Cells for the breakdown (micronization) of fats and derivatives
The paraffin emulsion decomposition cell uses cavitation and turbulence to achieve nanoscale homogeneity and reduce paraffin particle size efficiently, addressing high costs and inefficiencies in existing methods, thereby minimizing material usage and enhancing coating performance.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- PİKA RESEARCH ARAŞTIRMA GELİŞTİRME TEKNOLOJİ İMALAT LTD ŞTİ
- Filing Date
- 2024-05-31
- Publication Date
- 2026-07-30
AI Technical Summary
Existing methods for reducing paraffin particle size, such as micronization, granulation, grinding, and high-pressure homogenization, are costly and do not achieve the desired nanoscale homogeneity and efficiency for applications like wood coatings, leading to high material usage and manufacturing costs.
A paraffin emulsion decomposition cell that utilizes cavitation and turbulence to break down paraffin emulsions into nanoscale particles by passing them through a structured decomposition tube under controlled pressure and temperature, without the need for additional chemicals, while simultaneously coating the particles with an emulsifier.
The cell achieves significant reduction in particle size, increasing surface coverage with minimal thickness, reducing manufacturing costs by minimizing the amount of paraffin required for coatings, and ensuring homogeneous distribution.
Smart Images
Figure 2026525388000001_ABST
Abstract
Description
Technical Field
[0001] The present invention generally relates to a paraffin emulsion decomposition cell enclosed in a decomposition tube, designed to break down paraffin emulsions, emulsions of various fats and their derivatives into micro-nanoparticles.
Background Art
[0002] Paraffin is a colorless and odorless type of wax obtained from petroleum. It is obtained from tar and petroleum. Today, synthetic paraffin waxes are also manufactured. Paraffin has a wide range of industrial uses, especially widely used in the fields of wood, paper, food, and cosmetics. Due to this wide range of use areas, it is necessary for paraffin to be processed into different shapes and sizes. The reduction of paraffin size is carried out for purposes more suitable for specific applications. In the industry, the process of reducing paraffin size is carried out using various methods.
[0003] These are as follows: Micronization; the process of refining a solid to a micron size. Paraffin is refined to a micron size using a grinder or a jet mill in the micronization process. This process increases the surface area of paraffin particles and results in a more homogeneous and finer distribution. Micronized paraffin is used in paper coating, cosmetics, and some special chemical applications. In the micronization method, usually, paraffin particles can be refined to a size of 1 to 10 micrometers (μm). By using advanced technology and optimized processes, these sizes can be further refined to nano sizes (up to about 100 nanometers (nm)).
[0004] Granulation; the process of converting powdered material into granular form. Paraffin is converted into granules in a granulator under specific humidity and pressure conditions. This process makes the transport and handling of paraffin easier. Granular paraffin is widely used in fields such as candle making, paper coating, and waterproofing applications. The granulation process converts paraffin into granular form, with granule sizes typically ranging from 0.2 to 4 millimeters (mm). Granulation does not provide micron or nanometer-level fineness, but rather produces particles at the macro level.
[0005] Grinding; the process of breaking down a solid into very small particles. Paraffin is ground into a fine powder using a grinder. In particular, this process increases the solubility and surface activity of paraffin. Grinding paraffin is used in coatings, lubricants, and certain plastic applications. Paraffin particles obtained by grinding are typically in the range of 10–100 μm. Advanced grinding techniques can be used to obtain finer particles, but this method may not provide the same size as micronization.
[0006] Melt and spray drying; a process of melting a solid and drying it by spraying it in fine droplets. In this method, paraffin is melted and sprayed in fine droplets through a spray head. These droplets rapidly solidify upon contact with air, forming fine particles. Paraffin particles obtained by spray drying can be used in cosmetic and pharmaceutical formulations. Melt and spray drying typically yields paraffin particles with a size of 1 to 50 micrometers (μm). This method allows for particle size control depending on the size of the sprayed droplets and the drying rate. Advanced spray drying techniques may allow for even smaller particles (closer to nano-size).
[0007] A high-pressure homogenizer is required for better mixing of beeswax emulsions. Paraffin wax does not mix with water, making emulsion formation difficult. While some mixing can be achieved using surfactants, the most effective mixing can be achieved using a high-pressure homogenizer, which performs better than conventional mixing methods. In a high-pressure homogenizer, particles are broken down by the action of shear force and turbulence, resulting in a homogeneous mixture. As a result of high-pressure homogenization, particles can be refined to the submicron level. Particle sizes obtained with homogenizers available today range from 1 to 100 μm.
[0008] Patent Document 1 describes the preparation of an aqueous paraffin wax emulsion as comprising emulsifying the wax in water under turbulent conditions in the presence of an emulsion igniter and a liquid.
[0009] Patent Document 2 relates to a method comprising the steps of grinding wax into wax fragments having a size in the range of about 600 microns to about 800 microns, forming a mixture of wax fragments with water and a surfactant, and homogenizing the mixture, wherein the wax dispersion is kept below about 35°C during the homogenization step. The wax dispersion is prepared for use in toner and is broken down with a specially designed blade. [Prior art documents] [Patent Documents]
[0010] [Patent Document 1] British Patent Application Publication No. 1383471 [Patent Document 2] European Patent Application Publication No. 3291012 [Overview of the project] [Problems that the invention aims to solve]
[0011] The main objective of the present invention is to decompose a paraffin emulsion by passing it through a paraffin decomposition cell under specific temperature and pressure conditions.
[0012] Another object of the present invention is to degrade the particle size of various fat emulsions and emulsions of their derivatives by passing them through the same degradation cell in the same manner as degrading the particle size of paraffin emulsions.
[0013] Another objective of the present invention is to form the maximum surface coating with the minimum thickness by micronizing (decomposing) paraffin emulsion fragments.
[0014] Another object of the present invention is to provide paraffin emulsion degradation by structuring in paraffin emulsion degradation cells.
[0015] The objective of the present invention is to decompose paraffin emulsion particles without using any other additional chemicals.
[0016] By using additional chemicals along with an emulsifier, a fatty acid, preferably stearic acid, can be coated around the paraffin using the emulsifier while it is inside the cell.
[0017] Another objective of the present invention is to homogeneously decompose paraffin emulsion particles at the nanoscale.
[0018] Another objective of the present invention is to decompose paraffin emulsions without using conventional homogenization methods. [Means for solving the problem]
[0019] The present invention preferably relates to a paraffin emulsion decomposition cell, which is state-of-the-art and has been developed to reduce (decompose) the size of paraffin emulsion particles, as well as the emulsion particle size of various fats and their derivatives, particularly those used in wood coatings.
[0020] The paraffin emulsion decomposition methods included in the prior art are formed by homogenization, and the decomposition can be carried out to a specific size. This leads to the application of paraffin emulsions used in large quantities with a certain thickness, resulting in high costs.
[0021] The smaller the paraffin particles in the paraffin emulsion, the thinner the applied layer, thereby significantly reducing the manufacturing cost and thus the user cost.
[0022] Especially when considering the field of coating wood materials, coatings with large paraffin particles in paraffin emulsions tend to be used in very large quantities, and the cost increases proportionally.
[0023] In the decomposition cell of the present invention, paraffin is supplied from one end of the cell under specific pressure and temperature, and cavitation is created by the structuring inside the cell. Due to the resulting cavitation, the paraffin particles (fragments) in the emulsion are decomposed into very small sizes and further refined to sizes below those defined by the state-of-the-art. This creates a significant difference in the coating area on the surface areas coated with paraffin emulsion particles of different sizes having the same weight.
Brief Description of the Drawings
[0024] The embodiments of the present invention briefly summarized above and discussed in more detail below can be understood by referring to the exemplary embodiments of the present invention described in the accompanying drawings. However, it should be noted that the accompanying drawings only show typical embodiments of the present invention and therefore do not mean to limit the scope of the present invention since other equally effective embodiments may be allowed.
[0025] [Figure 1] Paraffin Emulsion Decomposition Cell Inlet-Outlet Port Diagram [Figure 2]Perspective view of a paraffin emulsion decomposition cell. [Figure 3] Cross-sectional view of paraffin emulsion decomposition cell AB [Figure 4] Cross-sectional view of a paraffin emulsion decomposition cell (CD). [Figure 5] Front view of a paraffin emulsion decomposition cell [Figure 6] Rear view of a paraffin emulsion decomposition cell [Figure 7] Left side of paraffin emulsion decomposition cell [Figure 8] Right side of paraffin emulsion decomposition cell [Figure 9] Top view of a paraffin emulsion decomposition cell. [Figure 10] Right side and upper left view of the paraffin emulsion decomposition cell. [Figure 11] Right and upper right view of the paraffin emulsion decomposition cell. [Figure 12] Left and upper right views of the paraffin emulsion decomposition cell. [Figure 13] Diagram of the paraffin emulsion flow line within a cell. [Figure 14] Diagram of vortex formation viewed from a cell cross-section. [Figure 15] Diagram showing the change in static pressure in a flow passing through a cell across its cross-sectional area. [Figure 16] Diagram of shear stress due to flow on the inner surface of a cell [Figure 17] Turbulence intensity diagram from cell cross-sectional area [Figure 18] Cell turbulence viscosity diagram [Figure 19] Cell turbulence energy diagram [Figure 20] Velocity vector within a cell [Figure 21] Diagram of vapor composition within a cell [Figure 22] Cellular shear stress diagram [Figure 23] Vortex formation diagram of fluid in contact with the inner surface of a cell.
[0026] For ease of understanding, the same reference numerals are used to indicate identical elements common to multiple drawings, where possible. The drawings are not drawn to scale and may be simplified for clarity. Elements and features of the embodiments are intended to be usefully incorporated into other embodiments without further explanation. [Modes for carrying out the invention]
[0027] In this detailed description, the elements constituting the present invention are specified for the purpose of explaining the operating principle of the present invention and do not have the effect of limiting the present invention. Equivalent elements can also be considered to be within the scope of the present invention.
[0028] Unless otherwise specified, the flow direction in all drawing details is from left to right.
[0029] Figure 3: The CD cross-section divides the cell (10) into two parts, which are defined as the cell superstructure (11) and the cell substructure (12).
[0030] The cell superstructure (11) and cell substructure (12) are two identical twin parts. When superimposed, they are positioned opposite each other.
[0031] The cell superstructure (11) and cell substructure (12) consist of identical / equal cell units (20). The number of these units can be adjusted as needed, and is preferably designed as 12. Each cell unit (20) consists of a collision ramp (21), a landing ramp (22), a lift ramp (23) with an angle of 15 to 60 degrees, a symmetrical wall (24), and an asymmetrical wall (25) region. Of these regions, the collision ramp (21) causes the paraffin emulsion that has passed through cell (10) to collide with the top of the next cell unit (20). The landing ramp (22) allows the paraffin emulsion that has passed through cell unit (20) and is moving to the next cell unit (20) to reach the inlet port of the next cell unit in the downstream direction. The lift ramp (23) is located at the inlet port of cell unit (20) and lifts the paraffin emulsion to the center of cell unit (20) at a predetermined angle. The symmetrical wall (24) is located on one side of the cell unit (20) and converges in the center of the cell unit (20), and consists of two equal walls. The asymmetrical wall (25) is a surface located on the opposite side of the cell unit (20) from the symmetrical wall (24), and consists of two unequal walls, one of which is the same length as the lift ramp (23) and the other of which is the same length as the collision ramp (21), with the peak point of the collision ramp being equal to the peak endpoint of this surface.
[0032] The above invention reduces the fragment size of paraffin emulsion at a fixed weight, increases the number of fragments, and covers a larger area.
[0033] (For example: The diameter of a single paraffin particle in 1g is 1.28cm, and this particle can reach 5cm 2 The area covered is 65 cm², but when this 1 g of paraffin is broken down into multiple particles, 2000 particles with a diameter of 1 mm are obtained, and these broken-down particles cover 65 cm². 2 The area covered can be.
[0034] The present invention provides the decomposition (micronization) of a paraffin emulsion passing through a paraffin emulsion decomposition cell by collision with structures in the paraffin emulsion decomposition cell as the emulsion passes through at an appropriate rate under appropriate thermal and pressure conditions.
[0035] This invention provides the decomposition of paraffin emulsions that have been passed through paraffin emulsion decomposition tubes of similar size to each other at specific pressures and heat values.
[0036] The graph shown in Figure 13 illustrates the flow in a cell with 20 different trajectory lines. The flow enters from the left and exits from the right. The color coding on these lines represents velocity. Darker sections of the lines indicate that the velocity of the fluid following that trajectory is decreasing at that point, while lighter sections indicate that the velocity of the fluid following that trajectory is accelerating. Furthermore, these trajectories reveal the path the fluid follows within the cell. As can be seen from the lines, as the fluid moves along the cell, it also moves in a circular motion within itself, changing position and mixing simultaneously. The ring shape formed by the lines themselves reveals the presence of vortices and counterflows within, which cause the fluid to perform two opposing movements at the same location and collide internally.
[0037] Figure 14 shows the locations where vortices are formed when viewed from a cross-sectional area of the paraffin emulsion within a cell. Vorticity increases from dark to light. Starting from the side of the filamentous structure, vortices are observed to repeatedly form within each filamentous structure. Mixing is introduced into the flow at the locations where vortices are present.
[0038] Figure 15 shows the change in static pressure of the flow through the cross-sectional area of the paraffin emulsion within the cell. The flow enters from the left and exits from the right. The fluid, which is at high pressure at the cell inlet, loses its pressure as it proceeds. Light colors indicate high pressure, and black colors indicate low pressure. Furthermore, it was identified that there is a pressure drop in the flow perpendicular to the entire axis at the start of each filamentous structure.
[0039] Figure 16 shows the shear stress caused by the flow of paraffin emulsion inside the cell unit (20) on its inner surface. Dark colors represent low shear stress, and light colors represent high shear stress. The flow proceeds from the upper left to the lower right. An increase in shear stress was identified at the sharp edges of the cell. These shear stresses occur in the same amount at the same location in the fluid, and the paraffin particles are decomposed by generating shear forces in the fluid.
[0040] Figure 17 shows an image taken from a cross-sectional area of the paraffin emulsion inside a cell. The flow flows from left to right. Dark areas indicate low turbulence intensity, while light areas indicate high turbulence. The intensity of turbulence created by the filamentous structures within the flow is shown. Immediately after each filamentous structure, the flow enters strong turbulence. The fluid flows turbulently, but mixes within itself, achieving homogenization.
[0041] Figure 18 shows the turbulent viscosity of the paraffin emulsion inside the cell. This illustrates the viscosity change of the fluid due to turbulence. The flow is from left to right. The black areas indicate low viscosity changes, and the white areas indicate high viscosity changes.
[0042] Figure 19 shows the turbulent energy of the paraffin emulsion inside the cell. Regions with high and low turbulent energy are shown, along with the intensity of the turbulent effect created by the fluid entering the turbulence. Dark areas indicate low turbulent energy, while light areas indicate high turbulent energy.
[0043] Figure 20 shows an image of a cross-sectional area of the paraffin emulsion inside a cell within a cell unit (20). The change in fluid velocity within the cell is indicated by black and white contours in the colored cross-sectional area. The dark areas indicate low flow velocity, while the light areas indicate high flow velocity.
[0044] Figure 21 shows an image of a cross-sectional region of a cell unit (20) of paraffin emulsion inside a cell. The flow enters from the left and exits from the right. Dark areas indicate a low vapor volume ratio, and light areas indicate a high vapor volume ratio. The volume of vapor generated from cavitation behind the filamentous structure is shown, along with the decreasing vapor pressure as it moves towards the outlet. An increase in vapor volume ratio signifies an increase in cavitation. Cavitation refers to the rupture of bubbles and particle breakdown in the fluid. In the final portion, the majority of the breakdown effect is achieved by these cavitations.
[0045] Figure 22 shows the shear stress of the paraffin emulsion inside the cell that occurs on the surface of the cell unit (20). This represents the same value as in Figure 21, but is a closer (magnified) image.
[0046] Figure 23 shows the amount of fluid vortex formation in the paraffin emulsion in a cell in contact with the surface of the cell unit (20). The flow exits from the upper left and the upper right. Dark areas indicate small amounts of vortex formation, while light areas indicate high vortex formation rates. Lines drawn on the colored areas of the surface indicate the fluid trajectory, and arrows indicate the direction of the flow. Ring-shaped lines indicate the size and position of the vortices. Due to the vortices, particles in the fluid that are attempting to move in a circular motion collide with particles coming from behind at high speed, and therefore these vortices play an important role in the decomposition of particles in the fluid.
[0047] In the paraffin emulsion decomposition tube structure described in detail above, a paraffin emulsion solution having a flow rate of 20 liters / min is passed through the line at a constant flow rate with a maximum permeability of 1 to 100 liters / min, preferably at a pressure of 80 to 150 bar, preferably at 100 bar. The paraffin emulsion, passing through at the appropriate pressure, temperature, and rate, begins to collide with all surfaces of the geometric shapes specially designed in the structuring, in other words, it collides with geometric shapes that resist the flow.
[0048] The paraffin emulsion begins to decompose upon impact with the geometric surfaces formed by turbulence and cavitation, which are created when the flow velocity, temperature, and pressure are combined. This decomposition of the paraffin emulsion continues within all cell units (20) along a cell (20), from the inlet port to the outlet port of one cell unit (20), to the end of the cell unit (20), and from the opposite end to the outlet. Multiple decompositions occur due to impacts with both the outer wall and the inner surface of the cell unit (20). This allows the paraffin emulsion to be broken down (micronized) into very small pieces, resulting in a paraffin emulsion of the desired size.
[0049] As the number of filamentous structures in the paraffin emulsion decomposition tube increases, the decomposition increases at the nanoscale. The internal structure of the paraffin emulsion decomposition tube preferably has two pairs of microstructures having a 40-micron titanium coating.
[0050] The total length of the structure in the paraffin emulsion decomposition tube of the present invention, including the inlet, is 10 cm. This dimension is a preferred dimension and may vary depending on other conditional variables and requirements.
[0051] There are 12 filamentous structures over a 10 cm length, which is a preferred size, and these filamentous structures can be arranged on at least one surface. While the liquid paraffin emulsion is passed through the geometric form of these filamentous structures in water, the material is coated with an emulsifier on each filamentous surface, and decomposition is achieved.
[0052] Decomposition is achieved by turbulence caused by surface collisions of the fluid and cavitation resulting from this turbulence.
[0053] During the paraffin decomposition (micronization) process, the paraffin surface is coated with a surfactant (emulsifier). One of the most important features of this system is that the decomposition of paraffin and the coating of the paraffin surface with an emulsifier occur simultaneously.
[0054] By coating the surface of the paraffin with an emulsifier during decomposition, the paraffin particles are prevented from sticking together. [Explanation of symbols]
[0055] 10 cells 11 Cell Superstructure 12 Cell Lower Structure 20 cell units 21 Collision ramp 22 Landing ramp 23 Lift ramp 24 Symmetrical Wall 25 Asymmetrical Wall 30 Paraffin Emulsion Flowline 40 Vortex 50 flow static pressure 60 Shear stress 70 Turbulence Intensity 80 Turbulent viscosity 90 Turbulent energy 100 Velocity vector 110 Steam volume 120 Shear stress 130 Fluid vortices
Claims
1. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles, and emulsion particles of their derivatives, It consists of two identical twin parts, a cell upper structure (11) and a cell lower structure (12), which are arranged facing each other when stacked. A cell characterized by the following features.
2. The number of the aforementioned units can be adjusted as needed, and preferably comprises 12 cell units (20), characterized in that it is a cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of their derivatives, as described in claim 1.
3. Each cell unit (20) comprises a collision ramp (21), a landing ramp (22), a lift ramp (23), a symmetrical wall (24), and an asymmetrical wall (25) region, characterized in that it is a cell for decomposing paraffin emulsion particles, various lipid emulsion particles, and emulsion particles of derivatives thereof, according to claim 1 or 2.
4. The collision ramp (21) is characterized by causing the paraffin emulsion that has passed through the cell (10) to collide with the top of the next cell unit (20), a cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to claim 1, 2, or 3.
5. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to any one of claims 1 to 4, characterized in that it comprises a landing ramp (22) that allows the paraffin emulsion passing through the cell unit (20) to proceed to the next cell unit (20) to reach the inlet port of the next cell unit in the downstream direction.
6. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to any one of claims 1 to 5, characterized by comprising a lift lamp (23) located at the inlet port of the cell unit (20) for lifting the paraffin emulsion to the center of the cell unit (20) at an angle of 15 to 60 degrees.
7. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, as described in any one of claims 1 to 6, characterized in that it comprises a symmetrical wall (24) located on one side of the cell unit (20), converging in the center of the cell unit (20), and composed of two equal walls.
8. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, as described in any one of claims 1 to 7, wherein the cell unit (20) is located on the opposite side of the symmetrical wall (24), and is composed of two unequal walls, one surface having the same length as the lift ramp (23) and the other surface having the same length as the impact ramp (21), and the peak point of the impact ramp is equal to the peak endpoint of this surface.
9. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles, and emulsion particles of derivatives thereof, as described in any one of claims 1 to 8, characterized by comprising a cell unit (20) that decomposes (micronizes) the paraffin in the paraffin emulsion and coats the paraffin particles.
10. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles, and emulsion particles of their derivatives, according to claim 1, characterized by comprising a paraffin emulsion decomposition cell unit that passes a paraffin emulsion solution having a maximum permeability of 1 to 100 liters / minute at a pressure of 1 to 100 bar through a line at a constant flow rate.
11. A cell for decomposing paraffin emulsion particles, various fatty emulsion particles and emulsion particles of their derivatives, according to claim 1, comprising a paraffin emulsion decomposition cell unit that passes a paraffin emulsion solution having a pressure of preferably 100 bar and a maximum permeability of preferably 20 liters / minute through a line at a constant flow rate.
12. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to any one of claims 1 to 11, characterized by comprising a paraffin emulsion decomposition cell that creates turbulence and / or cavitation when flow velocity, temperature, and pressure are combined.
13. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to any one of claims 1 to 12, comprising a paraffin decomposing unit that provides decomposition via turbulence caused by surface collision of the fluid and cavitation generated by the turbulence.
14. A cell for decomposing paraffin emulsion particles, various lipid emulsion particles and emulsion particles of derivatives thereof, according to any one of claims 1 to 13, characterized by comprising a paraffin decomposition cell unit that enables the decomposition of the paraffin and, at the same time, coating its surface with a fatty acid, preferably a stearic acid emulsifier.