ACH Batch Reactor Heel Retention for Low-Turbidity Production
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Solution Overview
Problem
Existing methods for producing aluminum chlorohydrate (ACH) are costly due to the high cost of aluminum metal used and result in high turbidity and unpredictable reaction times, often requiring specialized catalysts that affect the purity and cost of the end product.
Innovation Solution
The use of polyaluminum chloride (PAC) as a reactant with aluminum metal, combined with the practice of retaining a product heel of reactant fluid to cover unreacted pellets between batches, stabilizes the reaction and reduces turbidity, while using a support platform with appropriate specific gravity to manage cycling forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum metal is used as reactant, then aluminum chlorohydrate production is achieved, but cost increases and turbidity increases
Solution Approach 1:
The patent introduces an intermediary substance (achieve lower turbidity through specific reaction conditions and additives) that mediates between aluminum metal and the final product, reducing turbidity generation during the reaction process
2Quantity of substance
If aluminum metal is used as reactant, then aluminum chlorohydrate production is achieved, but production cost increases
Solution Approach 1:
The patent changes reaction parameters including temperature, pressure, and chemical composition to optimize the reaction between aluminum metal and produce ACH cost-effectively, achieving lower production costs through parameter optimization
3Quantity of substance
If conventional reaction methods are used, then aluminum chlorohydrate is produced, but reaction time becomes unpredictable
Solution Approach 1:
The patent implements feedback control by monitoring reaction progress and adjusting conditions in real-time, making reaction time predictable and controllable through continuous monitoring and adjustment
4Productivity
If specialized catalysts are used, then reaction efficiency is improved, but product purity decreases and cost increases
Solution Approach 1:
The patent replaces expensive specialized catalysts with cheaper, short-acting alternative substances that achieve similar reaction efficiency without negatively impacting product purity or increasing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces turbidity by 8.6 NTU on average and shortens reaction time by 15%, achieving stable and efficient ACH production with improved purity and reduced costs.
Implementation Method 1
reacting a metal, such as aluminum metal, with an acid, such as hydrochloric acid
Implementation Method 2
using a support platform with appropriate specific gravity to manage cycling forces
Data Source
AI summary
A method and system for batch manufacturing aluminum chlorohydrate (ACH) utilizing a reactor tank. The method comprises conducting two consecutive batch manufacturing processes, each batch manufacturing process producing aluminum chlorohydrate (ACH) by reacting solid-state aluminum metal pieces with an acid source in a reactor tank. Proximate the end of a first of the two batch manufacturing processes, after the aluminum chlorohydrate (ACH) being produced in that batch has reached a predetermined basicity level, a majority of the produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank but a heel-portion of the produced aluminum chlorohydrate (ACH) is retained in the reactor tank. The heel-portion comprises a sufficient amount of the produced aluminum chlorohydrate (ACH) to submerge therein a majority of unreacted solid-state aluminum metal pieces retained in the reactor tank at the time that produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank.