Static mixer and process for mixing at least two fluids

A layered assembly for mixing at least two fluids, the assembly comprising:

• a) a substantially planar cover layer having external and internal faces and defining first and second feed channels for receiving first and second fluids into the assembly, the first and second feed channels extending from the external surface to the internal surface to form first and second inlet ports, and;
• b) a substantially planar mixing layer having an upper and a lower face, the mixing layer upper face sealingly disposed on the cover layer internal face to define:
• i) a first supply channel having a first supply channel receiving end in fluid communication with the first feed channel and a first supply channel discharge end opposite the first supply channel receiving end;
• ii) a second supply channel having a second supply channel receiving end in fluid communication with the second feed channel and a second supply channel discharge end opposite the second supply channel receiving end, and
• iii) a mixing chamber in fluid communication with the first and second supply channel discharge ends, where one of the first or second supply channel discharge ends leads substantially tangentially into the mixing chamber and the other of the first or second supply channel discharge ends leads substantially radially into the mixing chamber, and;
• iv) a mixing chamber outlet channel in fluid communication with the mixing chamber for discharging a mixed stream of the first and second fluids from the mixing chamber.

A process for mixing at least two fluid streams, the process comprising:

• a) flowing a first fluid stream through a first feed channel and injecting the first fluid stream in a substantially radial direction into a mixing chamber;
• b) flowing a second fluid stream through a second feed channel and injecting the second fluid stream in a substantially tangential direction into the mixing chamber to create a vortex;
• c) withdrawing a stream of mixed first and second fluids from the central portion of the vortex;
• and
• d) flowing a plurality fluid streams through a plurality of feed channels and injecting the fluid streams in alternating tangential and radial directions into the mixing chamber.