Alkali Metal Salt Granule Manufacturing Process
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Solution Overview
Problem
Existing processes for manufacturing granules of alkali metal salts of aminopolycarboxylic acids are either economically inefficient or limited to producing powders, with low gas inlet temperatures requiring highly concentrated slurries or large amounts of gas, and non-agglomerating conditions only yielding powders.
Innovation Solution
A process involving the steps of providing an aqueous slurry of alkali metal salt of aminopolycarboxylic acid, maintaining it at a temperature of 50 to 90°C for 2 to 180 hours, and spray granulating with a gas inlet temperature of at least 150°C to produce granules with a desired particle size and moisture content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If a low gas inlet temperature (≤120°C) is used for spray granulation, then energy consumption is reduced, but highly concentrated slurries or large amounts of gas are required
Solution Approach 1:
The patent applies parameter changes by optimizing the gas inlet temperature to at least 150°C and maintaining the slurry at 50-90°C for 2-180 hours before granulation. This temperature parameter adjustment enables effective granulation at moderate concentrations without requiring excessive gas amounts, resolving the contradiction between energy efficiency and material requirements
Solution Approach 2:
The patent implements preliminary action through the aging step where the slurry is maintained at elevated temperature (50-90°C) for an extended period (2-180 hours) before spray granulation. This pre-treatment modifies the slurry properties to enhance granulation efficiency, allowing the process to achieve good results without requiring highly concentrated slurries or excessive gas consumption
2Shape
If non-agglomerating conditions are used for spray drying, then particle aggregation is avoided, but only powders are produced instead of granules
Solution Approach 1:
The patent applies dynamics by controlling the granulation process to achieve desired particle characteristics. Through optimized spray granulation parameters including gas inlet temperature (≥150°C) and slurry aging conditions, the process can dynamically produce either granules or powders depending on requirements, while maintaining control over particle aggregation and morphology
Solution Approach 2:
The patent uses parameter changes to control the granulation outcome. By adjusting the gas inlet temperature to at least 150°C and controlling the slurry aging temperature (50-90°C) and time (2-180 hours), the process can produce granules with desired size distributions and morphologies, overcoming the limitation of non-agglomerating conditions that only produce powders
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 process efficiently produces granules with excellent properties, such as broad or narrow particle diameter distribution, regular or irregular shapes, and low residual moisture, suitable for use in laundry and dishwashing detergents, offering improved percarbonate stability and flow characteristics.
Implementation Method 1
maintaining it at a temperature of 50 to 90°C for 2 to 180 hours
Implementation Method 2
spray granulating with a gas inlet temperature of at least 150°C to produce granules with a desired particle size and moisture content
Data Source
AI summary
Process for manufacturing granules of at least one alkali metal salt of aminopolycarboxylic acid (A), comprising the steps of (a) providing an aqueous slurry of alkali metal salt of aminopolycarboxylic acid (A), (b) maintaining said aqueous slurry at a temperature in the range of from 50 to 90° C. over a period of time in the range of from 2 to 180 hours, (c) spray granulating said slurry with a gas inlet temperature of at least 150° C.