Apparatus and method for continuous and controlled feeding of powdery material into a pressurized container

Abstract

The present invention relates to an apparatus and method for the continuous and controlled feeding of powdery material into pressurized containers The apparatus is composed of two main sub-assemblies: the eccentric conical hopper (2) and the twin screw barrel (8), each playing a crucial role in its operation. The hopper (2) serves as the initial point where the powdery material is introduced and pre-compacted, while the twin screw barrel (8) ensures the continuous and controlled feeding of the compacted powder into the pressurized container. The apparatus and method described are suitable for a wide range of industrial applications, enhancing the efficiency, safety, and reliability of processes requiring controlled addition of powders into containers under pressure.

Description

FIELD OF THE INVENTION Embodiments of the present invention generally relate to the technologies for handling powdery materials. Particularly, the present disclosure relates to providing an apparatus and method for the continuous and controlled feeding of powdery material into pressurized containers. BACKGROUND OF THE INVENTION The subject matter discussed in the background section should not be assumed to be prior art merely as a result of it being mentioned in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology. In various industries such as chemical, petrochemical, refinery, and pharmaceuticals, there is a critical need for the precise and continuous addition of powdery materials into pressurized containers. Many chemical reactions, including those that occur under high pressure, require the controlled feeding of catalysts or other powdery materials to maintain reaction efficiency and safety. Traditionally, the process of slow and continuous feeding of powders into containers has been conducted manually, which is labor-intensive and prone to inconsistencies. With advancements in technology, automatic powder charging equipment has been developed. These systems typically utilize vacuum or compressed air conveying methods to transport powders. However, these methods often result in intermittent and uncontrolled powder feeding, which is unsuitable for processes requiring continuous and gentle addition to a “pressurized container1’. Existing solutions such as double valve dumping systems and vacuum conveying systems provide intermittent feeding by dumping fixed quantities of powder at set intervals. These systems are not designed for continuous feeding and can lead to inefficiencies and operational interruptions. Additionally, the use of screw feeders, which are effective for continuous feeding into non-pressurized containers, faces significant challenges when applied to pressurized environments. Specifically, these systems are prone to pressure blowback, where the pressure from the container escapes through the helix of the screw of the feeder, causing powder blowback and system inefficiencies. Therefore, there is a significant need for an improved system that can continuously, gently, and controllably feed powdery materials into pressurized containers without causing pressure blowback or releasing pressure from the container. The present invention addresses these challenges by providing a novel apparatus and process that ensures continuous and controlled feeding of powders into pressurized containers, thereby improving safety, efficiency, and process control in various industrial applications. OBJECT OF THE INVENTION An object of the invention is to provide an improved apparatus and method for the continuous and controlled feeding of powdery materials into ‘pressurized containers’. Another object of the invention is to compact the powdery material within the cavities of the feeder screw sufficiently so that the compacted powder itself can withstand the back pressure from the container. Another object of the invention is to enable continuous feeding of powdery materials into pressurized containers, ensuring a consistent and uninterrupted supply. Yet another object of the present invention is to provide precise control over the rate of powder feeding into pressurised container, allowing for accurate and adjustable feeding rates as required by specific industrial processes. Yet another object of the present invention is to prevent blowback of pressure from the ‘pressurized container1 through the compacting and feeding mechanism, thereby ensuring system integrity and maintaining the desired pressure within the container. A further object of this invention is to incorporate mechanisms for de-lumping compacted powdery materials before feeding them into the pressurized container, ensuring a smooth and consistent flow. Another object of the invention is to incorporate a process for pre-compacting the powder and removing trapped air from the powdery materials before fully compacting and feeding them into the pressurized container, thereby enhancing the quality and consistency of the feed. Yet another object of the present invention is to improve the safety and efficiency by providing a reliable and controlled feeding system to a pressurised chemical process, minimizing the risk of uncontrolled reactions and enhancing overall process performance. SUMMARY OF THE INVENTION According to an aspect of the present invention, there is provided an apparatus for continuous and controlled feeding of powdery material into a ‘pressurized container’, comprises: an eccentric conical hopper (2), configured to receive and compact powdery material, includes a funnel positioned at the top of the eccentric conical hopper for smooth entry of the powdery material, a force feeder helical screw mounted on a shaft and driven by a geared motor via a belt and pulley arrangement, for precompacting the powdery material to the extent required, a sintered filter and vacuum port located at the bottom of the hopper to remove trapped air from the pre-compacted powder; a twin screw barrel, configured to compact the powdery material and to provide continuous and controlled feeding of powdery materials into pressurized containers, comprise one or more twin splined shafts driven by a gearbox and motor, with one or more screw elements mounted on the shafts, a feeding zone (A) with one or more screw elements of consistent pitch to convey powder from the hopper, a compaction zone (B) with one or more screw elements of reducing pitch for further compacting the powder, a decompression or delumping zone (C) with one or more screw elements designed to knead and facilitate the movement of powder through the system; and a motor and gear assembly to drive the force feeder helical screw and twin splined shafts. In accordance with an embodiment of the present invention, the sintered filter is made from high-strength, corrosion-resistant material compatible with the powdery material for removing trapped air from the incoming pre-compressed powdery material. In accordance with an embodiment of the present invention, the twin splined shafts are designed to rotate in co-current or counter-current directions, depending on the application requirements. In accordance with an embodiment of the present invention, the screw elements (9) intermesh without touching each other, and ensuring minimal gaps. In accordance with an embodiment of the present invention, the twin screw barrel (8) includes heating or cooling zones to manage the temperature of the powder during the feeding process. According to another aspect of the present invention, there is provided a method for continuous and controlled feeding of powdery material into a pressurized container, comprises fill a hopper through a funnel with powdery material; activate a force feeder helical screw to start pre-compacting the powdery material to the required extent; filter the pre-compacted powder via a sintered filter and remove trapped air via a vacuum port, ensuring the powder is dense and free of air pockets; transfer and feed the precompacted powder from a hopper to a twin screw barrel via a interconnecting port, designed for smooth and continuous flow; convey the powder through a feeding zone (A) of a twin screw barrel with one or more screw elements of consistent pitch; compact the powder in the cavities of the compaction zone (B) of a twin screw barrel with one or more screw elements having reducing pitch as compared to feeding zone (A); processing the powder in the decompression or delumping zone (C) of the twin screw barrel with one or more screw elements designed to knead and agitate the powder, breaking down any aggregates or lumps to maintain a consistent and smooth flow; and feeding the compacted and processed powder continuously and controllably into the pressurized container through the discharge end of the barrel, ensuring precise and gentle feeding, free of sudden pressure changes. In one embodiment of the present invention, the powdery material is compacted and filled into the cavities of the compaction zone (B) of the twin screw elements to such an extent that the compacted powder itself can withstand the back pressure from the pressurized container. In accordance with an embodiment of the present invention, integrate heating or cooling zones within the twin screw barrel to manage the temperature of the powder during the feeding process. In accordance with an embodiment of the present invention, select the pitch of the screw elements within each zone of the twin screw barrel based on the compaction ratio and bulk density of the powdery material to achieve desired compaction and prevent pressure blowback. In accordance with an embodiment of the present invention, select the diameter of the screw elements within each zone of the twin screw barrel to achieve desired feed rate of the powder into a pressurised container. In accordance with an embodiment of the present invention, the screw elements of the twin splined shafts intermesh without touching each other, ensuring minimal gaps; and the pre-compacted powder is further compacted through the gaps during conveyance, utilizing the strength of the compacted powdery material to prevent back pressure escape and withstand the back pressure from the pressurized container. BRIEF DESCRIPTION OF THE DRAWINGS So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein: Fig. 1 illustrates an apparatus for continuous and controlled feeding of powdery material into a pressurized container, in accordance with an embodiment of the present invention. Fig. 2 illustrates a side cross section of the apparatus, in accordance with an embodiment of the present invention. Fig. 3 illustrates a screw element of the apparatus, in accordance with an embodiments of the present invention. Fig. 4 illustrates a flow chart of the method for continuous and controlled feeding of powdery material into a pressurized container, in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE DRAWINGS The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention. The present invention relates to an apparatus and method for continuous and controlled feeding of powdery material into a pressurized container, designed to enhance efficiency and safety in various industrial applications. The present advanced apparatus addresses the limitations of existing technologies by providing significant improvements in safety, handling, operational efficiency, and processing quality. The present invention pertains to compacting powder during conveyance and utilizing the strength of the compacted powder as an advantage to prevent pressure leakage and withstand the back pressure from the pressurized container. Figure 1 illustrates an apparatus (100) for continuous and controlled feeding of powdery material into a pressurized container (17), in accordance with an exemplary embodiment of the present invention. The apparatus is composed of two main subassemblies: the eccentric conical hopper (2) and the twin screw barrel (8), each playing a crucial role in its operation. The hopper (2) serves as the initial point where the powdery material is introduced and pre-compacted, while the twin screw barrel (8) ensures the pre-compacted powder is further compacted to maximum extent, continuous and controlled feeding of the compacted powder into the pressurized container (17). Figure 2 illustrates a side cross-section of the apparatus (100), showing the detailed internal configuration and the interaction between components. The eccentric conical hopper (2) includes several key components to facilitate the initial processing of the powder. The funnel (1) is positioned at the top of the hopper, allowing for the smooth entry of the powdery material without spillage or clogging. The force feeder helical screw (4), mounted on a vertical shaft (3) and driven by a geared motor (14) connected via an arrangement of belt (16) and one or more pulleys (15), pre-compacts the powder as it rotates. The rotation of the force feeder helical screw can be increased, deceased or adjusted by regulating the motor (14) speed. The rotation of the force feeder helical screw controls the extent of pre-compaction. The higher speed of the force feeder helical screw, the higher will be the pre-compaction. The extent of pre-compaction is decided by the nature of the powder and the number of zones (9a, 9b, 9c) or stages in the twin screw compaction zone. Higher pre-compaction reduces the number of compaction zone requirement in the twin screw barrel (8). Force feeder helical screw (4) is also designed to ensure the twin screw conveying zone (9a) is fully filled in with pre-compacted powder. The bottom portion of the hopper is equipped with a sintered filter (5), the filter is integral to the vacuum application mechanism, as it permits the efficient removal of trapped air from the powdery material without allowing the powder to escape. When the vacuum is applied through the vacuum port (6) (as shown in Detail (M), air is drawn through the sintered filter, effectively de-aerating the powder. This ensures that the powder transferred to the twin screw barrel (8) is free of air pockets, which is essential for achieving uniform and maximum compaction and consistent feeding into the pressurized container (17). The sintered filters (5) can be made from a variety of materials, each chosen for specific properties such as strength, durability, and resistance to corrosion and high temperatures. The material used for the sintered filter (5) in this apparatus (100) must be compatible with the powdery material being processed and the operating conditions of the system. The sintered filter (5) facilitates the efficient removal of trapped air from the powdery material and ensuring its uniform compaction and consistent feeding into the pressurized container (17). Further, the twin screw barrel (8) is an integral component of the apparatus, designed for the continuous and controlled feeding of powdery material into a pressurized container (17). The barrel (8) comprises twin splined shafts (11) driven by a gearbox (12) and motor (13). These twin splined shafts (11) have screw elements along their length and facilitate the rotation of the screw elements (9). As the shafts (11) rotates, the screw elements (9) convey the powdery material from the hopper to the pressurized container. The screw elements (9) mounted on the twin splined shafts (11) are intermeshed without touching each other, ensuring minimal gaps that can be adjusted based on the powdery material being processed. The twin screw barrel (8) is designed with several functional zones, each playing a specific role in the compaction and feeding process. Firstly, a feeding zone (A) is located just below the hopper (2) and contains screw elements (9a) with a consistent pitch to convey the powder from the hopper. Secondly, a compaction zone (B), following the feeding zone, includes one or more screw elements (9b) with a reducing pitch to achieve the desired level of powder compaction. The pitch of the screw elements (9b) is less than the feeding zone (A). The effective volume per pitch of the screw available in zone (B) is less than the effective volume per pitch of the screw available in zone (A). Consequently, the powder gets compressed because volume available in Zone (B) is less than that of Zone (A). Compaction zone (B) maintains the pressure integrity within the system and preventing backflow of material. The compaction zone (B) includes screw elements (9b) in multiple numbers and with progressively reducing pitch, which is provided for multistage compaction of the powder within compaction zone (B) and utilizing the strength of the compacted powdery material as an advantage to prevent back pressure escape and withstand the back pressure from the pressurized container. The final zone within the twin screw barrel (8) is the decompression or delumping zone (C). Depending on the nature of the powder, this zone can either decompress the compacted powder or break down lumps to ensure a smooth and continuous flow into the pressurized container (17). The screw elements (9c) in this zone are designed to knead the powder and facilitate its movement through the system without causing blockages. The pitch of the screw element (9c) is less than the pitch of feeding zone (A) and compaction zone (B). The twin screw barrel (8) is equipped with twin splined shafts (11) (see section N-N), driven by a gearbox (12) and motor (13). These shafts rotate in co-current or countercurrent directions, depending on the application requirements, driving the screw elements to compact and convey the powder. The design includes careful management of gaps between the screw elements and between the screw outer diameter and the barrel inner diameter. These gaps, maintained at a minimum (typically in micrometers), are crucial for preventing pressure escape and ensuring effective compaction. Figure 3 illustrates one shaft of the twin splined shafts (11), equipped with screw elements (9). The screw elements (9) are mounted on the shaft (11) and are critical components of the twin screw barrel (8) in the apparatus for the continuous and controlled feeding of powdery material into a pressurized container. The shaft serves as the rotational axis for the screw elements, driven by a gearbox (12) and motor (13). The shafts (11) are designed to rotate either in co-current or counter-current directions, depending on the specific application requirements. The screw elements (9), when mounted on the twin splined shaft arrangement, intermesh in a manner that minimizes gaps while preventing direct contact. This design is essential for maintaining pressure integrity and preventing blowback during the compaction process. The screw elements (9) create different zones for processing the powdery material. As the shafts rotate, the screw elements convey the powdery material discharged from the hopper (8) into different processing zones and eventually deliver it to the pressurized container. The screw elements are strategically arranged in following different zones within the barrel: 1. The feeding zone (A) of the twin screw barrel (8) in the apparatus is positioned just below the hopper (2) and serves as the initial stage for conveying the pre-compacted powdery material from the hopper into the subsequent zones of the twin screw barrel. The feeding zone comprises one or more screw elements (9a) with a consistent pitch, designed to transport the powder forward efficiently and at a steady rate, without applying additional compaction pressure. The consistent pitch of the screw elements in feeding zone (A) ensures that the powder is moved smoothly, maintaining its integrity and flow characteristics before undergoing further processing. The screw elements intermesh in a manner that minimizes gaps while preventing direct contact, which is essential for maintaining the integrity of the powder and preventing blockages. Mounted on twin splined shafts (11) driven by a gearbox (12) and motor (13), these screw elements rotate in either co-current or counter-current directions based on application requirements. As the pre-compacted powder is introduced into the feeding zone from the hopper via the interconnecting port (7), the screw elements begin to move the powder forward. This consistent conveyance ensures that the powder maintains a uniform flow rate, preventing any disruptions or blockages that could affect subsequent processing stages. The feeding zone sets the stage for the subsequent compaction and feeding processes, maintaining the integrity of the powder and ensuring a smooth transition from the hopper to the compaction zone. 2. Following the feeding zone (A), the compaction zone (B) is where significant densification of the powder occurs. The compaction zone is equipped with one or more screw elements (9b) that have a reduced pitch compared to those in the feeding zone. The reduced pitch of the screw elements in the compaction zone increases the density of the powder by decreasing the volume of the cavities between the screws, thereby applying greater pressure on the powdery material. The densification process ensures that the powder is compacted uniformly, enhancing its density and consistency, compacted powder occupies every space available within the voidage of the screw. The intermeshing design of the twin screws, along with compacted powder is essential, as it prevents the backflow of material and maintains the pressure integrity within the system. The screw elements are mounted on twin splined shafts (11), which rotate to drive the compaction process. The continuous compacting and filling the powdery material in the cavities of the compaction zone (B) of the twin screw elements (9b) to the extent that the compacted powdery material itself is able to withstand the back pressure from the pressurised container (17). Compacting the powder during conveyance and utilizing the strength of the compacted powdery material as an advantage to prevent back pressure escape and withstand the back pressure from the pressurized container. The precise management of gaps between the screw elements and the barrel is critical to prevent pressure escape and ensure effective compaction. The compaction zone ensures that the powder occupies the void cavities fully and adequately compacted to withstand the high-pressure conditions of the pressurized container. 3. Positioned after the compaction zone (B), the decompression / delumping zone (C) serves a dual purpose depending on the nature and requirements of the powdery material being processed. The decompression / delumping zone utilises specially designed screw elements (9c) to either decompress the compacted powder or break down lumps that may have formed during the compaction process. When functioning as a decompression zone, the screw elements help gradually reduce the pressure on the compacted powder, ensuring a smooth transition into the pressurized container without causing sudden pressure changes that could disrupt the process. Alternatively, when operating as a delumping zone, the screw elements knead and agitate the powder, breaking down any aggregates or lumps to maintain a consistent and smooth flow. The design of the screw elements in this zone ensures that the powder is adequately processed and prepared for its final entry into the pressurized container. The kneading action prevents blockages and ensures that the powder flows continuously and evenly, which is crucial for maintaining the efficiency and reliability of the apparatus. The precise engineering of the decompression / delumping zone allows for customization based on the specific characteristics of the powder, providing flexibility and adaptability to different industrial applications. Together, the screw elements of all the zone are configured on same twin splined shafts in continuation to ensure efficient, continuous, and controlled feeding of powder into the pressurized container, enhancing the overall reliability and performance of the apparatus. Figure 4 illustrates a method (200) for continuous and controlled feeding of powdery material into a pressurized container (17). The method, as depicted, is a sequence of interrelated steps that ensure efficient and precise operation of the apparatus. The process begins with filling the hopper (2) through the funnel (1) with powdery material at step (202). In this step, the powdery material is introduced into the system, ensuring smooth flow without spillage or clogging. The conical shape of the funnel and hopper ensures the proper filling of the material in hopper compartment. Next, at step (204), the force feeder helical screw (4) is activated to start compacting the powdery material. This involves the slow rotation of the screw, driven by a geared motor (14), which pre-compacts the powder gently to prevent degradation of the particles. Pre-compaction plays a very important role in whole process. The extent of the pre-compaction is based on the rotational speed of the force feeder helical screw (4). Higher the speed of the force feeder screw (4) higher is the pre-compaction. The extent of pre-compaction is decided on the basis of the property of the powder, number of stages of compaction ( 9a, 9b, 9c ) in the twin screw barrel (8). The fluffy powders require higher pre-compaction and dense powder require lower pre-compaction. Effective pre-compaction increases the efficiency of the twin screw compaction zone ( 9a, 9b, 9c) It will also reduce the overall length of the barrel (8). The pre-compaction helps in preventing residual pressure blow back from the pressurised container (17). The force feeder helical screw also help to fill the cavities of the twin screw conveying zone (9a) effectively without any voidage. At step (206), after pre-compacting, the powdery material pass through bottom portion of the hopper is equipped with a sintered filter (5) and vacuum port (6) that are utilized to remove trapped air from the pre-compacted powder. The sintered filter, made of high-strength, corrosion-resistant material, allows the vacuum to effectively extract air without losing powder. This de-aeration ensures the powder is dense and free of air pockets, which is essential for uniform compaction and subsequent feeding. At step (208), the pre-compacted powder is transferred from the hopper (2) to the twin screw barrel (8) via the interconnecting port (7). The port (7) may be made of smooth surface designed to material transfer be smooth and continuous, minimizing any disruptions or blockages that could affect the flow of powder. The method then progresses to step (210), where the powder enters the feeding zone (A) of the twin screw barrel (8). In this zone, the screw elements (9a) convey the powder forward without further compaction, ensuring a steady movement into the next stage. At step (212), the powder moves into the compaction zone (B), where screw elements (9b) with a reduced pitch further compact the material. This stage is critical for achieving the desired high density and preventing backflow, as the intermeshing design of the twin screws ensures even compaction and maintains pressure integrity. Due to compression pressure inside, compacted Powder try to occupy every free space available within the voidage of screw elements. The powder is compacted to the maximum extent that it can withstand back pressure from the container with leaking or blowback. Following this, at step (214), the powder enters the decompression or delumping zone (C). Depending on the nature of the powder, this zone either decompresses the compacted powder or breaks down lumps. The screw elements in this zone are designed to knead the powder and facilitate its movement through the system, ensuring it is properly processed for entry into the pressurized container. In step (216), the compacted and processed powder is fed continuously and controllably into the pressurized container (17) through the discharge end of the barrel (8). The design of the apparatus ensures that this feeding is precise, gentle, and free of sudden pressure changes, maintaining the integrity of the pressurized system. Usually the barrel (8) at the delumping zone (C) opens into the pressurized container (17) through the valve (not shown in the drawing). Hence the powder directly falls into the container. Furthermore, in an accordance with an exemplary embodiment of present invention, the same pitch screw elements (9) throughout the spline shaft (11) and barrel (8) is selected when the compaction is not required or there is no pressure inside the container. As per above description, the apparatus can be configured in various embodiments to suit different applications. For moderate pressure applications, the apparatus may include only single compaction zone (B) for feeding powder into pressurised containers. For high-pressure applications, multiple compaction zones with screw elements of progressively reduced pitches may be used. Additionally, heating or cooling zones can be integrated into the twin screw barrel (8) to manage the temperature of the powder during the feeding process. According to an embodiment of the present invention, the apparatus may be configured with single screw with for feeding powdery material into container under moderate or low pressure. Screw elements may be configured as explained previously. The pitch of the screw elements refers to the distance between successive threads of the screw. It directly influences the movement, compaction, and pressure characteristics of the powder as it travels through the twin screw barrel. Selecting the pitch of the screw elements within each zone of the twin screw barrel is a critical aspect of achieving the desired compaction and preventing pressure blowback in the continuous and controlled feeding of powdery material into a pressurized container. Therefore, the present invention offers a robust and versatile solution for continuous and controlled feeding of powdery materials into pressurized containers. By addressing the limitations of existing technologies, it ensures gentle handling, prevents blowback, and allows for precise control over the feeding rate. The apparatus and method described are suitable for a wide range of industrial applications, enhancing the efficiency, safety, and reliability of processes requiring controlled addition of powders under pressure. Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.

Claims

I claim:

1. An apparatus (100) for continuous and controlled feeding of powdery material into a ‘pressurized container’ (17), comprising:an eccentric conical hopper (2), configured to receive and compact powdery material, includes:a funnel (1) positioned at the top of the eccentric conical hopper (2) for smooth entry of the powdery material;a force feeder helical screw (4) mounted on a vertical shaft (3) and driven by a geared motor (14), for pre-compacting the powdery material;a sintered filter (5) and vacuum port (6) located at the bottom of the hopper to remove trapped air from the pre-compacted powder;a twin screw barrel (8), configured to compact the powdery material and to provide continuous and controlled feeding of powdery materials into pressurized containers, comprise:a twin splined shafts (11) driven by a gearbox (12) and motor (13), with one or more screw elements (9) mounted on the shafts;a feeding zone (A) with one or more screw elements (9a) of consistent pitch to convey powder from the hopper;a compaction zone (B) with one or more screw elements (9b) of reducing pitch for further compacting the powder;a decompression or delumping zone (C) with one or more screw elements designed to knead and facilitate the movement of powder through the apparatus; anda motor and gear assembly to drive the force feeder helical screw (4) and twin splined shafts (11).

2. The apparatus (100) as claimed in claim 1, wherein the sintered filter (5) is made from high-strength, corrosion-resistant material compatible with the powdery material for removing trapped air from the incoming pre-compressed powdery material.

3. The apparatus (100) as claimed in claim 1, wherein the twin splined shafts (11) are designed to rotate in co-current or counter-current directions, depending on the application requirements.

4. The apparatus (100) as clamed in claim 1, wherein the screw elements (9) of the twin splined shafts intermesh without touching each other, ensuring minimal gaps; and the pre-compacted powder is further compacted through the gaps during conveyance, utilizing the strength of the compacted powdery material to prevent back pressure escape and withstand the back pressure from the pressurized container.

5. The apparatus (100) as claimed in claim 1, wherein the twin screw barrel (8) includes heating or cooling zones to manage the temperature of the powder during the feeding process.

6. A method (200) for continuous and controlled feeding of powdery material into a pressurized container, comprising:filling a hopper (2) through a funnel (1) with powdery material;activating a force feeder helical screw (4) to start pre-compacting the powdery material;filtering the pre-compacted powder via a sintered filter (5) and remove trapped air via a vacuum port (6), ensuring the powder is dense and free of air pockets;transferring the pre-compacted powder from the hopper (2) to a twin screw barrel (8) via a interconnecting port (7), designed for smooth and continuous flow;conveying the powder through a feeding zone (A) of the twin screw barrel (8) with one or more screw elements (9a) of consistent pitch mounted in a twin spined shafts (11);compacting the powder in the cavities of a compaction zone (B) of the twin screw barrel (8) with one or more screw elements (9b), having reducing pitch as compared to feeding zone (A), mounted in the twin spined shafts (11);processing the powder in the decompression or delumping zone (C) of the twin screw barrel (8) with one or more screw elements, mounted in the twinspined shafts (11), designed to knead and agitate the powder, breaking down any aggregates or lumps to maintain a consistent and smooth flow; andfeeding the compacted and processed powder continuously and controllably into the pressurized container (17) through the discharge end of the barrel (8), ensuring precise and gentle feeding free of sudden pressure changes.

7. The method (200) as claimed in claim 6, wherein compacting and filling the powdery material in the cavities of the compaction zone (B) of the twin screw elements (9b) to the extent that the compacted powdery material itself withstand the back pressure from the pressurized container (17).

8. The method (200) as claimed in claim 6, wherein the screw elements (9) of the twin splined shafts intermesh without touching each other, ensuring minimal gaps; and the pre-compacted powder is further compacted through the gaps during conveyance, utilizing the strength of the compacted powdery material to prevent back pressure escape and withstand the back pressure from the pressurized container.

9. The method (200) as claimed in claim 6, wherein integrating heating or cooling zones within the twin screw barrel (8) to manage the temperature of the powder during the feeding process.

10. The method (200) as claimed in claim 6, wherein selecting the pitch of the screw elements (9) within each zone of the twin screw barrel based on the compaction ratio and bulk density of the powdery material to achieve desired compaction and prevent pressure blowback.

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