due to 100-500 uM size constraints
Solution Approach 1:
The reaction chamber is segmented into multiple zones with progressively intense vortical flow patterns. Large solid particles are introduced into the chamber where they are gradually broken down and dispersed through the segmented vortex flow fields. The segmentation of the flow path allows particles to be progressively size-reduced and distributed throughout the reaction medium, enabling the system to handle solid feeds much larger than the 100-500 uM limitations of conventional shearing mixers.
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
This solution provides superior mixing efficiency, minimizes side reactions, and increases throughput with improved heat and mass transfer, reducing capital and operational costs, and is capable of handling solids without clogging.
Implementation Method 1
generating vortical movement of at least two chemical components through a flow-through interior chamber of a vessel component by an external off center rotation component. The vortical movement creates a vortical layer of vessel contents on an interior sidewall of the flow-through interior chamber
Implementation Method 2
an off center rotation component which is operatively connected to the vessel component... generating vortical movement... The vortical movement creates a vortical layer of vessel contents on an interior sidewall
Data Source
AI summary
An apparatus comprising: a vessel component comprising a flow-through interior chamber having an interior sidewall and an exterior sidewall; at least two inlets for introducing chemical components into the flow-through interior chamber; at least one outlet for removing product from the flow-through interior chamber; and an off center rotation component which is operatively connected to the vessel component. During operation of the apparatus, the off center rotation component generates vortical movement of at least two chemical components through the flow-through interior chamber of the vessel, and converts at least a portion of the at least two chemical components to at least one reaction product or product mixture. A method of using the apparatus to produce reaction products or product mixtures. The apparatus and method are useful for producing specialty chemicals such as fragrance and flavor compounds, insect pheromones, petrochemicals, pharmaceutical compounds, agrichemical compounds, and the like.