Alkali Metal Carbonate Extrusion for Shape and Dissolution Control
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Solution Overview
Problem
Existing methods for producing alkali metal bicarbonate particles are costly, time-consuming, and unsuitable for producing specific shapes, sizes, porosity, and bulk densities required for various applications, while also lacking control over dissolution times and CO2 release temperatures.
Innovation Solution
A process involving dissolving a functionalizing agent in a solvent and mixing it with alkali metal salts to form a paste-like composition, which is then extruded to create filaments or granules, allowing control over shape, size, porosity, and bulk density, with enhanced dissolution times and CO2 release properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional crystallization and drying processes are used to produce alkali metal bicarbonate particles, then basic particle formation is achieved, but control over specific shape, size, porosity, and bulk density is lost
Solution Approach 1:
The invention applies preliminary action by forming a paste-like composition with specific rheological properties before extrusion. The paste is prepared with controlled water content (0.1-20 wt%) and composition to enable subsequent extrusion into desired shapes. This preliminary preparation allows the final product to achieve precise control over shape, size, porosity, and bulk density without requiring complex post-processing operations.
2Shape
If multiple unit operations (crystallization, grinding, drying, sieving) are performed to modify particle shape and size, then particle morphology is improved, but production time and cost increase significantly
Solution Approach 1:
The invention merges multiple unit operations into a single extrusion process. Instead of performing crystallization, grinding, drying, and sieving as separate sequential operations, the paste-like composition is directly extruded through a die to produce particles with the desired shape and size in one step. This consolidation dramatically reduces production time while maintaining control over particle morphology.
3Quantity of substance
If standard extrusion methods are used with high sodium bicarbonate concentration (9.6-12.3 wt%), then material efficiency is improved, but dissolution time control and CO2 release temperature adjustment are compromised
Solution Approach 1:
The invention applies parameter changes by controlling the water content in the paste-like composition within a specific range (0.1-20 wt%) and adjusting the composition of functionalizing agents. These parameter modifications enable control over dissolution time and CO2 release temperature while maintaining high sodium bicarbonate concentration (70-90.9 wt%). The rheological properties of the paste are specifically tuned to achieve the desired extrusion characteristics and final product properties.
4Duration of action of moving object
If conventional processes are used without functionalizing agents, then process simplicity is maintained, but dissolution time extension and CO2 release temperature control are not achieved
Solution Approach 1:
The invention introduces functionalizing agents as intermediaries between the sodium bicarbonate and the environment. These agents (such as hydrocolloids, polymers, or surfactants) form a matrix around the sodium bicarbonate particles in the paste-like composition, controlling water penetration and thus dissolution time. They also influence CO2 release temperature. The functionalizing agents are incorporated during paste preparation, adding this functionality without requiring complex post-processing equipment.
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 process produces alkali metal salt formulations with extended dissolution times and controlled CO2 release temperatures, suitable for applications in plastics, flue gas cleaning, pharmaceuticals, cosmetics, detergency, and food/feed industries.
Implementation Method 1
dissolving a functionalizing agent in a solvent to obtain a solution comprising the functionalizing agent
Implementation Method 2
extruding the paste-like composition to obtain a powder, filaments or granules
Implementation Method 3
removing the solvent from the powder, filaments or granules
Data Source
AI summary
The present invention relates to a process for preparing a formulation comprising an alkali metal salt selected from the group consisting of alkali metal bicarbonate salts, alkali metal carbonate salts, alkali metal sesquicarbonate salts and combinations thereof, wherein said process comprises: (a) dissolving a functionalizing agent in a solvent; (b) mixing the alkali metal salt with the solution comprising the functionalizing agent that a paste-like composition is formed; (c) extruding the paste-like composition to obtain filaments or granules; (d) at least partially removing the solvent from the filaments or granules. The invention furthermore relates to a powder, filaments and granules obtainable from said process and to the use of the powder, filaments or granules in various applications such as in plastic foaming or in food and feed leavening compositions.