Amorphous Calcium Carbonate Spray Drying Process
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Solution Overview
Problem
Current methods for producing amorphous calcium carbonate are complex, energy-intensive, and have low yields, making them impractical for industrial scaling, and often require the use of promoter or slaking additives.
Innovation Solution
A process involving the conversion of calcium oxide to calcium hydroxide, followed by simultaneous drying and carbonation with CO2 in a spray dryer, eliminating the need for additives and allowing high-purity amorphous calcium carbonate production without complex purification steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If controlled crystallisation from solution is used with promoter or slaking additives, then amorphous calcium carbonate can be produced, but the process becomes complex and requires multiple additives
Solution Approach 1:
The invention extracts and eliminates the need for promoter or slaking additives from the process by using a novel spray drying approach. The process produces amorphous calcium carbonate directly from calcium hydroxide solution sprayed into a carbon dioxide atmosphere, removing the complexity associated with multiple chemical additives while maintaining reliable production of the desired product
Solution Approach 2:
The spray drying process enables self-service production where the calcium hydroxide solution automatically transforms into amorphous calcium carbonate through controlled evaporation and carbonation in the spray dryer. The system self-regulates the crystallization process without requiring external promoter additives, simplifying the overall process
2Reliability
If lab-sized controlled crystallisation processes are used, then amorphous calcium carbonate can be produced, but the yield is very low making up-scaling impractical
Solution Approach 1:
The invention changes the physical parameters of the process by transitioning from controlled crystallisation in solution to spray drying. This parameter change enables high-yield production by rapidly evaporating the solvent and simultaneously carbonating the calcium hydroxide, producing amorphous calcium carbonate at industrial scales with significantly improved productivity while maintaining product reliability
3Manufacturing precision
If complex purification steps are implemented, then high purity amorphous calcium carbonate can be achieved, but the process becomes more complex
Solution Approach 1:
The spray drying process performs preliminary action by controlling the evaporation and carbonation conditions to directly produce high-purity amorphous calcium carbonate. The rapid solvent removal and controlled carbon dioxide exposure prevent unwanted crystallization and impurities from forming, achieving high purity without requiring subsequent complex purification steps
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 achieves high-yield production of amorphous calcium carbonate with controlled particle size and surface area, suitable for various industrial applications, while avoiding the use of additives and complex purification processes.
Implementation Method 1
mixing the at least one calcium oxide containing material of step a) with water to convert the calcium oxide at least partially into dissolved calcium hydroxide
Implementation Method 2
drying the solution of dissolved calcium hydroxide obtained in step d)
Implementation Method 3
carbonating the dissolved calcium hydroxide obtained in step d) with the at least one gaseous CO2 source of step b) to convert the calcium hydroxide at least partially into amorphous calcium carbonate
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a process for preparing amorphous calcium carbonate, the amorphous calcium carbonate obtainable by the process, its use as well as a product comprising the amorphous calcium carbonate and the use of a spray dryer for the preparation of amorphous calcium carbonate.