Abstract:
A fluid mixer including an inner fluid flow ( 11 ) duct having a cylindrical wall ( 14 ) provided with the window openings ( 13 ) and an outer tubular sleeve ( 12 ) disposed outside and extending along the duct ( 11 ) to cover the openings ( 13 ). Fluids to be mixed are admitted to one end of duct ( 11 ) through an inlet ( 25 ) and the mixture flows out through outlet ( 32 ). Duct ( 11 ) is statically mounted in pedestals ( 15 ) fixed to a base platform ( 17 ). Sleeve ( 12 ) is mounted for rotation in further pedestals ( 16 ) and driven by motor ( 23 ) and drive belt ( 22 ) to rotate concentrically about duct ( 11 ) such that parts of the sleeve move across the window openings ( 13 ) to create viscous drag on fluid flowing through the duct and transverse flows of fluid in the regions of the openings to promote mixing.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates to fluid mixers and more generally to techniques for mixing materials within fluids.  
           [0002]    Typical static mixers are characterised by baffles, plates and constrictions that result in regions of high shear and material build-up. On the other hand, stirred tank mixers can suffer from large stagnant regions and if viscous fluids are involved, consumption of energy can be significant. Stirred tank mixers are also normally characterised by regions of high shear.  
           [0003]    The regions of high shear may destroy delicate products or reagents, for example, the biological reagents involved in viscous fermentations. Similarly, regions of high shear may produce dangerous situations when mixing small prills of explosives in a delicate but viscous fuel gel. Regions of high shear may also disrupt the formation and growth of particles or aggregates in a crystalliser. Alternatively, fibrous pulp suspensions may catch on the baffles or plates of a static mixer.  
           [0004]    The present invention provides an alternative form of mixer and a new mixing technique whereby a material can be mixed in a fluid in a manner which promotes effective mixing without excessive consumption of energy or the generation of excessive shear forces.  
         Disclosure of the Invention  
         [0005]    According to the invention there is provided a mixer comprising:  
           [0006]    an elongate fluid flow duct having a peripheral wall provided with a series of openings;  
           [0007]    an outer sleeve disposed outside and extending along the duct to cover said openings in the wall of the fluid flow duct;  
           [0008]    a duct inlet for admission into one end of the duct and consequent flow along and within the duct of a fluid and a material to be mixed with that fluid to form a mixture thereof;  
           [0009]    a duct outlet for outlet of the mixture from the duct;  
           [0010]    a drive means operable to impart relative motion between the duct and the sleeve such that parts of the sleeve move across the openings in the peripheral wall of the duct to create viscous drag on the fluid and tranverse flows of fluid within the duct in the regions of the openings whereby to promote mixing of said material in the fluid as they flow within and through the duct.  
           [0011]    The duct and outer sleeve may be concentric cylindrical formation and the drive means may be operable to impart relative rotation between the duct and the outer sleeve. More particularly, the duct may be static with the sleeve mounted for rotation about the duct and the drive means may be operable to rotate the outer sleeve concentrically about the duct.  
           [0012]    The openings may be in the form of arcuate windows each extending circumferentially of the duct.  
           [0013]    The windows may be of constant width and be disposed in an array in which successive windows are staggered both longitudinally and circumferentialy of the duct.  
           [0014]    The invention also provides a method of mixing a material in a fluid comprising:  
           [0015]    locating a fluid flow duct having a duct wall perforated by a series of openings within an outer sleeve which covers the duct wall openings;  
           [0016]    passing fluid and material to be mixed therewith through the duct; and  
           [0017]    imparting relative motion between the duct and the sleeve such that parts of the sleeve move across the openings in the duct wall to create viscous drag on the fluid flowing through the duct and transverse flows of the fluid in the vicinity of the duct openings whereby to promote mixing of said material in the fluid.  
           [0018]    In a preferred embodiment, the duct and the movable sleeve are cylindrical, the outer diameter of the inner cylinder is as close as practicable to the inner diameter of the outer cylinder and the outer cylinder is rotatable with respect to the inner cylinder.  
           [0019]    In operation the duct is maintained in a stationary mode and has a number of windows cut into its wall. The sleeve is mechanically moved with respect to the duct. The materials to be mixed or dispersed are fed into one end of the duct and pumped through it as the outer sleeve is moved with respect to the duct. The viscous drag from the outer sleeve, which acts on the fluid in the region of each window, sets up a secondary (tranverse) flow in the fluid. The non-window parts of the duct isolate the flow from the viscous drag of the outer sleeve in all regions except the windows. This ensures that the flow does not move simply as a solid body and ensures that the transverse flow within each window region is not axi-symmetric. Thus, as the flow passes from the influence of one window to the influence of the next, the flow experiences different shearing and stretching orientations. It is this programmed sequence of flow reorientation and stretchin that causes good mixing.  
           [0020]    The material for mixing with the fluid in the mixer of the present invention may be another fluid. It may also be minute bubbles of gas. It could also be solid particles for dissolution in a fluid or for the purpose of forming a slurry. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    In order that the invention may be more fully explained, the relevant design primciples and a presently preferred design will be discribed in some detail with reference to the accompanying drawings, in which:  
         [0022]    [0022]FIG. 1 is a diagrammatic representation of essential components of a cylindrical rotated arc mixer (RAM) operating in accordance with the invention;  
         [0023]    [0023]FIG. 2 is a further diagrammatic representation setting out significant design parameters of the mixer;  
         [0024]    [0024]FIG. 3 is a perspective view of a presently preferred form of mixer constructed in accordance with the invention;  
         [0025]    [0025]FIG. 4 is a plan view of essential components of the mixer shown in FIG. 3;  
         [0026]    [0026]FIG. 5 is a vertical cross-section on the line  5 - 5  in FIG. 4;  
         [0027]    [0027]FIG. 6 is a vertical cross-section on the line  6 - 6  in FIG. 4;  
         [0028]    [0028]FIG. 7 is a cross-section on the line  7 - 7  in FIG. 4;  
         [0029]    [0029]FIG. 8( a ) depicts the results of a poor choice of parameters, and FIG. 8( b ) depicts the results of a good selection of parameters;  
         [0030]    [0030]FIG. 9 illustrates the entry of two days streams into a rotated arc mixer;  
         [0031]    [0031]FIG. 10 shows one dye stream that has not mixed at all along the length of a mixer in which parameter selection was poor; and  
         [0032]    [0032]FIG. 11 shows the thorough mixing of dye streams in a mixer in which the selection of parameters is appropriate. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0033]    [0033]FIG. 1 depicts a stationary inner cylinder  1  surrounded by an outer rotatable cylinder  2 . The inner cylinder  1  has windows  3  cut into its wall. Fluids to be mixed are passed through the inner cylinder  1  in the direction of arrow  4  and the rotatable outer cylinder  2  is rotated in the direction indicated by the arrow  5 . For convenience, rotation in an anticlockwise direction is accorded a positive angular velocity and rotation in a clockwise direction is accorded a negative angular velocity in subsequent description.  
         [0034]    As shown in FIG. 2, the geometric design parameters of the mixer are as follows:  
         [0035]    (i) R—The nominal radius of the RAM (meters) is the inner radius of the conduit  
         [0036]    (ii) Δ—The angular opening of each window (radians)  
         [0037]    (iii) Θ—The angular offset between subsequent windows (angle from the start of one window to the start of the subsequent window, radians)  
         [0038]    (iv) H—The axial extent of each window (meters)  
         [0039]    (v) Z J —The axial window gap, or distance from the end of one window to the start of the next (can be negative, meters)  
         [0040]    (vi) N—The number of windows.  
         [0041]    In addition to the geometric parameters, there are several operationsl parameters:  
         [0042]    (i) W—The superficial (mean) axial flow velocity (m sec −1 )  
         [0043]    (ii) Ω—The angular velocity of the outer RAM cylinder (rad sec −1 )  
         [0044]    (iii) β—The ration of axial to rotational time scales (β=HΩ/W) (dimensionless).  
         [0045]    Only two of these operational parameters are independent.  
         [0046]    Finally, there are one or more dimensionless flow parameters that are a function of the fluid properties and flow conditions. For example, for Newtonian fluids, axial and rotational flow Reynolds numbers are,  
         R                   e     a                 x         =           2                 ρ                 W                 R     μ                   and                 R                   e     a                 z         =                      ρ                 Ω                   R   2         μ     .                             
 
         [0047]    These are related to Ω and W and their values may affecti the choice of RAM parameters for optimum mixing.  
         [0048]    For non-Newtonian fluids there will be other non-dimensional parameters that will be relevant, e.g. the Bingham number for psuedo-plastic fluids, the Deborah number for visco-elastic fluids, etc. The fluid parameters interact with the RAM&#39;s geometric and operational parameters in that RAM parameters can be adjusted, or tuned, for optimum mixing for each set of fluid parameters.  
         [0049]    The RAM&#39;s geometric and operational specifications are dependent on the rheology of the fluid, the required volumetric through-flow rate, desired shear rate range and factors such as pumping energy, available space, etc. The basic procedure for determining the required RAM parameters is as follows: (Note that steps (ii), (iii) and (iv) are closely coupled and may need to be iterated a number of times to obtain the best mixing)  
         [0050]    (i) Given the space and pumping constraints, fluid rheology, desired volumetric flow rate and desired shear rate range (if important) the radius, R, and the volumetric flow rate (characterised by W) can be determined.  
         [0051]    (ii) Based primarily on fluid rheology, specify the window opening, Δ.  
         [0052]    (iii) Factors such as fluid rheology, space requirements, pumping energy, shear rate etc. will then determine the choice of H and Ω (for example whether the rotation rate is low and the windows are long, or whether the rotation rate is high and the windows are short). H and Ω are chosen in conjunction with W and R to obtain a suitable value of β.  
         [0053]    (iv) once Δ and β are specified, the angular offset Θ is specified to ensure good mixing.  
         [0054]    (v) The axial window gap Z j is then specified, and is determined primarily by Θ and engineering constraints.  
         [0055]    (vi) Finally the number of windows, N, is specified based on the operation mode of the RAM (in-line, batch) and the desired outcome of the mixing process.  
         [0056]    An optimum selection of the parameters Δ, β and Θ cannot be determined directly from the fluid parameters alone—the design protocol outlined above or an equivalent should be followed. As part of this process, the parameter space must be systematically searched using a sequence of increasingly more mathematically sophisticated and computationally expensive design algorithms. This procedure ultimately leads to a small subset of the full parameter space in which good mixing occurs. Once this subset is found, the differences in mixing between close neighbouring points within the subset is small enough to be ignored. Thus any set of parameters within this small subset will result in good mixing. For a given application, more than one subset of good mixing parameters may exist, and the design procedure will locate all such subsets. Between each of these good mixing subsets, large regions of parameter space lie in which non-uniform and poor mixing occur. For a particular application there may be non-mixing factors which make a particular choice of one of the parameters desirable. In such cases, it will often be possible to find suitable values of the other parameters that lie within one of the good mixing subsets of the parameter space and which will still ensure good mixing.  
         [0057]    FIGS.  3  to  7  illustrate a preferred form of rotary arc mixer constructed in accordance with the invention. That mixer comprises an inner tubular duct  11  and an outer tubular sleeve  12  disposed outside and extending along the duct  11  so as to cover openings  13  formed in the cylindrical wall  14  of the inner duct.  
         [0058]    The inner duct  11  and the outer sleeve  12  are mounted in respective end pedestals  15 ,  16  standing up from a base platform  17 . More specifically, the ends of duct  11  are seated in clamp rings  18  housed in the end pedestals  15  and end parts of outer sleeve  12  are mounted for rotation in rotary bearings  19  housed in pedestals  16 . One end of rotary sleeve  12  is fitted with a drive pulley  21  engaging a V-belt  22  through which the sleeve can be rotated by operation of a geared electric motor  23  mounted on the base platform  17 .  
         [0059]    Th duct  11  and the outer sleeve  12  are accurately positioned and mounted in the respective end pedestals so that sleeve  12  is very closely spaced about the duct to cover the openings  13  in the duct and the small clearance space between the two is sealed adjacent the ends of the outer sleeve by O-ring seals  24 . The inner duct  11  and outer sleeve  12  may be made of stainless steel tubing or other material depending on the nature of the materials to be mixed.  
         [0060]    A fluid inlet  25  is connected to one end of the inner duct  11  via a connector  26 . The inlet  25  is in the form of a fluid inlet pipe  27  to carry a main flow of fluid and a pair of secondary fluid inlet tubes  28  connected to the pipe  27  at diametrically opposite locations through which to feed a secondary fluid for mixing with the main fluid flow within the mixer. The number of secondary inlet tubes  28  could of course be varied and other inlet arrangements are possible. In a case where two fluids are to be mixed in equal amounts for example, there may be two equal inlet pipes feeding into the mixer duct via a splitter plate. In cases where powders or other materials are to be mixed in a fluid, it would be necessary to employ different inlet arrangements, for example gravity or screw feed hoppers.  
         [0061]    The downstream end of duct  11  is connected through a connector  31  to an outlet pipe  32  for discharge of the mixed fluids.  
         [0062]    In the mixer illustrated in FIGS.  3  to  7 , the openings  13  are in the form of arcuate windows each extending circumferentially of the duct. Each window is of constant width in the longitudinal direction of the duct and the windows are disposed in a array in which successive windows are staggered both longitudinally and circumferentially of the duct so as to form a spiral array along and around the duct. The drawings show the windows arranged at regular angular spacing throughout the length of the duct such that ther is an equal angular separation between successive windows. However, this arrangement can be varied to produce optimum mixing for particular fluids as discussed below.  
         [0063]    A mixer of the kind illustrated in FIGS.  3  to  7  has been operated extensively to test flow patterns obtained with varied geometric and flow parameters and to compare these with predictions from numerical simulation and analysis. Because of the possible combinations of Δ, Θ and β define a large parameter space and only certain ranges result in good mixing, numerical modelling has been invaluable in determining suitable parameter choices. The basic procedure to investigate the parameter space is as follows:  
         [0064]    (i) Calculate the flow field in the RAM, using one of analytic solutions, two-dimensional CFD modelling or three-dimensional CFD modelling.  
         [0065]    (ii) Track a small number of massless “fluid particles” in this flow field and determine Poincaré sections (i.e. the set of points where these massless particles cross the planes located after 1, 2, . . . n apertures). Flows that may potentially mix well will have Poincaré sections in which the point density is evenly distributed across the entire cross section. Poincaré sections from flows that don&#39;t mix well will have one or more “islands” in which mixing does not occur efficiently.  
         [0066]    (iii) Identify a region in parameter space in which the Poincaré sections are densely filled and in which small changes to the parameters do not adversely effect the mixing.  
         [0067]    (iv) Once a promising region in parameter space is found, undertake dye tracing in which a numerical “dye blob” is tracked through the flow. The dye blob consists of a large number of massless fluid particles placed in a small region of the flow (typically 20-100 thousand points).  
         [0068]    (v) Design and manufacture a suitable RAM inner cylinder.  
         [0069]    The above sequence of design steps may be termed a “dynamical sieve” approach. A more comprehensive explanation of this process is provided in Appendix 1 to this specification.  
         [0070]    The two-dimensional flow generated in an aperture by the rotation of the outer cylinder flow field has an analytic solution for a Stokes flow (Re═O) that can be used as a good approximation for the solution in viscous Newtonian fluids. An axial flow profile must also be specified. For higher Reynolds number Newtonian flows or flows of non-Newtonian materials, a coupled solution is required. This can take the form of either a two-dimensional simulation with three components of velocity or a full three-dimensional solution. Full three-dimensional simulation is quite expensive and would only usually be used once a potential region of parameter space has been identified.  
         [0071]    The mixer of the kind illustrated in FIGS.  3  to  7  RAM has been optimised for mixing Newtonian fluids at low axial flow Reynolds numbers (less than approximately 25). The optimal values of the parameters for problems of this type are Δ=π/4, Θ=−3π/5, β=12, Z J =0. The exact value of H will depend on R, the viscosity of the fluid and the desired through-flow rate. Increasing the parameter N (i.e. the number of windows) will continually improve the mixing at the expense of making the total RAM length longer and the total energy input higher. If the RAM is used in batch mode and fluid is constantly recycling through the RAM, a small number of windows (approximately 6) will be effective. If the RAM is used in an in-line mode and fluid passes through only once, then approximately 10-30 windows will be needed, depending on the desired outcome of the mixing process.  
         [0072]    As indicated previously, the parameters specified above are not the only values that will lead to good mixing. For Newtonian flows in which the axial flow Reynolds number is less than approximately 25, the range of good mixing parameters will depend on the chosen Δ. A brief summary of some ranges of acceptable parameters is provid d in the following table.  
                                 TABLE 1                           Parameter ranges with good mixing for window openings       of π/4 and π/2. There are other, smaller, subsets       of the full parameter space that also result in good mixing.                Δ   β   Θ                       π/4    7 &lt; β &lt; 15   −2π/5 &lt; Θ &lt; −π/5               10 &lt; β &lt; 15   −3π/5 &lt; Θ &lt; −π/5           π/4   10 &lt; β &lt; 15     2π/5 &lt; Θ &lt; π                      
 
         [0073]    Worth noting is that the window offsets that provide good mixing for π/4 have negative values (i.e. Θ&lt;0) and those for π/2 have positive values (i.e. Θ&gt;0). The total number of windows N required to obtain good mixing an in-line (once through) application will range between 10-30 for all of these parameter values depending on the application and the desired outcome of the mixing process. For all cases, values of Z J =0 are satisfactory except for Δ=π/2, Θ&gt;4π/5 for which Z J =0.2R is an acceptable value.  
         [0074]    It is important to note that most parameter combinations result in poor mixing, sometimes even parameter sets that lie close to a set which mixes well. Thus an arbitrary choice of parameters is more likely to result in a poor mixer than a good one. This result is highlighted in FIG. 8( a ) which shows an example for Δ=π/4, Θ=3π/5 and β=14. These results were obtained from numerical simulation and show (on the left) a large “island” or region of the flow in which negligible mixing occurs. In contrast, FIG. 8( b ) is for the case of Δ=π/4, Θ=−3π/5 and β=14. A mixer having these parameters mixes well. In order to verify the mixing efficiency of these parameters predicted by simulation, experiments were undertaken with the same parameters. In these experiments, a mixer of the kind illustrated in FIGS.  3  to  7  was constructed with transparent plastic inner and outer tubes and was operated to inject two dye streams into a main fluid flow. The resulting mixing of the two dye streams could be observed and photographed through the transparent tubes. Typical results are shown in FIGS.  9  to  11 . FIG. 9 shows the entry of the two dye streams at the inlet end of the mixer. FIG. 10 shows a result in which one dye stream has not mixed at all along the length of the mixer when the parameter selection was poor and FIG. 11 shows thorough mixing of the dye streams when the parameter selection was optimised. The results are shown in FIG. 9, FIG. 10 and FIG. 11.  
         [0075]    In some applications (for non-Newtonian fluids in particular), it is desirable to modify the window offset Θ and/or the window opening Δ and/or length H in a quasi-periodic manner. For example, after each 4 windows, the window offset is increased by Θ H for one window only. Similar modifications to the window opening Δ and/or length H may be required. Thus windows may appear in groups with sequential groups having different values of A and/or H. There is no prescribed methodology for such modifications, and each mixing process must be considered on an individual basis. Moreover, it is not essential to fix the parameters Δ, Θ and β for optimum operation of a single mixer and it is quite possible to design a RAM in which there are successive sequences of windows which have different values of the parameter triplets Δ, Θ and β. It is also possible, and may be desirable in some applications to have more than one window at a given axial location and such windows may be of a different size.  
         [0076]    The performance of the RAM has been benchmarked against a commonly used static mixer. Some demonstrated characteristics of the RAM are:  
         [0077]    It can mix twice as well as an equivalent length static mixer  
         [0078]    It has a very much lower pressure drop, (about 7 times lower), than the static mixer  
         [0079]    It mixes using approximately ⅕of the total energy of an equivalent length static mixer.  
         [0080]    No internal surfaces (baffles, plates, etc.) for material to build up on.  
         [0081]    Mixers of the present invention have other advantages over both static mixers and stirred tanks. These are as follows:  
         [0082]    It has very low shear, but effective mixing  
         [0083]    No large stagnant regions in vessel (this is particularly relevant to stirred tanks in which yield stress and/or shear thinning fluids are being mixed with another material)  
         [0084]    Easy to clean  
         [0085]    Easier to scale-up designs between laboratory pilot and plant scale than stirred tanks  
         [0086]    Can be operated to ensure no air is entrained in the mixer  
         [0087]    Can handle very high viscosity fluids  
         [0088]    Can be optimized for different fluid rheologies  
         [0089]    Mixing computations are simpler.  
         [0090]    Several potential RAM applications have been identified. The following list is not exhaustive, and the RAM could be potentially utilised in any application in which one or more viscous fluids need to be mixed or in which small gas bubbles, an immiscible liquid, particulates or fibres need to be dispersed in a viscous liquid. Potential applications include:  
         [0091]    As a Bio-reactor for viscous fermentations in which high shear may destroy delicate products or reagents.  
         [0092]    Polymer blending of two or more viscous polymers.  
         [0093]    Pumped explosives in which small prill particles must be mixed in a delicate, but viscous, fuel gel.  
         [0094]    As a Crystallizer where high shear may disrupt formation and growth of particles or aggr gates.  
         [0095]    In fibrous pulp suspensions in which fibres may clog and block traditional in-line mixer elements.