Agitator Blade Design for Azo Compound Mixing
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Solution Overview
Problem
Conventional processes for producing azo compounds face a trade-off between energy consumption and productivity, with high energy consumption leading to reduced productivity and vice versa, and there is a need for a method that achieves both low energy consumption and superior productivity.
Innovation Solution
The process involves conducting a coupling reaction using an agitator with a specific shape, featuring a main agitating blade with tips separated from the tank wall to generate a rising liquid current and an auxiliary blade with scrapers and paddles arranged to promote circulatory mixing, allowing for efficient mixing and reduced energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If agitating is conducted at high speed to improve productivity, then productivity is improved, but energy consumption increases
Solution Approach 1:
The agitating blade is divided into multiple blades arranged at different radial positions and angles around the rotational axis, creating segmented flow paths that improve mixing efficiency without requiring high rotational speeds
Solution Approach 2:
Each blade is designed with specific local characteristics including different lengths, angles, and positions to create optimized local flow patterns that collectively achieve efficient overall mixing at lower energy consumption
2Use of energy by moving object
If agitating is conducted at low speed to reduce energy consumption, then energy consumption is reduced, but productivity deteriorates
Solution Approach 1:
The blade configuration creates dynamic flow patterns including radial and tangential components that enhance mixing efficiency at low rotational speeds, allowing the system to maintain productivity while consuming less energy
Solution Approach 2:
The three-dimensional arrangement of multiple blades at different radial positions and angles creates complex multi-dimensional flow patterns that improve mixing effectiveness without increasing rotational speed or energy consumption
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 enables the production of azo compounds with significantly lower energy consumption and higher productivity compared to conventional methods, as demonstrated by the production of azo pigments like C.I. Pigment Red 57:1, which typically requires high energy for mixing, showing a marked reduction in energy usage while maintaining favorable mixing properties.
Implementation Method 1
the main agitating blade has tips that are separated from the inner wall surface of the agitating tank so as to generate a rising liquid current during agitating
Implementation Method 2
the auxiliary agitating blade has scrapers close to the inner wall of the agitating tank that are either arranged vertically, or inclined so as to push the liquid up during rotation
Implementation Method 3
has paddles that are connected to the scrapers and are either arranged vertically, or inclined so as to push the liquid down during rotation
Data Source
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AI summary
A process for producing an azo compound of the present invention includes conducting coupling of a diazo component formed from a diazonium salt of an aromatic amine, and a coupler component formed from a naphthol and/or an acetoacetanilide, wherein the coupling is conducted within an agitator that has a rotational axis fitted with a main agitating blade and an auxiliary agitating blade inside an agitating tank. If required, heating and laking may also be conducted within the agitator.