EP2826547B1

EP2826547B1 - Mixing unit, devices using same and fluid mixing method

Info

Publication number: EP2826547B1
Application number: EP13760917.8A
Authority: EP
Inventors: Noboru Mochizuki
Original assignee: ISEL Co Ltd
Current assignee: ISEL Co Ltd
Priority date: 2012-03-13
Filing date: 2013-03-08
Publication date: 2017-08-23
Anticipated expiration: 2033-03-08
Also published as: CN104168990A; JPWO2013137136A1; CN104168990B; EP2826547A1; JP6229185B2; WO2013137136A1; EP2826547A4

Description

TECHNICAL FIELD

The present invention relates to a mixing unit for mixing a fluid such as a liquid or a gas and a device using such a mixing unit, and, more particularly, relates to a mixing unit that can be suitably utilized for static mixing where a fluid is mixed by being passed, dynamic mixing where a fluid is mixed by rotation within the fluid, the promotion of a reaction involving the mixing of a liquid and the like, and to a device using such a mixing unit.

BACKGROUND OF THE INVENTION

As a static mixing device for mixing a fluid, a static mixer or the like is widely used. Since this type of static mixing device generally does not include a movable component, the static mixing device is widely used in fields, such as the chemical industry and the food industry, in which fluids are required to be mixed in piping. On the other hand, as a dynamic mixing device, a product is widely used in which an agitation impeller is provided in a fluid within a mixing vessel and which rotates the agitation impeller to mix the fluid.
The patent document 1 discloses an example of a static fluid mixing device. The static fluid mixing device includes a tubular case body and a plurality of types of disc-shaped elements where a plurality of holes are drilled with a predetermined space apart within the tubular case body, and in which the elements are sequentially combined in the direction of thickness thereof to be fitted and fixed with a connection hardware.
In the fluid mixing device described above, a plurality of types of elements are sequentially combined, and thus static mixing agitation caused by the division and combination of a fluid is performed, and mixing agitation is also performed such as by eddies and disturbance resulting from enlarged and reduced cross sections and shearing stress.
However, in the fluid mixing device described above, since the direction from the inlet to the outlet of the mixing device is the same as the direction of the division and aggregation of the fluid, its static mixing effect is low. Although the cross sections of holes are enlarged and reduced to increase its flow resistance and thus the mixing effect is improved, the loss of pressure in the entire device is increased. Since the holes are trapezoidal and have a flow reduction portion, it is difficult to process the holes.
The patent document 2 discloses another example of a static fluid mixing device. The static fluid mixing device includes a cylindrical casing and a mixing unit member which is formed with a first mixing hollow core group and a second mixing hollow core group, each having a plurality of hollow cores within a cylindrical member inserted into the cylindrical casing.
In the fluid mixing device described above, a fluid entering from its inlet is prevented from flowing linearly to change its direction, and flows radially between the hollow cores communicating with each other, with the result that the fluid is dispersed and mixed such as by collision, dispersion, combination, meandering and eddying flow. Since the direction from the inlet to the outlet of the mixing device differs from the direction of the division and combination of the fluid, its static mixing effect is high.
However, in the fluid mixing device described above, since the mixing unit member is formed with only the first mixing hollow core group and the second mixing hollow core group, the dispersion and combination of the fluid is performed only planarly and two-dimensionally with respect to the radial direction. The fluid only flows
alternately between the first mixing hollow core group and the second mixing hollow core group, which overlap each other, and is thereby prevented from extending in the direction in which the first mixing hollow core group and the second mixing hollow core group overlap each other, with the result that the loss of pressure is increased.
The patent documents 3 and 4 also disclose other examples of static fluid mixing devices. Each mixing unit within both static fluid mixing devices is formed with a pair of mixing elements only, and the dispersion or division and combination of the fluid is performed only planarly and two-dimensionally with respect to the radial direction, with the result that the loss of pressure is increased.
Patent document 5 discloses a mixing unit in accordance with the preamble of claim 1 as well as a mixing device, an agitation impeller and a
pump mixer. The mixing unit includes a stacked member in which a plurality of mixing elements are stacked, a first plate and a second plate between which the stacked member is sandwiched and which are arranged opposite each other. The mixing elements are provided with a plurality of first through holes, wherein the second plate has an opening portion communicating with at least one of the first through holes. The mixing elements are arranged such that part or all of the first through holes in one of the mixing elements communicate with a first through hole in the adjacent mixing element to allow fluid to be passed in a direction in which the mixing elements extend.
Further, patent document 6 relates to a mixing element, a mixing device, a mixing method, a stirring blade, a stirring device, and a stirring method for mixing a large amount of fluid.

PRIOR ARTS DOCUMENTS

PATENT DOCUMENTS

Patent Document 1: Japanese published patent application No. 2000-254469
Patent Document 2: Japanese published patent application No. Hei11-9980
Patent Document 3: Japanese published patent application No. 2010-149120
Patent Document 4: U.S.Patent No.6,568,845
Patent Document 5: European published patent application No. 2 286 905
Patent Document 6: Japanese published patent application No. 2011-121020

SUMMARY OF THE INVENTION

PROBLEMS TO BE SOLVED BY THE INVENTION

It is a major object of the present invention to provide a mixing unit such that any fluid can be mixed with a high mixing effect even when the flow rate is high. It is a further object of the present invention to provide a useful device employing the above-mentioned mixing unit.

Means for solving the problems

The present invention provides a mixing unit in accordance with the features of claim 1 as well as a mixing device, a pump mixer, an agitation impeller, a reaction device, a catalyst unit, a fluid mixing method and a fluid as described below to resolve the above-mentioned problems.
As described herein, there is provided a mixing unit including: a stacked member in which a plurality of mixing elements are stacked; and a first plate and a second plate between which the stacked member is sandwiched and which are arranged opposite each other, wherein the mixing elements are provided with a plurality of first through holes, the second plate has an opening portion communicating with at least one of the first through holes in the mixing elements, and the mixing elements are arranged such that a part or all of the first through holes in one of the mixing elements communicate with a first through hole in an adjacent mixing element to allow a fluid to be passed in a direction in which the mixing element extends and a flow path that divides the fluid in a direction in which the mixing elements are stacked is provided.
"direction in which the mixing element extends" means a direction perpendicular or substantially perpendicular to a direction in which the mixing elements are stacked, and hereinafter the same.
As described herein, there is provided a mixing unit including a stacked member having a plurality of mixing elements which are stacked; and a first plate and a second plate between which the stacked member is sandwiched and which are arranged opposite each other, wherein each of the mixing elements has a plurality of first through holes and the second plate has an opening portion communicating with at least of the first through holes, wherein mixing elements are arranged such that, a part of the partition walls between the first through holes crossing a direction in which the mixing element extends is differently positioned between adjacent one of mixing elements to provide a flow path for passing fluid within one of the first through holes to one of the first through holes in adjacent one of mixing elements in the direction in which the mixing element extends and for dividing the fluid in a direction in which mixing elements are stacked, and wherein the opening portion of the second plate is an inlet or outlet of the fluid and an outer circumferential side of the stacked member is an outlet or inlet of the fluid.
According to the present invention, the mixing unit of the present invention is defined by the features of claim 1.
As described herein, there is provided a mixing unit including a stacked member having a plurality of mixing elements which are stacked; and a first plate and a second plate between which the stacked member is sandwiched and which are arranged opposite each other, wherein each of the mixing elements has a plurality of first through holes, the first through holes in each of mixing elements are non-linearly arranged in a direction in which the mixing element extends, the second plate has an opening portion communicating with at least of one of the first through holes in the stacked member, and wherein mixing elements are arranged such that a part or all of the first through holes in one of mixing elements communicate with the first through holes in adjacent one of mixing elements to allow fluid to be passed in a direction in which the mixing element extends.
In the mixing unit, the stacked member is sandwiched by the first plate and the second plate, and the first through holes of the mixing elements forming the stacked member are closed in portions contacting with the first plate and the second plate. Further, the first through holes in one of the mixing elements are arranged to communicate with the first through holes in adjacent one of mixing elements to allow fluid to be passed in a direction in which the mixing elements extend. The fluid flowing within the stacked member through the opening of the second plate or the fluid flowing-in from an outer circumferential side of the stacked member subsequently passes through the first through holes of the mixing elements in an outer or internal circumferential side direction in which the mixing elements extend. The fluid flowing in the first through holes passes through the first through holes by flow of division, turn over, collision and combination. The flow as described above is repeated one after another in a plurality of places, and consequently, the fluid is mixed.
As described above, the fluid is passed through a plurality of first through holes in a multilayer structure within the stacked member multiple times in a complicated manner, and thus mixing is performed significantly efficiently and satisfactorily. Consequently, it is possible to obtain high mixing effects.
Moreover, since portions through which the fluid is passed are configured by stacking a plurality of mixing elements, at least three or more mixing elements are stacked and a structure is formed where a plurality of layers of the flow paths for dividing the fluid in the direction in which the mixing elements are stacked are formed in one mixing element, and thus the flow paths extending in the direction in which the mixing element extends are formed in a multilayer structure of two or more layers, with the result that it is possible to produce complicated flow and obtain a high mixing capability. Since the cross-sectional area in the direction in which the mixing element extends is increased, even when the flow rate of the fluid is high, it is possible to perform mixing. In other words, since a plurality of first through holes are formed in the multilayer structure, the flow paths for dividing the fluid in the direction in which the mixing elements are stacked spread and pass the fluid not two-dimensionally and planarly but three-dimensionally and sterically, the loss of pressure is low. It is possible to mix a fluid of a high flow rate with a low pressure loss.
Particularly such a configuration as the above-mentioned third and fourth mixing units enables the fluid to flow in various variations, with the result that the fluid can be mixed well.
According to the present invention, there is provided a mixing device of the present invention including the mixing unit described above and a casing that accommodates the mixing unit and that has an inlet and an outlet, where the first plate of the mixing unit has an outer shape smaller than an inner shape of the casing, and the second plate of the mixing unit has an outer shape substantially equal to the inner shape of the casing and an outer side surface of the second plate is substantially in contact with an inner side surface of the casing.
According to this configuration, the fluid passing or being passed within the mixing unit is mixed by such mixing operation done by the mixing unit, with the result that a mixing device having efficient mixing is provided. The fluid can be mixed within the casing, whereby the device may be used as an inline static type mixing device and the fluid may be mixed sequentially.
According to the present invention, there is provided a pump mixer of the present invention including the above-described mixing unit within a casing, and a rotational axis to support the mixing unit to be driven to rotate, wherein the mixing unit is driven to rotate such that a fluid sucked through a suction port disposed in an end surface of the casing flows within the mixing unit, and is passed out through an outer circumferential portion of the mixing unit and discharged through a discharge port disposed in the casing.
According to this configuration, the fluid sucked through the suction port of the casing flows within the mixing unit rotating. As the mixing unit rotates, the fluid within the mixing unit is mixed by the mixing action done by the mixing unit, passed out through the outer circumferential portion of the mixing unit and discharged through the discharge port of the casing, with the result that the mixing effect is improved. With this configuration, it is possible to continuously mix a fluid in a pipe line path.
An agitation impeller of the present invention includes the above-described mixing unit supported by a rotation shaft that is driven to rotate.
According to this configuration, as the agitation impeller rotates within agitation vessel, a centrifugal force is applied to the fluid within the mixing unit, and the fluid is mixed by flowing through the communicating first through-holes. The fluid within an agitation vessel is sucked within the mixing unit, and through the first through-holes being open for an internal peripheral potion of the stacked member as the mixing unit rotates.
Mixed energy is applied to a fluid by a conventional paddle wing or disk turbine wing mainly only in a small space of the wing neighborhood. However, according to the above-mentioned configuration, by raising a volume ratio of the mixing unit among the agitation vessel, mixed energy can be applied to the fluid in a markedly large space in comparison with the conventional agitation impeller. Thus, the space in the agitation vessel can be used effectively and the fluid can be mixed effectively
According to the present invention, there is provided a reaction device that makes a fluid react within a vessel having an inlet and an outlet, wherein the above-described mixing unit is disposed within the vessel, the first plate of the mixing unit has an outer shape smaller than an inner shape of the vessel, the second plate of the mixing unit has substantially the same outer shape as the inner shape of the vessel, and an outer side surface of the second plate is substantially in contact with an inner side surface of the vessel.
In this configuration, the fluid that has entered the vessel is fed to the mixing unit together with another fluid, and in the mixing unit, they are mixed by the mixing action of the mixing unit as described above. Since the first plate has the outer shape smaller than the inner shape of the vessel, the fluid is reliably passed out or in through a space in the vicinity of the stacked member. Since the outer side surface of the second plate is substantially in contact with an inner side surface of the vessel, the fluid is reliably passed into or out of the stacked member through the opening portion of the second plate. Since the mixing of the reaction raw material and the reaction product is promoted, it is possible to increase the reaction efficiency.
When, for example, the number of stacked mixing elements of the stacked member is increased, and thus a multilayer structure of two or more layers of flow paths in the direction in which the mixing element extends is provided, the flow rate of the fluid that can be passed is increased, with the result that it is possible to make a larger amount of fluid react for a short period of time.
According to the present invention, there is provided a reaction device that makes a fluid react within a vessel having an inlet and an outlet, wherein at least two catalyst layers are provided within the vessel, the above-described mixing unit that mixes one or two or more fluids is provided in at least one space between the catalyst layers, the first plate of the mixing unit has an outer shape smaller than an inner shape of the vessel, the second plate of the mixing unit has substantially the same outer shape as the inner shape of the vessel, and an outer side surface of the second plate is substantially in contact with an inner side surface of the vessel.
In this configuration, the fluid that has entered the vessel is fed to the catalyst layer together with another fluid, and in the mixing unit, they are mixed by the mixing action of the mixing unit as described above. Since the sizes of the first plate and the second plate are set as described above, and thus the fluid is passed within the stacked member of the mixing unit as described above without fail, it is possible to reliably perform mixing.
Since mixing is performed with the mixing unit reliably and significantly efficiently as described above, it is possible to enhance the reaction rate of the fluid in the catalyst layer.
According to the present invention, there is provided a catalyst unit including the above-described mixing unit, wherein the mixing elements of the mixing unit have a catalytic ability.
In this configuration, the mixing elements that mix the fluid passing within the catalyst unit and have a catalytic ability to promote a reaction.
According to the present invention, there is provided a fluid mixing method including: a stacking direction division step of passing, between a plurality of stacked mixing elements each of which has an extending surface, a fluid along the extending surface of the mixing element and of dividing the fluid in a direction in which the mixing elements are stacked, wherein the fluid is divided in an extending direction division step of diving the fluid in a direction along the extending surface of the mixing element, and the fluid is discharged through the stacking direction division step and the extending direction division step so that the flowing fluid can be combined.
The "extending surface" described above refers to a surface extending in a direction in which the mixing element extends. The "extending surface" in the present invention includes surfaces that are formed not only planarly but also three-dimensionally such as curvedly and conically.

EFFECT OF THE PRESENT INVENTION

Thus, the present invention provides a high mixing effects and a mixing capability for mixing even large flow rate of fluid. Further the present invention provides useful devices such as a mixing device, a reaction device and so forth, whereby a fluid with a high mixing rate can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

[Fig. 1] An exploded perspective view of a mixing unit;
[Fig. 2] A plan view of mixing elements of the mixing unit;
[Figs. 3(a) and 3(b)] A plan view and a cross-sectional view showing the state of flow of a fluid within the mixing unit;
[Fig. 4] An exploded perspective view of the mixing unit;
[Fig. 5] A plan view showing how the mixing elements of Fig. 4 are stacked;
[Fig. 6] A plan view of the mixing elements of the mixing unit;
[Fig. 7] A computer analysis result showing the state of flow of the fluid flowing within the mixing unit;
[Fig. 8] A cross-sectional view showing the state of flow of the fluid within the mixing unit;
[Figs. 9(a) and 9(b)] A cross-sectional view showing how the fluid flows through the mixing unit and a perspective view of the mixing elements;
[Figs. 10(a) to 10(d)] Perspective views of the mixing elements;
[Figs. 11(a) and 11(b)] A perspective view of a main portion of the mixing elements stacked and a cross-sectional view showing the state of flow of the fluid;
[Fig. 12] A plan view of the mixing elements stacked;
[Figs. 13(a), 13(b) and 13(c)] Perspective views of the mixing elements;
[Fig. 14] A plan view of the mixing elements of the mixing unit;
[Fig. 15] A plan view of the mixing elements of the mixing unit;
[Figs. 16(a) and 16(b)] A perspective view of the mixing elements of the mixing unit and a cross-sectional view showing the state of flow of the fluid within the mixing unit;
[Figs. 17(a) and 17(b)] A perspective view of the mixing elements of the mixing unit and a cross-sectional view showing the state of flow of the fluid within the mixing unit;
[Figs. 18(a) and 18(b)] A perspective view of the mixing elements of the mixing unit and an enlarged view showing its cross-sectional shape;
[Figs. 19(a), 19(b) and 19(c)] Cross-sectional views showing the state of flow of the fluid within the mixing unit;
[Fig s. 20(a) and 20(b)] A perspective view of the mixing elements of the mixing unit and a partial cross-sectional perspective showing its cross-sectional shape;
[Fig. 21] A conceptual diagram showing the state of flow of the fluid within the mixing unit;
[Fig. 22] A partial cross-sectional perspective showing a cross-sectional shape of the mixing elements of the mixing unit;
[Figs. 23(a) and 23(b)] A perspective view of the mixing elements of the mixing unit and its cross-sectional view;
[Fig. 24] A cross-sectional view of a mixing device;
[Figs. 25(a) and 25(b)] Cross-sectional views of the mixing device;
[Fig. 26] A cross-sectional view of a pump mixture;
[Fig. 27] An exploded perspective view showing a mixing unit portion of the pump mixer;
[Figs. 28(a) and 28(b)] Cross-sectional views of the pump mixer;
[Fig. 29] An exploded perspective view of an agitation impeller;
[Fig. 30] A cross-sectional view of the agitation impeller in a used state;
[Fig. 31] An exploded perspective view of the agitation impeller;
[Fig. 32] A cross-sectional view of the agitation impeller in a used state;
[Fig. 33] A cross-sectional view of the agitation impeller in a used state;
[Fig. 34] A cross-sectional view showing a mixing unit portion of the agitation impeller;
[Fig. 35] A diagram showing the configuration of a mixing system;
[Fig. 36] A cross-sectional view of a reaction device;
[Fig. 37] A cross-sectional view of the reaction device;
[Figs. 38(a) and 38(b)] A cross-sectional view showing a mixing unit portion of the reaction device; and
[Fig. 39] A cross-sectional view of a catalyst unit.

EMBODIMENTS OF THE PRESENT DESCRIPTION

(First embodiment of a mixing unit)

Fig. 1 is a perspective view showing the constituent components of a mixing unit 1a according to the first embodiment of a mixing unit 1. Fig. 2 is a plan view showing two types of mixing elements 21a and 21b of the mixing unit 1a and the state of the mixing elements 21a and 21b stacked; Figs. 3(a) and 3(b) are a plan view and a cross-sectional view showing how a fluid A flows within the mixing unit 1a.
As shown in Figs. 1 and 2, the mixing unit 1a is configured by sandwiching a stacked member 2, in which a plurality of two types of disc-shaped mixing elements 21a and 21b (here, three mixing elements) are alternately stacked, between a first plate 3 and a second plate 4, for example, fixed with four bolts 11 and nuts 12 appropriately arranged. The mixing elements 21a and 21b and the first plate 3 and the second plate 4 can be separated from each other; the mixing unit 1a can be disassembled.
The first plate 3 is a disc that has holes 13 for the bolts and no other holes. The second plate 4 has not only holes 14 for the bolts but also a circular opening portion 41, in a center portion, through which the fluid A flows in and out. The first plate 3 and the second plate 4 are substantially equal in outside diameter to the mixing elements 21a and 21b. The outside shape of the first plate 3 is larger than the opening portion 41 of the second plate 4.
The two types of mixing elements 21a and 21b each have a plurality of first through holes 22 penetrating in the direction of thickness thereof. In other words, a plurality of first through holes are provided along an extending surface that extends in a direction in which the mixing elements 21a and 21b extend. Moreover, the two types of mixing elements 21a and 21b each have substantially circular second through holes 23 in the center portion. The second through hole 23 is substantially equal in inside diameter to and is substantially concentric with the opening portion 41 of the second plate 4. The mixing elements 21a and 21b are stacked, and thus the second through holes 23 form a hollow portion 24.
Each of the first through holes 22 is substantially rectangular as seen in plan view, and is arranged concentrically with respect to the center of the second through hole 23. The first through holes 22 are staggered; the two types of mixing elements 21 a and 21b differ from each other in the arrangement pattern of the first through holes 22 itself.
The first through holes 22 of the mixing elements 21b and 21c are partially displaced and overlapped in a radial direction and in a circumferential direction, and communicate with each other in the direction in which the mixing elements 21b and 21c extend. In other words, among partition walls between the first through holes 22, the partition walls that extend in a direction intersecting the direction in which the mixing elements 21a and 21b extend are displaced between the adjacent mixing elements, and are arranged such that the fluid can be sequentially passed through the first through holes 22 of the adjacent mixing elements 21a and 21b in the direction in which the mixing elements 21a and 21b extend.
As shown in Fig. 2, on one hand, in the mixing element 21 a, the first through holes 22 arranged along the inner circumferential surface are not open, and on the other hand, in the mixing elements 21b, the first through holes 22 in the inner circumferential surface are open. The size of and the pitch between the first through holes 22 are increased as the first through holes 22 extend outward in the radial direction. Furthermore, in the state where the mixing elements 21 a and 21b are stacked, the areas in which the first through holes 22 overlap each other are equal to each other in the circumferential direction.
The stacked member 2 is formed by stacking the mixing elements 21a and 21b described above.
As shown in Fig. 3(b), the first through holes 22 of the mixing elements 21a and 21b on both ends of the stacked member 2 are closed, in the direction in which they are stacked, by the first plate 3 and the second plate 4 arranged opposite each other on both ends of the stacked member 2 in the stacking direction. In other words, the first through holes 22 are blocked. Hence, the fluid A within the stacked member 2 is prevented from flowing from the first through holes 22 of the mixing elements 21 a on both ends of the stacked member 2 in the direction in which the mixing elements 21a and 21b are stacked, and is, as shown in Fig. 3(a), reliably passed within the stacked member 2 in the direction in which the mixing elements 21a and 21b extend.
Therefore, the fluid A is passed within the mixing unit 1a from the inner circumferential portion to the outer circumferential portion or vise verse, that is, from the outer circumferential portion to the inner circumferential portion. As described above, a plurality of first through holes 22 are formed to communicate with each other such that the fluid A can be passed between the first through holes 22 in the direction in which the mixing elements 21 a and 21b extend.
In the mixing unit 1a described above, for example, the fluid A flows through the opening portion 41 of the second plate 4 into the hollow portion 24 with appropriate pressure, and then the fluid A flows into the stacked member 2 through the first through holes 22 of the mixing elements 21a and 21b which are open to the inner circumferential surface of the hollow portion 24. Then, the fluid A is passed through other first through holes 22 that communicate with the above-mentioned first through holes 22, and is further passed through the first through holes 22 that communicate with the above-mentioned other first through holes 22. Finally, the fluid A flows out of the stacked member 2 through the first through holes 22 of the mixing elements 21a and 21b which are open to the outer circumferential surface of the stacked member 2.
As described above, the fluid A within the stacked member 2 substantially radially flows through the first through holes 22 communicating with each other within the stacked member 2 from the inner circumferential portion to the outer circumferential portion.
A plurality of layers of flow paths along which the fluid A flows are provided in the direction in which the mixing elements 21a and 21b are stacked; in the example of Fig. 3(b), two layers are provided. Since a plurality of flow paths that divide the fluid A in the direction in which the mixing elements 21a and 21b are stacked are provided, when the fluid A passes through the first through holes 22, as shown in Figs. 3(a) and 3(b), the fluid A is divided in the direction in which the mixing elements 21a and 21b are stacked, and is thereafter combined. In other words, the flow of the fluid A is performed not only two-dimensionally in the radial direction such that the division and combination are performed planarly but also three-dimensionally while extending in the direction in which the mixing elements 21a and 21b are stacked.
While the flow described above is performed, the fluid A is highly mixed by repeating dispersion, combination, reversal, turbulent flow, eddying flow, collision and the like.
Since the first through holes 22 of the mixing elements 21a and 21b are staggered, when the fluid flows from the above-mentioned first through holes 22 to other first through holes 22 on the upper and lower surfaces, the flow is easily divided or easily combined, and thus the fluid is efficiently mixed.
On the contrary to what has been described above, the fluid A may be made to flow in through the outer circumferential portion of the stacked member 2 of the mixing elements 21a and 21b and flow out through the inner circumferential portion.
The hollow portion 24 is sufficiently larger in size than the first through holes 22; the second through holes 23 of the mixing elements 21a and 21b constituting the hollow portion 24 are substantially equal in inside diameter to each other, and are substantially concentric with each other. Hence, the flow resistance to the fluid A flowing through the hollow portion 24 is smaller than that of the fluid A flowing within the stacked member 2, and the loss of pressure is also smaller. Therefore, even when a large number of mixing elements 21a and 21b are stacked, the fluid A substantially uniformly reaches the inner circumferential portion of the mixing elements 21a and 21b regardless of the position in the direction in which the mixing elements 21a and 21b are stacked, and substantially uniformly flows within the stacked member 2 from the inner circumferential portion to the outer circumferential portion.
Since the hollow portion 24 is provided, as compared with a case where there is no hollow portion 24, the fluid is more likely to enter the mixing unit 1a and to be passed to the first through holes 22. Likewise, the fluid entering the mixing unit 1a through the outer circumferential side thereof and passing through the first through holes 22 is made to smoothly flow out without being disturbed.
In first through holes 22 of the mixing elements 21a and 21b whose upper surface and lower surface are in contact with other mixing elements 21a and 21 b within the mixing unit 1a, since the fluid A flows out from the above-mentioned first through holes 22 to the above-mentioned other first through holes 22 on the upper and lower surfaces, the fluid A is dispersed through the above-mentioned other first through holes 22 on the upper and lower surfaces. Moreover, since the fluid A flows in from the above-mentioned other first through holes 22 on the upper and lower surfaces to the above-mentioned first through holes 22, the fluid A from the above-mentioned other first through holes 22 on the upper and lower surfaces is combined. Therefore, significant mixing effects are acquired and the fluid A is highly mixed.
In particular, when the flow rate is increased and thus the flow state is transferred to the turbulent flow, the effects of the turbulent flow and the eddying flow are increased, and thus the mixing effects of the fluid resulting from the dispersion and the combination described above are further increased. Even when the flow rate is low and thus the flow state is a laminar flow, the fluid is dispersed toward the upper and lower surfaces and is combined, with the result that the fluid is highly mixed.
Since the first through holes 22 on both end surfaces in the stacking direction of the stacked member 2 are blocked by the removable first plate 3 and second plate 4, it is possible to separately produce the individual members. For example, it is possible to produce a large number of mixing elements 21a and 21b for a short period of time by drilling holes in a metal plate having a given thickness through punching processing or the like. Hence, it is possible to easily and inexpensively produce the mixing unit 1a.
Since the mixing elements 21a and 21b and the first plate 3 and the second plate 4 can be divided into individual pieces, it is possible to easily perform a washing operation such as the removal of stuff and foreign matter left in the first through holes 22 of the mixing elements 21a and 21b. Since the first through holes are holes that penetrate in the direction of thickness, it is easy to clean the first through holes 22 by the washing operation.
Since the mixing elements 21a and 21b and the first plate 3 and the second plate 4 have simple structures, it is possible to produce them with a material such as ceramic. Thus, it is possible to apply the mixing unit 1a to applications in which corrosion resistance and heat resistance are required.
Moreover, when the first plate 3 and the second plate 4 are appropriately held, it is possible to freely apply the mixing unit 1a to various portions. Thus, it is possible to apply the mixing unit 1a to various devices, and it is therefore possible to widely utilize its high mixing capability.

(Second embodiment of the mixing unit)

Fig. 4 is a perspective view showing the constituent components of a mixing unit 1b according to the second embodiment of the mixing unit 1. Fig. 5 is a plan view showing a mixing element 21c and the overlapping of the first through holes 22 in a stacked state of mixing elements 21c adjacent to the mixing element 21c in the direction in which the mixing elements 21c are stacked. In Fig. 5, in order for the overlapping of the first through holes 22 to be clearly shown, the portions where the first through holes 22 overlap each other are filled with black.
The mixing unit 1b of the second embodiment differs from the mixing unit 1a of the first embodiment in that the first through holes 22 are formed to be circular as seen in plan view and that the number of mixing elements 21c is changed from three to six. The inside diameter and the pitch of the first through holes 22 are substantially equal to each other. As shown in Fig. 5, parts of the first through holes 22 are arranged such that they are displaced with respect to the first through holes 22 of the mixing elements 21c adjacent to each other and are partially overlapped, and spaces formed with the first through holes 22 are made to communicate with each other in the direction in which the mixing elements 21c extend.
Among the first through holes 22, the first through holes 22 on the inner circumferential edge are open to the inner circumferential surface of the mixing elements 21c, and the first through holes 22 on the outer circumferential edge are open to the outer circumferential surface of the mixing elements 21c.
Even with the mixing unit 1b configured described above, the fluid A made to flow into the mixing unit 1b with appropriate pressure flows into the stacked member 2 through the opening portion 41 of the second plate 4 and the first through holes 22 open to the inner circumferential surface of the mixing elements 21c. Then, while the fluid A is being passed radially within the stacked member 2, the fluid A is passed through the first through holes 22 communicating with the mixing elements 21c, with the result that the fluid A is highly mixed.
In particular, since a larger number of mixing elements 21c are provided than three, a larger number of flow paths extending in the direction in which the mixing elements 21c extend are provided than the two layers. Hence, a large number of flow paths that divide the fluid in the direction in which the mixing elements 21c are stacked are obtained in the stacking direction, and the division and combination of the fluid are three-dimensionally performed in a wide area in the direction in which the mixing elements 21c are stacked. Consequently, it is possible to obtain higher mixing effects. It is also possible to reduce the loss of pressure.
The other parts of the configuration of and the other effects of the mixing unit 1b of the second embodiment are the same as those of the mixing unit 1a of the first embodiment.

(Third embodiment of the mixing unit)

Fig. 6 is a plan view showing the two types of mixing elements 21a and 21b and the state of the mixing elements 21a and 21b stacked.
The mixing elements 21a and 21 b of the third embodiment differ from the mixing elements 21a and 21b of the second embodiment in that, in the state of the two types of mixing elements 21a and 21b stacked, the area of a certain portion where the first through holes 22 overlap each other is not equal in the circumferential direction to the area of another portion adjacent to the above-mentioned portion.
In order to realize the configuration described above, the two types of mixing elements 21 a and 21 b are configured such that, among the partition walls between the first through holes 22, partition walls 25a extending in the radial direction are arranged at different angles with respect to an imaginary straight line passing through the center of the mixing elements 21a and 21b and connecting bolt holes 26.
Even with the mixing unit including the mixing elements 21 a and 21b described above, the fluid is highly mixed as described above; in this case, in particular, the fluid passing through the first through holes 22 is unevenly divided in the circumferential direction. Consequently, it is possible to further enhance the mixing efficiency.
Fig. 7 is a result obtained by analyzing, with a computer, the state of flow of the fluid when the areas where the first through holes 22 overlap each other are uneven in the circumferential direction (the structure in the third embodiment). As shown in Fig. 7, it is found that the unevenness of the areas produces various types of flow of the fluid.
The other parts of the configuration of and the other effects of the mixing unit of the third embodiment are the same as those of the mixing unit 1a of the first embodiment.

(Fourth embodiment of the mixing unit)

Fig. 8 is a cross-sectional view showing how the fluid A flows within the mixing unit 1 a of a fourth embodiment.
This mixing unit 1a differs from the mixing unit 1a of the first embodiment in that, as shown in Fig. 8, the width of a flow path, in the direction in which the mixing elements 21a and 21 b extend, that is formed in the portion where the first through holes 22 overlap each other by the stacking of the mixing elements 21 a and 21b is narrower than the thickness of a partition wall 25b, in the stacking direction, that is connected to the upstream side of the above-mentioned flow path and that is between the above-mentioned first through holes 22. In the example of Fig. 8, in particular, the width of the flow path is narrower than half of the thickness of the partition wall 25b, and more specifically, is narrower than one-fourth thereof
In the mixing unit 1 a configured as described above, when the fluid A flows in the direction in which the mixing elements 21a and 21b extend, the fluid A likewise flows separately in the direction in which the mixing elements 21a and 21b are stacked and in the direction along the extending surface extending in the direction of the extension. However, since a flow path along which the fluid A flows from the first through hole 22 of one mixing element 21 a to the first through hole 22 of the mixing element 21b adjacent to the above-mentioned mixing element 21a is narrow, it is possible to provide a shearing force to the fluid, with the result that it is possible to enhance the degree of mixing of the fluid.
In the case where the width of the flow path is made narrower than one-fourth of the thickness of the partition wall 25b, when the fluid flows through the flow path from one first through hole 22 into other two first through holes 22, each flow rate is increased to be twice or more as high as before, with the result that it is possible to further increase the effect of enhancing the degree of mixing of the fluid.
The other parts of the configuration of and the other effects of the mixing unit 1a of the fourth embodiment are the same as those of the mixing unit 1a of the first embodiment.

(Fifth embodiment of the mixing unit)

Fig. 9(a) is a cross-sectional view showing how the fluid A flows within a mixing unit 1c of a fifth embodiment; Fig. 9(b) is a perspective view showing a mixing element 21d of the mixing unit 1c.
This mixing unit 1c differs from the mixing unit 1a of the first embodiment in that, as shown in Figs. 9(a) and 9(b), a plurality of mixing elements 21d have the first through holes 22 over the entire surface without the provision of the second through holes 23 in the center portion and a frame portion 27 (see Fig. 9(b)) that prevents the first through holes 22 from being open to the outer circumferential portion. Each of the first through holes 22 is formed in the shape of a quadrangle (see Fig. 9(b)). Furthermore, the diameter of the first plate 3 in the outer circumferential shape is smaller than the diameter of the mixing elements 21d (see Fig. 9(a)) such that the first through holes 22 in the outer circumferential portion of the mixing elements 21d stacked on the first plate 3 are open.
Even with the mixing unit 1c configured as described above, the fluid A made to flow into the mixing unit 1c with appropriate pressure flows into the stacked member 2 through the opening portion 41 of the second plate 4. The fluid entering the stacked member 2 is passed radially within the stacked member 2 and is passed through the first through holes 22 with which the mixing elements 21d communicate. Here, since the flow is performed in the direction in which the mixing element 21d extends, and the fluid A is repeatedly divided and combined while extending in the direction in which the mixing elements 21d are stacked, the fluid A is highly mixed. Finally, the fluid A flows out through the first through holes 22 that are open to the outer circumferential portion of the first plate 3 arranged on one end of the stacked member 2.
As described above, since, in the mixing unit 1c of the fifth embodiment, the first through holes 22 are formed over the entire surface of the mixing element 21d, it is unnecessary to provide the second through hole 23 in the center portion, with the result that it is easy to produce the mixing unit 1c.
The other parts of the configuration of and the other effects of the mixing unit 1c of the fifth embodiment are the same as those of the mixing unit 1a of the first embodiment.
The mixing unit 1 of the present invention is not limited to those described in the first to fifth embodiments; many variations are possible.

(First variation of the mixing unit)

For example, the first through hole 22 of the mixing element 21 is not limited to be circular or rectangular. As shown in Figs. 10(a) to 10(d), the first through hole 22 may be formed in the shape of a polygon such as a square, a triangle, a hexagon or a rectangle. By forming the first through hole 22 in the shape of a rectangle or a polygon to increase the aperture ratio of the mixing element 21, it is possible to reduce the flow resistance of the mixing unit 1. Although the pitches between the first through holes 22 of the mixing elements 21a are substantially equal to each other, the present invention is not limited to this configuration. As in the above-described mixing elements 21a and 21b, the size of and the pitch between the first through holes 22 may be increased as the mixing element extends from the inner circumferential portion to the outer circumferential portion.
Although the outer circumferential shape of the mixing elements 21 is substantially circular and the outer circumferential shape of the first plate 3 and the second plate 4 is circular, the present invention is not limited to this configuration. Any other shape that achieves the equivalent function can be employed. Although the second through holes 23 of the mixing elements 21 are substantially circular and the opening portion 41 of the second plate 4 is circular, the present invention is not limited
to this configuration. Any other shape that achieves the similar function can be employed. Although the mixing elements 21 have the second through holes 23 in the center portion, the second plate 4 has the opening portion 41 in the center portion and the second through hole 23 and the opening portion 41 are substantially equal in diameter to each other and are substantially concentric with each other, the present invention is not limited to this configuration, and any other shape that achieves the similar function can be employed.
The mixing unit 1 may be formed as follows. The mixing elements 21 having a plurality of first through holes 22 arranged in the same positions and having the same shape are used; the first through holes 22 are displaced such that the first through holes 22 overlap each other in the radial direction and the circumferential direction.
Two types of mixing elements having different inside and outside diameters are used, and thus the first through holes 22 in the inner circumferential portion and the outer portion may be open.

(Second variation of the mixing unit)

Fig. 11 (a) is a perspective view of a main portion in a state where one mixing element 21 a and one mixing element 21 b of the two types of mixing elements 21 a and 21b are stacked; Fig. 11(b) is a cross-sectional view showing the state of the fluid A flowing within the mixing elements 21a and 21b.
Even when only the two mixing elements are stacked, in these mixing elements 21a and 21b, two or more layers of the flow paths aligned in the stacking direction are provided.
Specifically, among the partition walls between the first through holes 22 of the mixing elements 21 a and 21b, in the partition walls 25b extending in the direction intersecting the direction in which the mixing elements 21a and 21b extend, cut portions 25c whose height is lower than that of the partition walls 25a extending in the radial direction of the mixing elements 21a and 21b are formed. When the two mixing elements are stacked, the mixing elements 21 a and 21b are stacked with the sides where the cut portions 25c are not present in the mixing elements 21a and 21b arranged to face the contact surface.
The shape of the first through holes 22 of the mixing elements 21a and 21b, that is, the shape of the partition walls, is the same as in the first embodiment of the mixing unit shown in Figs. 1, 2 and 3. Among the first through holes 22 of the mixing elements 21b shown on the upper side of the figure, the first through holes 22 on the inner circumferential edge are open to the inner circumference; among the first through holes 22 of the mixing elements 21 a shown on the lower side of the figure, the first through holes 22 on the outer circumferential edge are open to the outer circumference. Hence, the partition walls 25b extending in the circumferential direction, which is the direction intersecting the direction in which the mixing elements 21a and 21b extend, are displaced between the stacked mixing elements 21a and 21b in the circumferential direction.
That is, in the partition walls 25b extending in the circumferential direction, the position in the circumferential direction differs from the position in the stacking direction. In other words, each of the two types of mixing elements 21a and 21b stacked has a flow path that divides the fluid in the direction in which the mixing elements 21 a are stacked. Hence, unlike the case where one flow path that divides the fluid in the direction in which the mixing elements 21 a are stacked is present as shown in Fig. 3(b), two flow paths can be formed as shown in Fig. 10(b).
In the configuration described above, even when a small number of mixing elements 21a and 21b stacked are provided, it is possible to provide a multilayer structure where two or more layers of the flow paths along which the fluid A flows, with the result that it is possible to obtain a high mixing capability.
Although, in Figs. 11 (a) and 11(b), the example where the cut portions 25c are formed over the partition walls 25b extending in the direction intersecting the direction in which the mixing elements 21a and 21b extend has been shown, the cut portions 25c may be formed partially or intermittently. The mixing elements 21a and 21b may be stacked such that the partition walls 25b extending in the direction intersecting the direction in which the mixing elements 21a and 21b where the cut portions 25c of the stacked mixing elements 21a and 21b are formed extend are in contact with each other. Even in this case, it is possible to form at least one flow path that divides the fluid in the direction in which the mixing elements 21a and 21b are stacked. Furthermore, three or more layers of the mixing elements 21a and 21b as described above may be stacked.

(Third variation of the mixing unit)

Fig. 12 is a plan view in a state where the two types of mixing elements 21 a and 21b are stacked.
In these mixing elements 21a and 21b, in the corner portions of the substantially rectangular first through hole 22, rounded corner portions 22a are formed.
When the rounded corner portions 22a are provided as described above, the fluid is unlikely to be left in the corner portions. Consequently, the leaving of the fluid in the mixing element is reduced, and thus it is possible to perform satisfactory mixing and washing.

(Fourth variation of the mixing unit)

The mixing element 21, the first plate 3, the second plate 4 and the like can be divided into separate structures of various shapes. In this case, it is possible to easily produce even a large mixing unit 1.
When the mixing element 21 has an annular shape as shown in Figs. 13(a) and 13(b), the mixing element 21 can be divided into separate structures, each composed of a sector-shaped divided member 21z. When the mixing element 21 is formed in the shape of a quadrangle as shown in Fig. 13(c), the mixing element 21 can be divided into separate structures, each composed of a rectangular divided member 21z.

(Fifth variation of the mixing unit)

As shown in Figs. 14 and 15, the first through holes 22 of the mixing elements 21 may be non-linearly arranged in the direction in which the mixing elements 21 extend.
Fig. 14 is a plan view showing the two types of mixing elements 21e and 21f and the state of the mixing elements 21e and 21f stacked.
As shown in Fig. 14, the first through holes 22 are non-linearly arranged from the center side of the mixing elements 21e and 21f to the outer circumference. Specifically, among the partition walls between the first through holes 22, partition walls 25d continuous from the center portion to the outer circumference extend in the form of a curve curving to one direction; more specifically, the partition walls 25d extend substantially in the form of an involute curve. The "substantially in the form of an involute curve" means that it includes an involute curve.
In addition to the partition walls 25d, partition walls 25e that substantially perpendicularly interest the partition walls 25d and that extend so as to connect the partition walls 25d are provided.
The arrangements of the partition walls 25d and 25e are made to differ between the two types of mixing elements 21e and 21f; among the partition walls, the positions of the partition walls extending in the direction intersecting the direction in which the mixing elements 21e and 21 f extend, that is, the partition walls 25d and 25e, are displaced between the adjacent mixing elements 21 e and 21f; the fluid is passed by being made to sequentially pass through the first through holes 22 of the adjacent mixing elements 21e and 21f in the direction in which the mixing elements 21e and 21f extend
The first through holes 22 are non-linearly arranged as described above, and thus it is possible to increase the path length of the fluid as compared with the case where the first through holes 22 are linearly arranged. In other words, since the number of times the fluid passes through the first through holes 22 can be increased, it is possible to satisfactorily mix the fluid.
Even when the mixing elements 21e and 21f are small, it is possible to increase the path length and obtain high mixing effects, with the result that it is possible to reduce the size of the mixing unit.
As the non-linear configuration, a configuration where the curvature of a curve is increased toward the direction in which the mixing element extends or the like can be employed as necessary. In the direction in which the mixing elements 21e and 21f extend, the first through holes 22 may be spaced regularly along the same direction in the form of a substantially same curve or an involute curve; moreover, the mixing elements 21e and 21f may be spaced irregularly.
Fig. 15 is a plan view showing the two types of mixing elements 21e and 21f and the state of the mixing elements 21e and 21f stacked.
In the mixing elements 21e and 21f shown in Fig. 15, among the partition walls between the first through holes 22, the partition walls 25d continuous from the center portion to the outer circumference extend substantially in the form of an involute curve curving to one direction, and the partition walls 25d are coupled by the partition walls 25e extending in the circumferential direction. The partition walls 25e extending in the circumferential direction are formed concentrically with respect to the center point of the mixing elements.
In the mixing elements 21e and 21f described above, it is possible to perform satisfactory mixing as described above; in particular, when the mixing unit is actively rotated to perform mixing, since a rotational force can be efficiently transmitted to the fluid, it is possible to enhance the mixing effects.

(Sixth variation of the mixing unit)

The partition walls between the first through holes 22 in the mixing element 21 described above may be formed in a shape other than a square as seen in cross section.
Fig. 16(a) is a perspective view in a state where two types of mixing elements 21g and 21h are stacked; Fig. 16(b) is an illustrative diagram showing a state where the fluid flows within the mixing elements 21g and 21h.
As shown in Fig. 16(a), in the mixing elements 21g and 21h, the cross-sectional shape of partition walls 25f extending in the radial direction and partition walls 25e extending in the circumferential direction is formed substantially in the shape of a vertically long ellipse. The "substantially in the shape of an ellipse" described above means that it includes an ellipse.
The flow of the fluid within the mixing elements 21g and 21h having the partition walls 25e and 25f shaped as described above is the same as in, for example, the first embodiment of the mixing unit; as compared with partition walls whose end surfaces rise steeply, an impact at the time of collision with the fluid is reduced, and thus it is possible to make the fluid flow smoothly. This type of flow is suitable for a fermentation process that deals with yeast or the like.
The partition walls between the first through holes 22 in the mixing elements 21 may have a cross-sectional shape including a chamfered portion as seen in cross section.
Fig. 17(a) is a perspective view in a state where the two types of mixing elements 21g and 21h are stacked; Fig. 17(b) is an illustrative diagram showing a state where the fluid flows within the mixing elements 21 g and 21h.
As shown in Fig. 17(a), in the mixing elements 21g and 21h, the cross-sectional shape of the partition walls 25f extending in the radial direction and the partition walls 25e extending in the circumferential direction is formed in the shape of a triangle where the width of its upper portion is narrow and the width of its lower portion is wide. Hence, the surface opposite the direction in which the mixing elements 21g and 21h extend is inclined in such a direction that, as the surface extends upwardly, the thickness of the partition walls 25e and 25f is decreased. The inclined portion described above is the chamfered portion 28, and forms inclined surfaces 29.
In the flow of the fluid within the mixing elements 21g and 21h having the partition walls 25e and 25f shaped as described above, since the chamfered portions 28 are provided, as compared with partition walls whose end surfaces rise steeply, an impact at the time of collision with the fluid is reduced. Thus, it is possible to make the fluid flow smoothly.
Fig. 18(a) is a perspective view in a state where the two types of mixing elements 21g and 21h are stacked; Fig. 18(b) is a perspective view showing the cross-sectional shape of the mixing elements 21g and 21h. Fig. 19(a) is an illustrative diagram showing a state where the fluid flows within the mixing elements 21g and 21h.
As shown in Fig. 18(a), in the mixing elements 21g and 21h, the cross-sectional shape of the partition walls 25f extending in the radial direction and the partition walls 25e extending in the circumferential direction is formed substantially in the shape of a rhombus where corners are present in upper, lower, left and right portions. The "substantially in the shape of a rhombus" means that it includes a rhombus.
Hence, the surface opposite the direction in which the mixing elements 21 g and 21h extend is inclined in such a direction that, as the surface extends upwardly or downwardly, the thickness of the partition walls 25e and 25f is decreased. The inclined portion described above is the chamfered portion 28, and forms inclined surfaces 29.
In the flow of the fluid within the mixing elements 21g and 21h having the partition walls 25e and 25f shaped as described above, since the chamfered portions 28 are provided as shown in Fig. 19(a), as compared with partition walls whose end surfaces rise steeply, an impact at the time of collision with the fluid is reduced. Thus, it is possible to make the fluid flow smoothly.
The angle of the inclined surfaces 29 is set as necessary, and thus it is possible to adjust and control the direction in which the fluid flows.
As shown in Figs. 19(b) and 19(c), the angles of the upper and lower inclined surface 29 are made to differ from each other, and thus it is possible to increase and decrease the magnitude of the flow of the fluid in the up/down direction (the stacking direction), with the result that it is possible to change the entire flow. For example, with consideration given to a direction in which satisfactory mixing can be performed and the like, the angle of the inclined surfaces 29, the distance between the partition walls 25e and 25f and the like are set as necessary, and thus it is possible to realize desired mixing.
The control of the direction in which the fluid flows can be performed such as by setting the cross-sectional shape of the partition walls 25e and 25f as necessary, inclining the partition walls 25e and 25f of the cross-sectional shape as in the example described above or twisting the partition walls 25e and 25f.
Fig. 20(a) is a perspective view in a state where the two types of mixing elements 21g and 21h are stacked; Fig. 20(b) is a perspective view showing the cross-sectional shape of the mixing elements 21g and 21h.
As shown in Figs. 20(a) and 20(b), the cross-sectional shape of the partition walls 25f extending in the radial direction and the partition walls 25e extending in the circumferential direction is formed substantially in the shape of an ellipse; as the partition walls 25e extending in the circumferential direction extend upwardly, the partition walls 25e are inclined so as to extend circumferentially; the partition walls 25f extending in the radial direction are inclined to one of the leftward and rightward directions.
As the mixing elements 21g and 21h are relatively moved, differences in the resistance between the partition walls 25e and 25f are made, and thus directivity is given to the fluid within the mixing elements 21g and 21h having the partition walls 25e and 25f shaped as described above. Since the fluid is made to flow easily in the circumferential direction along the partition walls 25e by the partition walls 25f inclined to the circumferential direction and extending in the radial direction, it is possible to obtain spiral flow shown conceptually in Fig. 21. The inclination of the partition walls 25f to the circumferential direction of the mixing elements 21g and 21h of Figs. 20(a) and 20(b) is reversed in the left/right direction, and thus it is also possible to reverse the spiral flow of Fig. 21.
When the cross-sectional shape of the partition walls 25e and 25f is formed in the shape of a rhombus, among the partition walls, the resistance of the partition walls extending from the center portion of the mixing elements to the outer circumference to the fluid and the resistance of the other partition walls to the fluid are made to differ from each other, and thus it is possible to likewise achieve spiral flow.
Fig. 22 is a perspective view showing a cross-sectional shape in a state where the two types of mixing elements 21g and 21h are stacked.
As shown in Fig. 22, the partition walls 25e and 25f between the first through holes 22 in the mixing elements 21g and 21h have the inclined surfaces 29 whose upper and/or lower ends are narrower in width, and, with respect to the inclination angle of the inclined surfaces 29 described above, among the partition walls, the inclination angle of the partition walls 25f extending in the radial direction from the center portion of the mixing elements to the outer circumference is narrower than the inclination surface of the cross-sectional shape of the other partition walls 25e extending in the circumferential direction.
In the fluid within the mixing elements 21g and 21h having the partition walls 25e and 25f shaped as described above, the flow in the circumferential direction is promoted more than in the radial direction, and resistance is given to the flow of the fluid in the radial direction by the partition walls 25e in the circumferential direction, with the result that it is possible to produce spiral flow.

(Seventh variation of the mixing unit)

Since the mixing elements 21 can be formed to have various cross-sectional shapes as described above, as necessary, a plurality of members can be stacked.
Fig. 23(a) is a perspective view in a state where the mixing elements 21g and 21h are stacked; Fig. 23(b) is a vertical cross-sectional view thereof.
As shown in Fig. 23(a), the mixing elements 21g and 21h include the partition walls 25e and 25f whose cross-sectional outline is substantially rhombic. As shown in Fig. 23(b), the partition walls 25e and 25f are configured by stacking a plurality of plate members having different width dimensions. The plate members are fixed to each other
such as by adhesion or welding as necessary.
By stacking a plurality of plate member as described above, it is possible to freely obtain the mixing elements 21 g and 21h having various cross-sectional shapes that cannot be formed by pressing or the like.
Although the partition walls 25e and 25f shown in Figs. 23(a) and 23(b) have ladder-shaped steps, it is possible to provide the partition wall having the inclined surfaces by chambering the plate members.

(First embodiment of a mixing device)

Fig. 24 is a cross-sectional view showing how the fluid A flows within a mixing device 5a according to an embodiment of a mixing device 5.
In the mixing device 5a of the present embodiment, as shown in Fig. 24, a flange 54 having an inlet 51 and an outlet 52 and formed in the shape of an outer circumferential disc is removably fitted to a casing 50 having a flange 53 and formed in the shape of a cylinder. Within the casing 50, there are provided four stacked members 2 in which a plurality of mixing elements 21 (here, three mixing elements) composed of discs described above are stacked.
In the side of the inlet 51 of the casing 50, a second plate 4 having an opening portion 41 in the center portion and an outside diameter substantially equal to the inside diameter of the casing 50 is provided, and a first stacked member 2a of the mixing element 21 is provided on the bottom surface of the second plate 4. On the bottom surface of the first stacked member 2a, a first plate 3 having an outside diameter substantially equal to the outside diameter of the mixing element 21 is provided. Then, a second stacked member 2b, the second plate 4, a third stacked member 2c, the first plate 3, a fourth stacked member 2d and the second plate 4 are sequentially provided.
In the mixing device 5a shown in Fig. 24, the mixing unit 1 can be fixed within the casing 50 with fixing units such as bolts and nuts.
As with the mixing units 1a and 1b according to the embodiment of the mixing unit 1, the mixing element 21 has a plurality of first through holes 22 and a substantially circular second through hole 23 in the center portion. The inside diameter of the second through hole 23 of the mixing element 21 is substantially equal to the inside diameter of the opening portion 41 of the second plate 4; the second through hole 23 is substantially concentric with the opening portion 41 of the second plate 4. The mixing elements 21 are stacked, and thus the second through holes 23 constitute a first hollow portion 24a, a second hollow portion 24b, a third hollow portion 24c and a fourth hollow portion 24d, which are hollow space portions. The hollow portions 24a to 24d are hollow portions corresponding to the stacked members 2a to 2d, respectively.
A first annular space portion 55a is formed between the inner circumferential portion of the casing 50 and the outer circumferential portion of the first stacked member 2a and the second stacked member 2b; a second annular space portion 55b is formed between the inner circumferential portion of the casing 50 and the outer circumferential portion of the third stacked member 2c and the fourth stacked member 2d.
Within the stacked members 2a to 2d, part of a plurality of first through holes 22 communicate with each other in the direction in which the mixing element 21 extends, and part thereof are open to the inner circumferential surface and the outer circumferential surface of the mixing elements 21.
The first plate 3 and the second plate 4 arranged on both end portions of each of the stacked members 2a to 2d and opposite each other close the first through holes 22 in both end portions of each of the stacked members 2a to 2d in the stacking direction. This prevents the fluid A within the stacked member 2 from flowing out through the first through holes 22 in both end portions of each of the stacked members 2a to 2d in the stacking direction; the fluid A is reliably passed within the stacked members 2a to 2d in the direction in which the mixing element 21 extends.
In the mixing device 5a configured as described above, for example, the fluid A flows in through the inlet 51 with an appropriate pressure feeding unit, and flows into the first hollow portion 24a. Then, the fluid A flows into the first stacked member 2a through the first through holes 22 open to the inner circumferential surface of the first hollow portion 24a, and is passed in the outer circumferential direction through the first through holes 22 communicating with each other. Then, the fluid A flows out through the first through holes 22 open to the outer circumferential surface of the first stacked member 2a, and flows into the first annular space portion 55a.
Then, the fluid A flows into the second stacked member 2b through the first through holes 22 open to the outer circumferential surface of the second stacked member 2b, and is passed in the inner circumferential direction through the first through holes 22 communicating with each other. Then, the fluid A flows out through the first through holes 22 open to the inner circumferential surface of the second hollow portion 24b, and flows into the second hollow portion 24b.
Thereafter, the fluid A flows from the third hollow portion 24c to the third stacked member 2c to the second annular space portion 55b to the fourth stacked member 2d and to the fourth hollow portion 24d, and flows out through the outlet 52.
As described above, the fluid A is passed through the through holes 22 communicating with each other while flowing within the stacked members 2a to 2d from the inner circumferential portion to the outer circumferential portion or from the outer circumferential portion to the inner circumferential portion in a meandering manner, with the result that the fluid A is highly mixed. In this way, the fluid A flows in through the inlet 51 of the mixing device 5a, is highly mixed and flows out through the outlet 52.
In the mixing device 5a described above, the first plate 3 and the second plate 4 arranged on both end portions of each of the stacked members 2a to 2d and opposite each other allow the direction in which the fluid A flows within the stacked member 2 to be changed from the inner circumferential portion to the outer circumferential portion or vise versa, that is, from the outer circumferential portion to the inner circumferential portion. Thus, the fluid A is passed through a larger number of first through holes 22 communicating with each other, with the result that the degree of mixing can be further increased.
Even in the mixing device 5a, as with the mixing unit 1a or 1b, each of the hollow portions 24a to 24d is sufficiently larger in size than the first through holes 22, and the second through holes 23 of the mixing elements 22 constituting the hollow portion 24 are substantially equal in inside diameter to each other, and are substantially concentric with each other. Hence, the flow resistance to the fluid A flowing through the hollow portions 24a to 24d is smaller than that of the fluid A flowing through the stacked members 2a to 2d; the loss of pressure is also smaller. Therefore, even when a large number of mixing elements 21 are stacked, the fluid A substantially uniformly reaches the inner circumferential portions of the mixing elements 21 regardless of the position in the mixing direction, and substantially uniformly flows within the stacked members 2a to 2d from the inner circumferential portion to the outer circumferential portion or vise versa, that is, from the outer circumferential portion to the inner circumferential portion.
The fluid A flows from the annular space portions 55a and 55b into the stacked members 2b and 2d in the same manner as the hollow portions 24a to 24d described above.
Furthermore, since, in the mixing device 5a described above, the fluid A can be mixed within the casing 50 having the inlet 51 and the outlet 52, it is possible to use the mixing device 5a as an in-line static mixing device and mix the fluid A continuously.
Moreover, since the outer circumferential shapes of the mixing element 21, the first plate 3 and the second plate 4 are circular and thus the casing 50 can be cylindrical, it is possible to increase the pressure resistance of the casing 50. Thus, it is possible to mix the fluid A at a high pressure.
Instead of the mixing units 1a and 1b, the mixing elements 22 in which the second through holes 23 are not provided as in the mixing unit 1c may be used.
As in the variations of the mixing unit, the mixing device 5 according to the present invention is not limited to the embodiment of the mixing device described above. Variations are possible within the scope of the present invention, and it is possible to practice variations.

(Second embodiment of the mixing device)

Figs. 25(a) and 25(b) are cross-sectional views of a mixing device 5b that includes the mixing unit 1 within a tube member 56 through which the fluid flows. Fig. 25(a) shows the linear mixing device 5b; Fig. 25(b) shows the curved mixing device 5b.
In each of the mixing device 5b, the mixing unit 1 is provided within the tube member 56 connected to a pipe line 57 so as not to protrude in the longitudinal direction of the tube member 56. In other words, the first plate 3 of the mixing unit is formed to have the same size as the outer circumference of the stacked member 2, and the second plate 4 is formed to have a size corresponding to the flange 56a of the tube member 56. The opening portion 41 of the second plate 4 is equal in size to the hollow portion 24 of the stacked member 2.
In order for the mixing unit 1 to be fixed to the tube member 56, the first plate 3 of the mixing unit 1 is inserted into the tube member 56, and the second plate 4 is joined to the outer side surface of the flange 56a.
As shown in the figures, the mixing unit 1 may be provided at each end of the tube member 56 or may be provided at one end. The mixing unit 1 may be provided in an intermediate portion of the tube member 56 in the longitudinal direction.
Since in the mixing device 5b configured as described above, the mixing unit 1 does not protrude in the longitudinal direction of the tube member 56, the mixing device 5b can be used by being attached to the pipe line 57 that has been already provided. Thus, it is possible to mix fluid within a piping system as necessary. It is also easy to perform maintenance.
Since the mixing unit 1 has high mixing effects as described above, it is possible to sufficiently perform mixing, it is not necessary to provide a mixing device separately and it is also possible to save space.
In addition to the example described above, the mixing device 5 of the present invention can be configured as follows.
The outer circumferential shapes of the mixing element 21, the first plate 3 and the second plate 4 are not limited to be circular. This is because, even if the outer circumferential shapes are not circular, there is no problem at all in practicing the invention.
A fluid that is mixed is not limited to a gas or a liquid; it may be a solid mixture consisting of a liquid and a powder and granular material or the like.
With respect to applications, in addition to an application for making the concentration of a fluid uniform, for example, the mixing device can also be used for mixing the same type of fluid having different temperatures so that the fluid has a uniform temperature.
Since the mixing device does not need a large space or can be provided in a pipe line, for example, the mixing unit 1 or the mixing device 5 can also be used in a place, such as a diesel automobile or an exhaust gas line, where an installation space is limited.

(First embodiment of a pump mixer)

Fig. 26 is a cross-sectional view showing how the fluid A flows within a pump mixer 6a according to a second embodiment of a pump mixer 6.
As shown in Fig. 26, the pump mixer 6a includes the mixing unit 1, a cylindrical casing 50, a rotation shaft 58 and an electric motor 59 serving as a drive source. The electric motor 59 drives and rotates the mixing unit 1; in the present embodiment, the electric motor 59 is driven to rotate by the supply of electric power from an unillustrated power supply. While the rotation shaft 58 is coupled to the electric motor 59, the rotation shaft 58 supports the mixing unit 1. A seal member 50a is provided to a portion in which the rotation shaft 58 slides with respect to casing 50 so as to prevent the leakage of the fluid A within the pump mixer 6a.
The casing 50 has an inlet 51 and an outlet 52 formed in the shape of a flange; the fluid A is sucked into the pump mixer 6a through the inlet 51 and is discharged through the outlet 52.
As shown in Fig. 27, the mixing unit 1 has an axis portion 32 connected to the rotation shaft 58. The axis portion 32 is provided at the center of the first plate 3; an opening portion 31 is formed around the axis portion 32. As with the opening portion 41 of the second plate 4, the opening portion 31 is a portion through which the fluid flows. The mixing unit 1 is configured as described above.
When the mixing unit 1 is driven to rotate by the electric motor 59, the fluid A sucked through the inlet 51 of the pump mixer 6a flows into the hollow portion 24 through the opening portions 31 of the first plate 3 and the opening portion 41 of the second plate 4 of the mixing unit 1. Then, the fluid A flows into the stacked member 2 through the first through holes 22 in the mixing elements 21 open to the inner circumferential portion of the hollow portion 24.
A force acting outwardly in a radial direction resulting from the centrifugal force is applied to the fluid A that has flowed into the stacked member 2. The fluid A receiving the force is radially passed through the first through holes 22 communicating with each other within the stacked member 2 from the inner circumferential portion to the outer circumferential portion, and is discharged outwardly from the outer circumferential portion of the stacked member 2 through the first through holes 22 open to the outer circumferential portion. The fluid A that has flowed out is discharged from the pump mixer 6a through the outlet 52.
Part of the fluid A that has flowed out of the mixing unit 1 flows again into the hollow portion 24 through the opening portion 31 of the first plate 3 and the opening portion 41 of the second plate 4, further flows into the stacked member 2 and flows out from the outer circumferential portion of the stacked member 2, with the result that the fluid A circulates within the stacked member 2 of the mixing unit 1.
Then, while the fluid A substantially radially flows through the first through holes 22 communicating with each other within the stacked member 2 from the inner circumferential portion to the outer circumferential portion, the fluid is repeatedly dispersed, combined, reversed and subjected to turbulent flow, eddying flow, collision and the like, and thus the fluid is highly mixed.
Although, in the first embodiment, the casing 50 is cylindrical, the present invention is not limited to this configuration. The opening portion 31 may be omitted in the first plate 3.
When the required degree of mixing is low, the clearance between the mixing unit 1 and the inlet 51 is reduced as in a conventional centrifugal pump and thus the flow rate of fluid A circulating within the pump mixer 6a may be reduced.

(Second embodiment of the pump mixer)

Figs. 28(a) and 28(b) are diagrams showing a pump mixer 6b according to the second embodiment of the pump mixer 6. Fig. 28(a) is a cross-sectional view taken along line I-I of Fig. 28(b); Fig. 28(b) is a cross-sectional view showing how the fluid A flows within the pump mixer 6b.
The pump mixer 6b differs from the pump mixer 6a of the first embodiment in that the outer circumferential shape of the first plate 3 and the second plate 4 is larger than that of the mixing elements 21, and that blades 15 (here, six blades) extending in the direction in which the mixing elements 21 are stacked are provided in the outer circumferential portion of the stacked member 2, that is, in a space formed by the first plate 3 and the second plate 4.
When the mixing unit 1 rotates, the fluid A that has flowed out of the outer circumferential portion of the stacked member 2 flows out of the mixing unit 1 by receiving a force from the blades 15. Since the ends of the blades 15 are closed by the first plate 3 and the second plate 4, the fluid A that has flowed out of the outer circumferential portion of the stacked member 2 efficiently receives the force from the blades 15, and thus it is possible to increase the pressure of the fluid A discharged from the pump mixer 6b.
As the mixing elements of the mixing unit 1, the mixing elements 21e and 21f shown in Fig. 15 are used, and thus the fluid A is mixed and receives the force efficiently.
Although the blades 15 are provided in the space formed by the first plate 3 and the second plate 4, the present invention is not limited to this configuration. For example, another disc may be attached to the mixing unit 1 to fix the blades 15. Although the blades 15 are provided to extend in a direction perpendicular to the direction in which the mixing elements 21 extend, the present invention is not limited to this configuration. The blades 15 may be inclined as long as the effects of the present invention are achieved. The shape of the blades 15 is set as necessary.
The other parts of the configuration of and the other effects of the pump mixer 6a according to the second embodiment of the pump mixer 6 are the same as those of the pump mixer 6a of the first embodiment.

(Embodiment of an agitation impeller)

Fig. 29 is a perspective view showing the constituent components of an agitation impeller 7a according to an embodiment of an agitation impeller 7. Fig. 30 is a cross-sectional view showing how the fluid A circulates within the agitation impeller 7a and a mixing vessel 63 in an agitation device 60 in which the agitation impeller 7a is arranged within the mixing vessel 63.
As shown in Fig. 29, the agitation impeller 7a has the mixing unit 1, and the mixing unit 1 is configured by sandwiching the stacked member 2, in which a plurality of substantially disc-shaped mixing elements are stacked, between the first plate 3 and the second plate 4 with fastening members composed of four bolts 11 and nuts 12 appropriately arranged.
The first plate 3 is a disc that has holes 13 for the bolts and four opening portions 31 through which the fluid A flows in, and has a rotation shaft 62 fitted thereto. The second plate 4 has holes 14 for the bolts and a circular opening portion 41 in the center portion through which the fluid A flows out. The first plate 3 and the second plate 4 are substantially equal in outside diameter to the mixing elements 21.
The mixing elements 21 have a plurality of first through holes 22, and have substantially circular second through holes 23 in the center portion through which the fluid A circulating within the mixing vessel 63 flows in. The second through holes 23 in the mixing elements 21 are substantially equal in inside diameter to and are substantially concentric with the opening portion 41 in the second plate 4. The mixing elements 21 are stacked, and thus the second through holes 23 form the hollow portion 24.
The other parts of the configuration of the mixing unit 1 of the agitation impeller 7a are the same as those of the mixing unit 1a or 1b according to the embodiment of the mixing unit.
As shown in Fig. 30, when the agitation impeller 7a, that is, the mixing unit 1 fitted to the rotation shaft 62 is driven to rotate by a drive motor 61 to which electric power is supplied from an unillustrated power supply, a force acting outwardly in a radial direction resulting from the centrifugal force is applied to the fluid A within the stacked member 2 of the mixing unit 1. The fluid A receiving the force is substantially radially passed through the first through holes 22 communicating with each other within the stacked member 2 from the inner circumferential portion to the outer circumferential portion, and is discharged outwardly from the first through holes 22 open to the outer circumferential surface.
On the other hand, the fluid A within the mixing vessel 63 is sucked into the hollow portion 24 within the stacked member 2 through the opening portion 41 in the second plate 4 on the lower end of and the four opening portions 31 in the first plate 3 on the upper end of the mixing unit 1. The sucked fluid A flows into the stacked member 2 through the first through holes 22 open to the inner circumferential surface of the hollow portion 24. Then, a force acting outwardly in a radial direction due to the centrifugal force resulting from the rotation operation of the mixing unit 1 is applied to the sucked fluid A, and the sucked fluid A is discharged outwardly from the first through holes 22 open to the outer circumferential surface.
Then, when the fluid A substantially radially flows within the stacked member 2 from the inner circumferential portion to the outer circumferential portion, the fluid A is passed through the first through holes 22 communicating with each other, with the result that the fluid A is highly mixed.
Since the fluid can be mixed by being sucked from the upper and lower portions of the agitation impeller 7a, it is possible to expect to effectively perform mixing.
In the agitation impeller 7a described above, since the number of mixing elements 21 stacked is increased to increase the number of through holes 22 within the mixing unit 1 through which the fluid is passed and which communicate with each other, it is possible to reduce a time period during which the fluid is mixed within the mixing vessel 63.
The agitation impeller 7 of the present invention is not limited to the configuration described above.

(Variations of the agitation impeller)

As with an agitation impeller 7b shown in Fig. 31, the rotation shaft 62 of the agitation impeller 7 may be provided on an end side of the mixing unit 1, that is, on the second plate 4. In the agitation impeller 7b configured as described above, it is possible to suck a larger amount of fluid in the upper portion of the mixing vessel than the fluid in the lower portion of the mixing vessel.
As with an agitation impeller 7c shown in Fig. 32, the opening portion may not be formed in the first plate 3 of the mixing unit 1, that is, the first plate 3 may be closed. In other words, the first plate 3 present near the fluid surface is closed.
In this configuration, since the fluid flows in only from below at the time of the rotation, it is possible to mix the fluid by raising up particles and the like deposited within the mixing vessel 63. The surface of the fluid A within the mixing vessel 63 is unlikely to be frothed. When a fluid, such as a paint, in which bubbles are desired to be prevented from being mixed at the time of agitation is agitated, this configuration is suitably used.
As shown in Fig. 33, an agitation impeller 7d in which the rotation shaft 62 is provided with a plurality of mixing units 1 may be used. An appropriate space is provided between the mixing units 1.
Since the agitation impeller 7d configured as described above has a plurality of mixing units 1, it is possible to suck the fluid from the upper and lower portions of each of the mixing unit 1. Hence, it is possible to perform agitation even when the mixing vessel 63 is deep.
Fig. 34 is a cross-sectional view showing the portions of the mixing unit 1 of the agitation impeller 7. In this mixing unit 1, the agitation impeller 7 is configured not by providing the rotation shaft 62 directly on the first plate 3 but by using a fixing plate 62a provided an end of the rotation shaft 62 and an auxiliary plate 62b which forms a pair with the fixing plate 62a to sandwich the mixing unit 1 and which is fixed with the bolts 11 and the nuts 12.
Opening portions 62c are formed in positions corresponding to the second through holes 23 of the mixing elements 21 in the fixing plate 62a and the auxiliary plate 62b. Likewise, the opening portions 41 and 31 are formed in positions corresponding to the second through holes 23 of the mixing elements 21 in the first plate 3 and the second plate 4.
In the agitation impeller 7 configured as described above, since the first plate 3 and the second plate 4 close the through holes 22 at both ends of the stacked member 2 in the stacking direction to form one unit, one type of rotation shaft 62 having the fixing plate 62a and the auxiliary plate 62b is provided, and thus it is possible to obtain the agitation impeller 7 that corresponds to the mixing units 1 having different sizes and structures.

(Embodiment of a mixing system)

Fig. 35 is a diagram showing the configuration of an embodiment of a mixing system for mixing the fluid with the pump mixer 6. In this example of use, the fluid is continuously mixed by the pump mixer 6 and is fed out.
A fluid B and a fluid C are fed to a fluid storage vessel 80 from pipe lines 77a and 77b through valves 78a and 78b, respectively. The fluid storage vessel 80 is provided with an agitation impeller 81 for agitating the fluids B and C somewhat uniformly. A nozzle 86 is provided on a lower portion of the fluid storage vessel 80, and is connected to the inlet 51 of the pump mixer 6 through a valve 87. The outlet 52 of the pump mixer 6 is connected to a feed-out line 89 through a valve 88. The feed-out line 89 branches off to a circulation line 85 communicating with the fluid storage vessel 80. The circulation line 85 is provided with a valve 84 for controlling the flow rate of circulated fluid.
In this example of use, in order for the mixing to be performed on the fluids B and C, the fluids B and C are stored in the fluid storage vessel 80, and are somewhat uniformly agitated by the agitation impeller 81. Then, the electric motor 74 is driven to rotate the mixing unit 1, and the fluids B and C are sucked from the inlet 51 by the pump action resulting from the rotation.
Within the pump mixer 6, the sucked fluids B and C are radially passed through the first through holes 22 communicating with each other within the stacked member 2 constituting the mixing unit 1 from the inner circumferential portion to the outer circumferential portion, with the result that the fluids B and C are mixed. The mixed fluids B and C are discharged from the outlet 52 of the pump mixer 6, are controlled by a flow rate controller 82 and a flow rate control valve 83 and are fed out of the system through the feed-out line 89.
The feed-out line 89 branches off to the circulation line 85 communicating with the fluid storage vessel 80, and part of the fluids B and C discharged from the pump mixer 6 is returned to the fluid storage vessel 80. Since the circulation line 85 is provided in this way and thus the fluids B and C are returned from the fluid storage vessel 80 to the pump mixer 6 where the fluids B and C are repeatedly mixed, the degree of mixing of the fluids B and C is increased, and the fluids B and C can be fed out of the system.
Since the degree of opening of the outlet valve 88 arranged in the outlet 52 of the pump mixer 6 is adjusted and thus it is possible to adjust the flow rate of fluid circulating within the stacked member 2 of the mixing unit 1 within the pump mixer 6, it is possible to adjust the degree of mixing of the fluids B and C by the pump mixer 6.
Moreover, since the degree of opening of the valve 84 arranged in the circulation line 85 is adjusted and thus it is possible to adjust the flow rate of fluid circulating through the circulation system including the fluid storage vessel 80 and the pump mixer 6, it is also possible to adjust the degree of mixing of the fluids B and C. In this case, the valve 88 and the valve 84 may be automatically controlled valves.

(First embodiment of a reaction device)

Fig. 36 is a cross-sectional view showing an internal structure of a reaction device 9a according to an embodiment of a reaction device 9 and how the fluid flows therewithin.
Since the structure of the reaction device 9a shown in Fig. 36 is the same as that of the mixing device 5a shown in Fig. 24, the same symbols are used, and their detailed description will not be repeated.
In this reaction device 9a, when a plurality of types of fluid that are to undergo reaction are made to flow in through the inlet 51, the fluid is passed, one after another, within the stacked members 2a to 2d and the annular space portions 55a and 55b, and flows toward the outlet 52. While the fluid is passed through the stacked members 2a to 2d and the annular space portions 55a and 55b, the fluid is highly mixed as described above.
In other words, the fluid that is a reaction raw material is satisfactorily mixed. Hence, the reaction is promoted, and thus it is possible to rapidly obtain a desired reaction product. Since the fluid is mixed while the fluid is being passed within the reaction device 9a, it is possible to satisfactorily mix not only the reaction raw material but also the reaction product.

(Second embodiment of the reaction device)

Fig. 37 is a cross-sectional view showing how a fluid D and a fluid E flow within a reaction device 9b according to an embodiment of the reaction device 9; Figs. 38(a) and 38(b) are cross-sectional views showing how the fluid D and the fluid E flow within mixing units 1d to 1f arranged in the reaction device 9b.
In the reaction device 9b, catalyst layers 93a to 93d are provided within a substantially cylindrical vessel 90a having an inlet 91 and an outlet 92, and the mixing units 1d to 1f and cooling gas feed nozzles 94a to 94c are arranged between the catalyst layers 93a to 93d.
In this embodiment, the reaction device 9a can be desirably used as a methanol synthesis reactor that involves a heterogeneous exothermic reaction; for example, a preheated high-temperature raw gas (fluid D) is fed from the inlet 91, and low-temperature raw gases (fluids E1 to E3) that are not preheated are fed from the cooling gas feed nozzles 94a to 94c.
The mixing units 1d to 1f are configured by sandwiching the stacked member 2, in which a plurality of substantially disc-shaped mixing elements 21 are stacked, between the first plate 3 and the second plate 4 with appropriate fixing means, and the mixing units 1d to 1f are further fixed within the vessel 90a with predetermined fixing means.
The first plate 3 is a circular plate; the outside diameter of the first plate 3 is substantially equal to the outside diameter of the mixing elements 21. The second plate 4 is a circular plate having a circular opening portion 41 substantially in the center portion through which the fluids D and E flows in; the opening portion 41 is substantially equal in inside diameter to the second through holes 23 of the mixing elements 21, and the outside diameter of the opening portion 41 is substantially equal to the inside diameter of the vessel 90a. The overlapped state of the first through holes 22 in the mixing elements 21 constituting the mixing units 1d to 1f is the same as that of the mixing units 1a, 1b and 1c.
With respect to the mixing units 1d to 1f described above, for example, in the mixing unit 1d, a high-temperature fluid A1 that has flowed from the inlet 91 of the reaction device 9a with appropriate pressure and that has passed through the first catalyst layer 93a along with a fluid E1 fed from the cooling gas feed nozzle 94a flows into a hollow portion 24 through the opening portion 41 of the second plate 4. The fluids A1 and E1 that have flowed in flow into a stacked member 2a through the first through holes 22 in the mixing element 21 communicating with the hollow portion 24, and repeatedly flow in and out between the first through holes 22 communicating with each other, with the result that the fluids A1 and E1 are mixed. The mixed fluids A1 and E1 flow out of the stacked member 2a through the first through holes 22 in the mixing element 21 communicating with an outside space portion 28a of the stacked member 2a.
As described above, when the fluids A1 and E1 are passed through the first through holes 22 communicating with each other within the stacked member 2a from the inner circumferential portion to the outer circumferential portion, they are dispersed, combined, reversed and subjected to turbulent flow, eddying flow, collision and the like, and thus the fluids A1 and E1 are highly mixed. Then, the highly mixed fluids A1 and E1 are fed to the downstream catalyst layer 93b, and thus the reaction rate in the catalyst layer 93b is increased.
Likewise, even with the mixing unit 1e, fluids A2 and E2 are highly mixed.
On the other hand, in the mixing unit 1f, in contrast to the mixing units 1d and 1e, the first plate 3 is arranged on the upper portion of the stacked member 2c and the second plate 4 is arranged on the lower portion thereof. Even with the mixing unit 1g configured as described above, fluids A3 and E3 flow into the stacked member 2c
through the first through holes 22 in the mixing element 21 communicating with an outside space portion 28c of the stacked member 2c, and flow out through the first
through holes 22 in the mixing element 21 communicating with a hollow portion 24, with the result that the fluids A3 and E3 are highly mixed.
As described above, in the mixing unit 1 according to this embodiment, the second plate 4, the stacked member 2 and the first plate 3 may be stacked in this order in the direction in which the gas flows or, by contrast, the first plate 3, the stacked member 2 and the second plate 4 may be stacked in this order (see Figs. 37 and 38(a) and 38(b)).
By freely selecting the number of the mixing elements 21 stacked, it is easy to control the loss of pressure of the mixing units 1d to 1f. For example, since the fluid A3 is obtained by adding the fluids E1 and E2 to the fluid A1, the flow rate of fluid flowing into the mixing unit 1f is larger than the flow rate of fluid flowing into the mixing unit 1d. In this case, by increasing the number of mixing elements 21 stacked in the mixing unit 1f more than the number of mixing elements stacked in the mixing unit 1d, it is easy to decrease the loss of pressure of the mixing unit 1f.

(An embodiment of a catalyst unit)

Fig. 39 is an exploded perspective view of a catalyst unit 8 according to an embodiment of a catalyst unit.
The configuration of the catalyst unit 8 is the same as that of the mixing units 1a to 1f except that the mixing elements 21 have a catalytic ability.
In other words, the mixing elements 21 forming the catalyst unit 8 are formed of material having a catalytic action or have catalyst layers on their surfaces. The type of catalyst is selected as necessary according to a desired reaction.
In the catalyst unit 8 formed as described above, while the fluid passes through the first through holes 22 within the catalyst unit 8 one after another, the mixing of a reaction raw material and a reaction product is promoted. Since the promotion of
mixing of the reaction raw material promotes the reaction, it is possible to rapidly perform a desired reaction.
The embodiments disclosed above should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is indicated not by the embodiments described above but by the scope of claims, and includes meaning equivalent to the scope of claims and all modifications and variations within the scope.
For example, although the example where the two types of mixing elements described above are provided and they are alternately stacked has been described, for example, three or more types of elements may be provided. Instead of stacking the types of elements one by one, the types of elements can be irregularly stacked.
Although the embodiments discussed above have been described mainly with consideration given to the mixing and the reaction of a liquid and a gas as the fluid, the "fluid" of the present invention is not limited to what has been described above but includes a multiphase flow consisting of at least two or more types of liquids including a gas and a mist and solids such as a powder and granular material. The liquid may be a fluid such as a highly viscous liquid, a low viscous liquid, a Newtonian fluid or a non-Newtonian fluid.

EXPLANATION OF THE MARK

1, 1a, 1b, 1c, 1d, 1e and 1f... mixing unit
2, 2a, 2b, 2c and 2d... stacked member
3... first plate
4... second plate
5 and 5a... mixing device
6, 6a and 6b... pump mixer
7, 7a, 7b, 7c and 7d... agitation impeller
8... catalyst unit
9, 9a and 9b... reaction device
21a, 21b, 21c, 21d, 21e, 21f, 21g and 21h... mixing element
22... first through-hole (of mixing element)
23... second through-hole (of mixing element)
24, 24a, 24b, 24c and 24d... hollow portion
25a, 25b, 25c, 25d, 25e and 25f... partition wall
28... chamfered portion
29... inclined surface
31... opening portion (of the first plate)
41... opening portion (of the second plate)
A, B, C, D and E... fluid

Claims

A mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) comprising:
a stacked member (2, 2a, 2b, 2c, 2d) in which a plurality of mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) are stacked; and
wherein the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) includes a plurality of first through holes (22), and
wherein the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) are arranged such that part or all of the first through holes (22) in one of the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) communicate with a first through hole (22) in an adjacent mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) to allow fluid to be passed in a direction in which the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) extends,

characterized in that the first through hole (22) in the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) overlaps the first through hole (22) in the adjacent mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) such that the fluid is unevenly divided in the direction in which the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) extends.
The mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of claim 1, further comprising
a first plate (3) and a second plate (4) between which the stacked member (2, 2a, 2b, 2c, 2d) is sandwiched and which are arranged opposite each other,
wherein the second plate (4) includes an opening portion (41) communicating with at least one of the first through holes (22) in the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h).
The mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of claim 1,
wherein a partition wall (25e, 25f) between the first through holes (22) in the mixing element (21g, 21h) is formed substantially in a shape of an ellipse as seen in cross section.
The mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of one of the preceding claims,
wherein the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) includes second through holes (23) larger than the first through holes (22),
wherein the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) are arranged such that the second through holes (23) communicate with each other in a direction in which the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) are stacked to form a hollow portion (24, 24a, 24b, 24c, 24d) in the stacked member (2, 2a, 2b, 2c), and
wherein the opening portion (41) of the second plate (4) communicates with, through the hollow portion (24, 24a, 24b, 24c, 24d), at least one of the first through holes (22) in the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h).
The mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of any one of claims 1 to 4,
wherein the partition wall (25e, 25f) between the first through holes (22) in the mixing element (21g, 21h) includes an inclined surface (29) whose upper and/or lower ends are narrower in width, and
wherein an inclination angle of the inclined surface (29) of the partition wall (25e, 25f) extending from a center portion of the mixing element (21g, 21h) to an outer circumference is narrower than the inclined surface (29) of a cross-sectional shape of the other partition walls (25e, 25f).
A static type mixing device (5, 5a) comprising the mixing unit (1, 1a, 1b, 1c) of any one of claim 2 and claims 3 to 5, if dependent on claim 2, and a casing (50) that accommodates the mixing unit (1, 1a, 1b, 1c) and that includes an inlet (51) and an outlet (52),
wherein the first plate (3) of the mixing unit (1, 1a, 1b, 1c) includes an outer shape smaller than an inner shape of the casing (50), and
the second plate (4) of the mixing unit (1, 1a, 1b, 1c) includes an outer shape substantially equal to the inner shape of the casing (50) and an outer side surface of the second plate (4) is substantially in contact with an inner side surface of the casing (50).
A mixing device (6, 6a, 6b) having the mixing unit (1, 1a, 1b, 1c) of any one of claim 2 and claims 3 to 5, if dependent on claim 2, provided within a casing (50),
wherein the mixing unit (1, 1a, 1b, 1c) is supported by a rotational axis that is driven to rotate,
wherein the mixing unit (1, 1a, 1b, 1c) is driven to rotate such that the fluid sucked through a suction port (51) provided in an end surface of the casing (50) is passed into the mixing unit (1, 1a, 1b, 1c), is further passed out through an outer circumferential portion of the mixing unit (1, 1a, 1b, 1c) and is discharged through a discharge port (52) provided in the casing (50).
An agitation impeller (7, 7a, 7b, 7c, 7d) comprising the mixing unit (1, 1a, 1b, 1c) of any one of claim 2 and claims 3 to 5, if dependent on claim 2, supported by a rotation shaft (62) that is driven to rotate.
A reaction device (9, 9a, 9b) that makes a fluid react within a vessel (90a) including an inlet (51, 91) and an outlet (52, 92) comprising the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of any one of claim 2 and claims 3 to 5, if dependent on claim 2, within the vessel (90a),
wherein the first plate (3) of the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) includes an outer shape smaller than an inner shape of the vessel (90a), and
wherein the second plate (4) of the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) includes substantially the same outer shape as the inner shape of the vessel (90a) and an outer side surface of the second plate (4) is substantially in contact with an inner side surface of the vessel (90a).
A reaction device (9, 9a, 9b) that makes a fluid react within a vessel (90a) including an inlet (91) and an outlet (92),
wherein at least two catalyst layers (93a, 93b, 93c, 93d) are provided within the vessel (90a),
wherein the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of any one of claim 2 and claims 3 to 5, if dependent on claim 2, that mixes one or two or more fluids is provided in at least one space between the catalyst layers (93a, 93b, 93c, 93d),
wherein the first plate (3) of the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) includes an outer shape smaller than an inner shape of the vessel (90a), and
wherein the second plate (4) of the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) includes substantially the same outer shape as the inner shape of the vessel (90a) and an outer side surface of the second plate (4) is substantially in contact with an inner side surface of the vessel (90a).
A catalyst unit (8) comprising the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of any one of claim 2 and claims 3 to 5, id dependent on claim 2,
wherein the mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) of the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) has a catalytic ability.
A mixing system comprising
the mixing device (5, 5a) of claim 7,
a driving unit (74) for rotating the rotational axis, and
a fluid storage vessel (80).
An agitation device (60) comprising
the mixing unit (1, 1a, 1b, 1c) of one of claim 2 and claims 3 to 5, if dependent on claim 2,
a rotation shaft (62) supporting the mixing unit (1, 1a, 1b, 1c), and a mixing vessel (63) in which the mixing unit (1, 1a, 1b, 1c) is disposed.
A fluid mixing method using the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of claim 1 to 5, comprising the steps of:
passing fluid into the stacked member (2, 2a, 2b, 2c, 2d), and

dividing and combining the fluid through the first through holes (22) arranged in the direction in which the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) extends.
A fluid mixing method using the mixing unit (1, 1a, 1b, 1c, 1d, 1e, 1f) of claim 1 to 5, comprising:
a stacking direction division step of passing, between a plurality of stacked mixing elements (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h) each of which includes an extending surface, a fluid along the extending surface of the mixing element and of dividing the fluid in a direction in which the mixing elements are stacked,

wherein the fluid is divided in an extending direction division step of dividing the fluid in a direction along the extending surface of the mixing element (21, 21a, 21b, 21c, 21d, 21e, 21f, 21g, 21h), and
wherein the fluid is discharged through the stacking direction division step and the extending direction division step such that the flowing fluid can be combined.