Bituminous Membrane Cooling Unit Nebulization
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Solution Overview
Problem
Existing cooling units for bituminous membranes are inefficient, requiring long cooling times due to their reliance on direct contact cooling methods or air/water sprays, which extend production times and increase equipment and operational costs, especially when cooling membranes at lower temperatures.
Innovation Solution
A high-pressure nebulization cooling unit that uses a closed chamber to deliver fluid as mist, reducing cooling times by creating micro-drops that evaporate quickly, preventing wetting and insulating layers, and effectively cooling membranes at temperatures below 60°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If direct contact cooling methods (tanks, belts, rolls) are used to cool bituminous membranes, then the membranes can be cooled to the desired temperature, but very long cooling times are required which reduce overall plant productivity
Solution Approach 1:
The patent replaces traditional mechanical contact cooling systems (rolls, belts, tanks) with a fluid spray cooling system. The cooling fluid is delivered as a fine mist through nozzles, transitioning from mechanical contact to fluid-based heat transfer. This substitution enables much faster cooling times while maintaining effective temperature reduction, thereby improving plant productivity without sacrificing cooling performance
Solution Approach 2:
The invention changes the physical parameters of the cooling fluid delivery system by delivering the cooling fluid as a fine mist with specific droplet size distributions rather than as liquid pools or contact surfaces. By controlling droplet size and distribution, the system optimizes heat transfer efficiency and cooling rate, achieving rapid cooling that restores productivity while maintaining effective temperature control
2Temperature
If air/water spray devices are used to cool bituminous membranes, then cooling can be achieved, but the membranes become wet requiring additional drying devices and time which extends production time and increases equipment bulk
Solution Approach 1:
The patent carefully controls the physical parameters of the cooling fluid delivery, specifically the droplet size distribution and delivery pressure. By optimizing these parameters, the system achieves effective cooling while minimizing the amount of fluid that remains on the membrane surface, thereby eliminating or reducing the need for separate drying equipment and reducing overall system complexity
Solution Approach 2:
The invention utilizes the phase transition of the cooling fluid from liquid to vapor as it evaporates from the membrane surface. This evaporative cooling mechanism provides efficient heat removal while the controlled evaporation rate prevents excessive wetting, eliminating the need for additional drying devices and reducing equipment bulk
3Temperature
If water spray is used on bituminous membranes at lower temperatures (55°C-60°C), then cooling can be attempted, but the water particles are difficult to vaporize and wet the membrane surface creating an insulating layer that reduces cooling efficiency
Solution Approach 1:
The patent addresses the problem of water vaporization at lower temperatures by changing the physical parameters of the spray system. By delivering the cooling fluid as a fine mist with smaller droplet sizes and optimized distribution, the system increases the surface area to volume ratio of the cooling fluid, enabling more efficient evaporation even at lower membrane temperatures. This maintains cooling efficiency while preventing surface wetting issues
Solution Approach 2:
The invention relies on controlled phase transition of the cooling fluid from liquid to vapor through optimized spray parameters. The fine mist delivery ensures that droplets are small enough to vaporize efficiently at lower temperatures, maintaining reliable cooling performance without creating insulating wet layers on the membrane surface
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
The high-pressure nebulization method significantly reduces cooling times, enhances cooling efficiency, and prevents wetting, thereby improving productivity and reducing overall production costs and equipment complexity.
Implementation Method 1
deliver it into the cooling chamber in the form of mist with a delivery pressure of at least 50 bar so as to cool the bituminous membrane
Implementation Method 2
at least a nebulization member configured to nebulize a fluid and to deliver it into the cooling chamber in the form of mist
Implementation Method 3
preventing wetting and insulating layers
Data Source
Figure 1
Figure 2
AI summary
A cooling unit for bituminous membranes (20), insertable in a plant (10) for producing said bituminous membranes (20), comprises at least a nebulization member (16) configured to nebulize a fluid in a cooling chamber (40) to cool said bituminous membrane (20) which is made to transit through the latter.