Mixing system for pipeline with a variable static mixer

Description

Background of the Invention

[0001] This invention relates to mixing devices commonly referred to as static mixers. Generally such mixers are disc-like in shape and include a plate having a central opening or orifice of various fixed geometric configurations and mounted in a pipe through which fluid passes so as to create a turbulent mixing action to the fluid such that other materials introduced into the stream generally via injection nozzles located downstream and generally adjacent the plate are uniformly mixed with the fluid.

[0002] As indicated, standard static mixers have a fixed geometry, which means that the headloss is a direct function of the velocity of the fluid in the pipeline. Generally speaking, a mixer designed for low (0,3-0,91 m/s) = (1-3 FPS) velocity will generate excessive headloss at high pipeline velocity (2,44-3,66 m/s) = (8-12 FPS). Conversely, a mixer designed for reasonable mixing and headloss at high velocity generally will not provide good mixing at low velocity.

[0003] To date, this problem has been addressed by making separate mixers with mixing characteristics suited for particular pipeline velocities. For instance, the present applicant commercially supplies three separate mixers with different orifice diameters or beta ratios (beta ratio = orifice diameter/pipe inside diameter) of .7,.8 and .9. See Fig. 9 for further beta information. This enables a user to choose a mixer that gives good mixing performance at high, medium or low pipeline fluid velocities respectively, but no one mixer achieves good performance at al of these different velocities.

[0004] EP-A1-1 166862 discloses a mixer for mixing gases and other Newtoninan liquids comprising an adjustable baffle. US-A-4 846 212 discloses a bleed valve assembly for use in a double block and bleed valve system. US-A-2 624 541 discloses a butterfly valve positionable between open and closed positions. GB 730 046 A discloses a foam delivery nozzle. EP-A2-0 095 791 discloses mixing apparatus having a plurality of rotatably mounted mixing guides.

[0005] It is therefore an object of at least the preferred embodiments of the present invention to provide a mixer and mixing system that can be adjusted to achieve good mixing performance at differing pipeline velocities without the need of removing one mixer and substituting another mixer in the pipeline.

[0006] According to the invention there is provided a mixing system for fluid flow flowing in a pipeline comprising: a first static mixer having a plate having an edge and having a face defining at least one mixing orifice extending therethrough, said first static mixer being fixedly positioned in said pipeline with said face surface disposed so as to be generally across the fluid flow in said pipeline; and a second variable position static mixer also having a plate having a face surface defining at least one mixing orifice extending therethrough, said second mixer being positioned in said pipeline downstream of said first mixer, the plate of said second mixer being mounted for movement between a first generally non-mixing position wherein the plate face surface is substantially aligned with the fluid flow and a second mixing position wherein the plate face is disposed generally across the fluid flow direction within said pipeline.

[0007] Other preferred but optional features are set out in the subordinate claims. In a preferred form the second static mixer has a generally centrally disposed orifice disposed within a generally flat plate adapted for mounting within a pipe such that the plate is adjustably moveable to various alternate operable positions between a first essentially non-mixing position wherein the plate edge is disposed in line with the fluid flow within the pipe to a fully mixing position wherein the plate face is disposed normal to the fluid flow within the pipe.

[0008] Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.

Description of the Drawings

[0009] In the drawings :

Fig. 1 is a top view of a pipe section including the static mixer system of the present invention installed therein;

Fig. 2 is an exploded perspective view of Fig. 1;

Fig. 3 is a side elevational view of Fig. 1;

Fig. 4 is a stylized sectional view along line 4-4 of Fig. 3;

Fig. 5 is a stylized sectional view along line 5-5 of Fig. 3 showing the variable mixer in a full mixing position;

Fig. 6 is an elevational view of the variable position mixer of the present invention positioned within a pipeline in its first essentially non-mixing position;

Fig. 6A is an alternate embodiment of the variable position mixer installed in a swing gate check valve;

Fig. 6B is another alternate embodiment of the variable position mixer when installed in a gate valve;

Fig. 7 is a perspective view of a fixed mixer device disposed within a pipe and viewed from the upstream direction;

Fig. 8 is a view similar to Fig. 7 but viewed from the downstream position; and

Fig. 9 is an illustrative explanation of the term "beta" as applied herein.

Description of the Invention:

[0010] Turning now to the drawings and particularly Figs. 7 and 8 thereof, a typical static mixer is depicted. The device 10 is of an overall circular outside configuration, that is, a disc-like body 12 including an outside flange portion 14 extending inwardly from the outer periphery 16 of the disc 12 approximately one third of the radius of the entire disc 12 and a pair of radially opposed flaps 18 inwardly extending from the inner periphery 20 of such flange towards each other but not touching so as to form, in essence, a central open area 22 of a dumbbell-type configuration. The flange 14 includes flat opposed upstream and downstream surfaces 14a and 14b which project into the fluid stream, that is, portions of the fluid stream (generally the portions closer to the pipe wall) contact and, in effect, are diverted by surface 14a prior to passing through the central open area formed by the inner peripheral surface 20. In addition, the flaps 18 are bent downwardly inwardly towards the flow direction of the fluid through the pipe 24 in which the device 10 is mounted. Such mounting of the device 10 in the pipe 24 is accommodated by an outer plate 26 of cylindrical configuration and including a radially outwardly extending step 28 on the upstream side thereof such that the periphery 16 of the disc body may contact such step 28 and be held within the confines of the pipe 24 thereby. Pipe collars 30 may be provided at opposed ends of the pipe 24 to accommodate the insertion of the plate 26 therebetween and affixation thereto by bolts or other conventional means (not shown) passing through the plate and collars 26, 30 respectively.

[0011] It will also be apparent from this and other drawings that the flaps preferably 18 as well as the flange 14 extend inwardly into the fluid flow and that additionally the flaps extend at an angular relationship to such internal pipe or wall surface of approximately 15 degrees in the downstream direction but could even extend at angles of 25 or to 40 degrees. Preferably, the configuration of the flaps 18 is semi-elliptical or semi-circular such that defined open area 22 is entirely made up of rounded boundaries, that is, the areas where the flaps 18 meet the internal periphery 20 of the flange 14 are rounded.

[0012] It should be stated that the particular static mixer configuration above described is that of applicant's issued U. S. Patent No. 5,839,828. It should also be stated that other static mixers of the same general type could also be utilized in the present invention, e.g., those mixers shown in Figs. 12 and 13 of U. S. Patent No. 6,595,682.

[0013] The present invention utilizes the above-described static mixers by installing a first mixer in a fixed position in an upstream location. Such first mixer is adapted to provide good mixing at high fluid velocities. In addition as will be discussed hereinafter, a second but variable position static mixer is installed downstream therefrom. The second mixer is dimensioned to provide efficient mixing for low fluid velocities and when coupled with the first mixer in the subject system can provide efficient mixing over a wide range of fluid velocities unachievable with systems incorporating only one of the static mixers in a fixed position.

[0014] Specifically with respect to the particular static mixers that applicant produces, applicant installed a conventional .9 beta mixer with standard chemical injection nozzles downstream of one or both trailing tabs. A second movable .7 beta ratio mixer is installed two pipe diameters downstream from the first fixed mixer. The second mixer is designed to pivot 90 degrees on its vertical axis (same as a disc in a butterfly valve). The rotary position of this second mixer is controlled either by an externally mounted operating lever or by a standard electric butterfly valve operator (gear motor) hereinafter referred to as means for pivoting mixer plate (see Fig. 6).

[0015] In operation at high velocities, the first .9 beta mixer provides good mixing and low headloss. The second .7 beta mixer is rotated so that the disc is parallel to the direction of flow thus providing very little additional headloss and mixing. This fully open (pivoted 90 degrees) position of the second mixer plate is shown in Fig. 6. As the pipeline velocity decreases, the second mixer (the .7 beta mixer) is progressively rotated closed (right angles to the direction of flow). Thus at very low pipeline velocity (0,91-2,44 m/s) = (3 - 8 FPS), the second.7 beta mixer would be completely closed thus providing a .9 beta mixer followed by the.7 beta mixer.

[0016] The variable static mixer system above described provides excellent mixing and minimal headloss for all pipe velocities.

[0017] The position of the movable second mixer could be automatically controlled to provide constant headloss over a range of velocities.

[0018] The shape of each of the mixer plates may be that of the plates described in U.S. Patent No. 5,839,828 issued to the present applicant, Robert W. Glanville, November 24, 1998. It should be noted that by the phrase "designed to pivot 90 degrees" means that the second mixer plate is adapted to rotate on its vertical axis from a fully mixing position or closed position as shown in Figs. 2 and 5 to an essentially non-mixing or fully open position as shown in Fig. 6 and that the second mixer plate could, of course, encompass slightly less or much greater rotational angles so long as the above described mixing modes as well as intermediate mixing modes are accomplished.

[0019] With reference to Figs. 1 - 5, additive material is introduced into the system 100 shown therein in conjunction with the first mixer 10. As is known in the art, additive materials are injected through pipes or quills 38 that lead to injection ports 40 in the plates 26 on the downstream side of the mixer. The turbulence created by fluid passing through the orifice or central open area 22, in effect, draws in the additive material to accomplish at least partial mixing thereof within the fluid stream. The particular system shown in the drawings utilizes a fixed static mixer 10 having a beta of .9 that provides good mixing at high velocities. However in order to obtain better improved and more flexible operation and mixing efficiencies at medium and lower fluid velocities, a second and movable static mixer 102 with a lower beta, e.g., .7, is positioned in the pipe downstream from the first mixer 10. A separation distance of two pipe diameters was utilized with the effective results as indicated above. It is believed that such separation distance of at least two pipe diameters should be maintained for mixing efficiency and physical placement

[0020] Preferably, the movable mixer 102 is of the same general configuration and type as the first mixer 10 but is mounted so as to move, i.e., pivot, from a first non-mixing position as shown in Fig. 6 wherein the plate-like body 112 thereof is positioned so that the fluid stream impinges on the narrow vertically disposed edge 113 thereof and thus, in effect, causes little or no headloss or mixing action to a second fully engaged mixing position as shown in Fig. 5 wherein the body 112 is positioned with the face 115 thereof across the pipe opening such that the peripheral flange 117 thereof and the orifice or central open area 122 are in full contact with the fluid flow. In this second full mixing position, the static mixer exhibits the characteristics of its beta number, that is, if the second mixer is a .7 beta, it will exhibit those mixing characteristics. In this way, the system can thus be efficiently utilized for high flow as well as lower flow by regulating the movable mixer to either its non-mixing or mixing positions.

[0021] It is also desirable to be able to fix the flange 117 position to partially open positions between the extremes of fully open or fully closed indicated above and through such intermediate flows between high and low can be efficiently accommodated. It is also desirable to sense the flow rate in the pipe upstream of the system and utilize such results to automatically control the opening and closing and partially open positions of the flange 117. Such sensing and control means are well known for other devices in the art.

[0022] With respect to the means 130 for pivoting the flange 117, such may comprise of known components such as butterfly valves and include such simple mechanisms as a hand movable handle or knob 132 connected to a rod 134 passing thru the outer plate 136 and, in turn, attached to the flange for rotational movement thereof.

[0023] Also, the vertical axis of rotation of the butterfly-type valve action of the movable flange 90 degrees in either direction as shown in Fig. 6 could be shifted to the horizontal where the flange edge would be positioned horizontally across the pipe in the non-mixing first position. Additionally, a similarly horizontally positioned flange of the second mixer could be incorporated within a conventional swing gate check valve structure such as shown by Fig. 6A such that the non-mixing position is equivalent to the fully open position of the mixer plate adjacent to the valve body and in such case attached to the operating hinge and the mixing position equivalent to the closed position of the valve across the flow path. The operating hinge mechanism as well as the mixer plate in its non-mixing position can be housed in the upper chamber of the valve. Similarly, a standard gate valve structure as shown in Fig. 6B could support the mixer plate of the movable mixer by attaching such to the operating spindle such that moving the spindle up or down positions the mixer flange either into, out of or partially into the fluid stream.

[0024] As above indicated, the preferred form of the invention positions a movable static mixer preferably of a low beta valve downstream from a fixed static mixer usually of a higher beta value

[0025] It should also be indicated that in those types of static mixers wherein the structure supporting the mixing orifice (or orifices or orifice pattern) is not entirely within the plane defined by the plate surface, e.g., the supporting structure extends outwardly thereof, that the non-mixing position in those situations wherein the plate edge is disposed in line with the fluid flow that portions of the supporting structure may project into the fluid stream and cause some turbulence but with only minimal mixing consequences. Also especially with larger diameter plates, the fixed mixer can be directly mounted such as by welding to the pipeline.

[0026] It should be noted that additives can be introduced at other points other than through the pipes or quills and that the material comprising the fluid flow in the pipe could itself compose unmixed feed.

Claims

1. A mixing system (100) for fluid flow flowing in a pipeline (24) comprising:

a first static mixer (10) having a plate (12) having an edge (16) and having a face (14) defining at least one mixing orifice (22) extending therethrough, said first static mixer (10) being fixedly positioned in said pipeline (24) with said face surface (14) disposed so as to be generally across the fluid flow in said pipeline (24); and

a second variable position static mixer (102) also having a plate (112) having a face surface (115) defining at least one mixing orifice (122) extending therethrough, said second mixer (102) being positioned in said pipeline (24) downstream of said first mixer (10), the plate (112) of said second mixer (102) being mounted for movement between a first generally non-mixing position wherein the plate face surface (115) is substantially aligned with the fluid flow and a second mixing position wherein the plate face (115) is disposed generally across the fluid flow direction within said pipeline (24).

2. The system (100) of claim 1, wherein said plate (112) of the second mixer (102) is arranged to pivot about a radial axis of said pipe section (24) through at least 90 degrees between said positions and wherein the diameter of said plate (112) is less than the internal diameter of said section (24).

3. The system (100) of claim 1, wherein said plate (112) of the second mixer (102) is arranged to pivot about an axis positioned adjacent the internal wall of said pipe section (24) between said positions and wherein said plate edge (113) of the plate (112) of the second mixer (102) is disposed adjacent said internal wall when in a non-mixing position.

4. The system (100) of claim 1, wherein the plate (112) of the second mixer (102) is disposed laterally offset from an internal wall of the pipe section (24) in a non-mixing position and is arranged to move into and across said pipe section (24) to a mixing position.

5. The system (100) of claim 1, wherein the plate (112) of the second mixer (102) is fixedly positionable at an intermediate position, preferably any intermediate position, between said first and second positions.

6. The mixing system (100) of any preceding claim, wherein the first (10) and second mixers (102) are separated by at least two pipeline diameters.

7. The mixing system (100) of any preceding claim, wherein said first mixer (10) has a higher beta than said second mixer (102).

Ansprüche

1. Mischsystem (100) für einen Flüssigkeitsstrom, der in einer Rohrleitung (24) fließt, mit:

einem ersten statischen Mischer (10), der eine Platte (12) mit einer Kante (16) und einer Stirnfläche (14) aufweist, die wenigstens eine Mischöffnung (22) definiert, die sich hindurch erstreckt, wobei der erste statische Mischer (10) in der Rohrleitung (24) fest positioniert ist, wobei die Stirnfläche (14) so angeordnet ist, dass sie im Allgemeinen quer zum Flüssigkeitsstrom in der Rohrleitung (24) ist; und

einem zweiten statischen Mischer (102) mit variabler Position, der ebenfalls eine Platte (112) mit einer Stirnfläche (115) aufweist, die wenigstens eine Mischöffnung (122) definiert, die sich hindurch erstreckt, wobei der zweite Mischer (102) in der Rohrleitung (24) dem ersten Mischer (10) nachgeordnet ist, wobei die Platte (112) des zweiten Mischers (102) zur Bewegung zwischen einer ersten im Allgemeinen nicht-mischenden Position, bei der die Plattenstirnfläche (115) im Wesentlichen mit dem Flüssigkeitsstrom ausgerichtet ist, und einer zweiten Mischposition, bei der die Plattenstirnfläche (115) im Allgemeinen quer zu der Flüssigkeitsstromrichtung in der Rohrleitung (24) angeordnet ist, angebracht ist.

2. System (100) nach Anspruch 1, wobei die Platte (112) des zweiten Mischers (102) so angeordnet ist, dass sie sich um eine radiale Achse des Rohrabschnitts (24) um wenigstens 90 Grad zwischen den Positionen dreht, und wobei der Durchmesser der Platte (112) kleiner ist, als der Innendurchmesser des Abschnitts (24).

3. System (100) nach Anspruch 1, wobei die Platte (112) des zweiten Mischers (102) so angeordnet ist, dass sie sich um eine Achse, die nahe der Innenwand des Rohrabschnitts (24) angeordnet ist, zwischen den Positionen dreht, und wobei die Plattenkante (113) der Platte (112) des zweiten Mischers (102) nahe der Innenwand angeordnet ist, wenn er sich in einer nicht mischenden Position befindet.

4. System (100) nach Anspruch 1, wobei die Platte (112) des zweiten Mischers (102) in einer nicht mischenden Position seitlich von einer Innenwand des Rohrabschnitts (24) versetzt und so angeordnet ist, dass sie sich in und durch den Rohrabschnitt (24) in eine Mischposition bewegt.

5. System (100) nach Anspruch 1, wobei die Platte (112) des zweiten Mischers (102) an einer Zwischenposition, bevorzugt an einer beliebigen Zwischenposition, zwischen der ersten und der zweiten Position fest positionierbar ist.

6. Mischsystem (100) nach einem der vorhergehenden Ansprüche, wobei der erste (10) und der zweite (102) Mischer um wenigstens zwei Rohrleitungsdurchmesser voneinander getrennt sind.

7. Mischsystem (100) nach einem der vorhergehenden Ansprüche, wobei der erste Mischer (10) ein höheres Beta hat, als der zweite Mischer (102).

Revendications

1. Système de mélange (100) pour écoulement de fluide s'écoulant dans une conduite de transport (24) comprenant :

un premier mélangeur statique (10) possédant une plaque (12) possédant un bord (16) et possédant une face (14) définissant au moins un orifice de mélange (22) s'étendant à travers celle-ci, ledit premier mélangeur statique (10) étant positionné de façon fixe dans ladite conduite de transport (24) avec ladite surface de face (14) disposée afin d'être généralement en travers de l'écoulement de fluide dans ladite conduite de transport (24) ; et

un second mélangeur statique à position variable (102) possédant également une plaque (112) possédant une surface de face (115) définissant au moins un orifice de mélange (122) s'étendant à travers celle-ci, ledit second mélangeur (102) étant positionné dans ladite conduite de transport (24) en aval dudit premier mélangeur (10), la plaque (112) dudit second mélangeur (102) étant montée pour un mouvement entre une première position généralement de non-mélange, dans laquelle la plaque surface de face (115) est sensiblement alignée avec l'écoulement de fluide, et une seconde position de mélange, dans laquelle la plaque face (115) est disposée généralement à travers la direction d'écoulement de fluide à l'intérieur de ladite conduite de transport (24).

2. Système (100) selon la revendication 1, dans lequel ladite plaque (112) du second mélangeur (102) est agencée pour pivoter autour d'un axe radial de ladite section de conduite (24) selon au moins 90 degrés entre lesdites positions et dans lequel le diamètre de ladite plaque (112) est inférieur au diamètre interne de ladite section (24).

3. Système (100) selon la revendication 1, dans lequel ladite plaque (112) du second mélangeur (102) est agencée pour pivoter autour d'un axe positionné de façon adjacente à la paroi interne de ladite section de conduite (24) entre lesdites positions et dans lequel ledit bord de plaque (113) de la plaque (112) du second mélangeur (102) est disposé de façon adjacente à ladite paroi interne lorsqu'elle est dans une position de non-mélange.

4. Système (100) selon la revendication 1, dans lequel la plaque (112) du second mélangeur (102) est disposée de façon décalée latéralement par rapport à une paroi interne de la section de conduite (24) dans une position de non-mélange et est agencée pour se déplacer dans et en travers de ladite section de conduite (24) jusqu'à une position de mélange.

5. Système (100) selon la revendication 1, dans lequel la plaque (112) du second mélangeur (102) peut être positionnée de façon fixe dans une position intermédiaire, de préférence une quelconque position intermédiaire, entre lesdites première et seconde positions.

6. Système de mélange (100) selon une quelconque revendication précédente, dans lequel les premier (10) et second (102) mélangeurs sont séparés par au moins deux diamètres de conduite de transport.

7. Système de mélange (100) selon une quelconque revendication précédente, dans lequel ledit premier mélangeur (10) possède un bêta supérieur à celui dudit second mélangeur (102).

Drawing