Efficient mixing of fluids and solids is essential for many industry sectors. The means by which this mixing is undertaken are many, the choice of which is dependent upon the nature of the materials being mixed and the degree and rate of mixing required.
Numerous concepts and frequent efforts have been made to improve the efficiency and effectiveness of liquid and solid mixing systems. Several notable methods that have met with relative success, depending upon the nature of the materials being mixed, have included: nozzle geometry distortion, motive flow pulsation, and the introduction of a diffuser as part of the system.
Nozzle distortion attempts to create turbulent flow by altering the geometry of the interaction of the motive flow with the nozzle surface, as shown in
Referring to
In motive flow pulsation, pulsating the velocity of the motive flow, either with or without a nozzle, does change the velocity that creates turbulent flow, but will not permit the maintenance of a vacuum conducive to consistent and rapid induction of the secondary solid. Furthermore, such efforts require additional control systems and external energy reducing the efficiency of the process.
A third methodology which has seen more positive results is that of the motive flow utilizing the combination of nozzle and diffuser. This combination is referred to as an eductor. The relative velocity of the motive flow passing through the void on the outlet of the nozzle effectively maintains the vacuum required to permit induction of the secondary solids, but does not create recirculation zones sufficient in size and intensity to permit optimal mixing.
The action of the motive flow through the nozzle into the void space at the outlet of the nozzle carries the secondary solid into the eductor but does not succeed in mixing the two to any great extent. All nozzle geometries create vortices at the micro level downstream of the nozzle. It has been suggested that some nozzle geometries, such as lobed nozzles, can create these vortices faster (i.e. at a lower pipe diameter lengths) for liquid in liquid applications. However, the intensity of the vortices does not change and applications to induced solids in liquid are unknown._ Furthermore the speed at which the micro vortices are created in eductor based liquid-solid mixing applications is not critical as several pipe diameters are available prior to discharge.
The creation of a vacuum to induce solids into the motive fluid and large eddy current vortices is necessary to entrain and mix the solids with the motive fluid. Therefore, without the addition of a downstream diffuser which is used to create vacuum and create short and intense large eddies, mixing is limited and solids are simply carried along the plane of the motive flow only to be inefficiently mixed several pipe diameters downstream at a very slow rate.
One effective method of controlling the location of large eddies and recirculation mixing zones created between the nozzle outlet and the diffuser inlet is through nozzle and diffuser geometry and position. Through the combination of these geometries and positions, several large eddies are generated that maximize solids induction and solid-liquid interface while limiting pressure drop. Typically, nozzles with or without distorted geometries are placed in the center of the motive flow and produce only limited contact with the solids and motive fluid. Therefore the turbulence and consequent mixing along the linear axis of the motive flow are limited. Further, protruding nozzles can be an impediment to the induction of the solids. Such an impediment will reduce the induction rate and negatively impact mixing performance.
This problem has been addressed with the introduction of a multi-lobed circular nozzle in conjunction with a lightly tapered single throat diffuser. While effective, this concept can be improved upon in such a manner so as to increase the rate at which secondary solids can be induced into the motive flow, improving the solids-liquid surface contact through a flat profile jet stream, improve the generation of three large eddy currents through the use of diffuser geometry, maintain turbulent flow throughout the mixing body through nozzle and diffuser geometry, increase and maintain the vacuum which facilitates the rapid induction of solids, reduce the pressure loss through the eductor system through nozzle geometry and improve overall mixing performance as measured by rate of hydration of secondary solids.
In one aspect, the claimed subject matter is generally directed to an improved in-line liquid/solid nozzle. The present invention provides an improved fluid mixing nozzle that achieves one or more of the following: accelerates the motive fluid; provides improved mixing of fluids and secondary solids; utilizes a unique semicircular nozzle geometry; improves the vacuum in the void between the nozzle outlet and diffuser inlet; improves the rate of induction of secondary solid; allows the use of a shorter diffuser section ; utilizes a diffuser section with non-uniform diffuser inlet angles; utilizes a diffuser with a primary mixing zone plus two additional mixing zones in the diffuser; improves pre-wetting of solids in the primary mixing zone; creates a turbulent flow zone; induces macro and micro vortices in the motive flow; improves rate of hydration of solids; increases motive flow rates through the nozzle; permits consistent performance with low or inconsistent line pressure; reduces pressure drop through the eductor, in addition to other benefits that one of skill in the art should appreciate. The eductor includes a nozzle, an initial mixing area, and a segmented diffuser. The nozzle is a semi-circular orifice that is off-center from a central axis. The nozzle outlet feeds motive flow into the initial mixing area. The solid material is also directed into the initial mixing area. The initial mixing area is of a size sufficient to create a temporary vacuum within the area, enhancing mixing in this first mixing zone. From the initial mixing area, the combined motive flow and entrained solid are fed into the segmented diffuser. The diffuser has two segments, the first of which contains a sloped inlet converging to a throat and a sloped outlet diverging to an intermediate cavity. The diffuser throat is elliptical, consistent with the shape of the jet stream. The second segment inlet is also sloped, converging to a throat while the outlet is sloped, diverging to the eductor outlet. The intermediate cavity serves as a second mixing zone, while the exit of the second diffuser serves as a third mixing area.
Another illustrated aspect of the claimed subject matter is a method for liquid/solid mixing. A liquid fluid acting as a motive flow passes through a nozzle into a void. The motive flow through the nozzle into the void creates a temporary vacuum, which permits the enhanced induction of a separate solid entrained into the motive flow external to the nozzle. The flat profile of the jet stream allows for improved entrainment of solids. A large turbulent region having turbulent intensity at minimal pressure loss is produced by the nozzle. This region of turbulence is conducive to mixing the motive flow and the induced solid. The motive flow carries the induced solid into the diffuser section. In each of the diffuser cavities, large eddy currents and recirculation mixing zones are created as velocity increases and boundary flow separation occurs. In these recirculation mixing zones and diffuser convergent sections, there exists areas of turbulent flow conducive to mixing. The mixed fluid is discharged from the diffuser unit.
Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
a and 1b are views of a prior art nozzle.
a through 2d are contours of volume fractions of solids through a prior art nozzle.
a through 8d are contours of volume fractions of solid particles through the eductor.
The claimed subject matter relates to a eductor 100 and a method for mixing liquids with solids. Referring to
Turning to
A standard round nozzle 200 may be incorporated into eductor 100 instead of nozzle 134. As shown in
Returning to
A chamber outlet 158 directs the initial mixture of motive flow and solid particles into the diffuser segments of the eductor 100. Chamber outlet 158 is aligned with nozzle outlet 134, thereby minimizing energy lost by the motive flow as the solid particles are received into initial mixing chamber 150 at an angle substantially normal to stream of the motive flow.
Chamber outlet 158 feeds the initial mixture into a first diffuser 160. First diffuser 160 includes a first converging section 162 and a first diverging section 166, between which is a first throat 164. First throat 164 has an elliptical cross-sectional shape (not shown), consistent with the shape of the jet stream. The converging and diverging sections 162, 166 of first diffuser 160 serve to induce turbulence into the flow, enhancing the mixing of the motive flow and solid particles.
The first diverging section 166 feeds the initial mixture into intermediate mixing chamber 168, which is in alignment with the first diffuser 160. Within intermediate mixing chamber 168, a second mixing zone 222, shown in
From the intermediate mixing chamber 168, the intermediate mixture is fed into a second diffuser 170. The second diffuser 170 is similar to the first diffuser 160, having a second converging section 172, a second throat 174, and a second diverging section 176. Additional mixing is enhanced by the turbulence created by the second diffuser 170. Downstream from second diffuser 170, a third mixing zone 224 forms, as shown in
Referring to the cross-sectional views of the flow through the eductor 100 shown in
For this description, additional increments of the mixture between the solids-free fluid 180 and the solids 188 are included. Reference 184 refers to a mixture, wherein the solids are effectively entrained in the fluid. Boundary layers of ineffectively mixed fluid 182 and ineffectively mixed solids 186 are also depicted.
In
Referring to
Referring to
Referring to
The computer-generated water velocity profile, shown in
Test
A test was conducted using a variety of powdered materials representative of solids that would be mixed with base liquid to form a drilling mud. The same hopper was utilized with the exception that the mixing nozzles indicated were used. Bentonite, polyanionic cellulose, and XC polymer were each introduced to the base liquid through the various nozzles. Such particles are representative of other particles having the same or similar densities.
Rheological properties of the resulting drilling muds were measured and recorded. Such properties included fisheyes, yield point, and funnel viscosity. Fisheyes are known by those of skill in the art to be a globule of partly hydrated polymer caused by poor dispersion during the mixing process. The yield point is the yield stress extrapolated to a shear rate of zero. The yield point is used to evaluate the ability of a mud to lift cuttings out of the annulus of the well hole. A high yield point implies a non-Newtonian fluid, one that carries cuttings better than a fluid of similar density but lower yield point. The funnel viscosity is the time, in seconds for one quart of mud to flow through a Marsh funnel. This is not a true viscosity, but serves as a qualitative measure of how thick the mud sample is. The funnel viscosity is useful only for relative comparisons. The comparison of each of these rheological properties may be seen in Table 1 below:
As can be seen, the fisheyes in the mud made from bentonite mixed with the inventive nozzle weighed less per volume than that mixed with the prior art nozzles. Further, the mud yield point was higher than the mud mixed with the prior art nozzles.
Mechanical properties of the resulting drilling muds were also measured and recorded. These properties included mixing energy, pressure drop, motive flow, vacuum, and solids induction.
From the table, it is seen that the eductor 100 can entrain nearly the same volume of solids per hour into the motive stream at a lower mixing energy than the prior art mixer.
A method of mixing solid particles with a motive flow includes introducing a motive fluid to an initial mixing chamber 150. This may be done through the nozzle 110, previously described. Inside initial mixing chamber 150, a vacuum is created by the motive flow. Solids are introduced into initial mixing chamber 150 and are induced into the motive fluid by the vacuum that has been created. A region of turbulence is provided to initially mix the motive flow and the induced solids. The motive flow, now carrying the induced solids is diffused to further entrain the solid particles. The initial mixture is further mixed in an intermediate mixing chamber. The intermediate mixture is then diffused again to provide additional turbulence to enhance mixing. Prior to each diffusion, the mixture may be subjected to an increased flow rate by reducing the cross sectional area through which the mixture flows.
While the claimed subject matter has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the claimed subject matter as disclosed herein. Accordingly, the scope of the claimed subject matter should be limited only by the attached claims.
This application claims priority to U.S. Provisional application 60/532,159 filed on Dec. 23, 2003, entitled “Device and Methodology for Improving Liquid/Solid Mixing,” hereby incorporated by reference.
Number | Name | Date | Kind |
---|---|---|---|
4519423 | Ho et al. | May 1985 | A |
4590057 | Hicks | May 1986 | A |
5664733 | Lott | Sep 1997 | A |
5799831 | Spriggs et al. | Sep 1998 | A |
6000839 | Lott | Dec 1999 | A |
6328226 | Goenka et al. | Dec 2001 | B1 |
6974546 | Wood | Dec 2005 | B2 |
Number | Date | Country | |
---|---|---|---|
20050189081 A1 | Sep 2005 | US |
Number | Date | Country | |
---|---|---|---|
60532159 | Dec 2003 | US |