Carbonized Silica Production with Continuous Atmospheric CO2 Absorption
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Solution Overview
Problem
Existing silica production methods using carbon dioxide as an acidifying agent face challenges with complex production devices, low carbon dioxide absorption rates, and lack of continuity in the reaction process, particularly when scaling up.
Innovation Solution
A high-efficiency short-process production system and method that decomposes the synthesis reaction into carbonization and precipitation stages, utilizing a carbonization assembly, precipitation assembly, cooling assembly, filter assembly, and drying assembly, with continuous addition of liquid sodium silicate and carbon dioxide, high-intensity stirring, and controlled reaction conditions to enhance carbon dioxide absorption and particle aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carbon dioxide acidification technology is used to replace sulfuric acid, then environmental pollution is reduced and carbon emission is decreased, but the production device becomes relatively complicated and the reaction process lacks continuity
Solution Approach 1:
The production process is divided into distinct functional modules: a carbonization reaction kettle for CO2 absorption, a precipitation reaction kettle for silica formation, a cooling reaction kettle for temperature control, a filter assembly for solid-liquid separation, and a drying assembly for product dehydration. Each module performs a specific function, allowing for simplified individual components while maintaining overall process efficiency and continuity.
2Productivity
If multi-kettle series pressurized carbonization is adopted, then carbon dioxide absorption rate is improved, but the production device and control process become complicated
Solution Approach 1:
The system employs continuous addition of carbon dioxide gas and liquid sodium silicate into the carbonization reaction kettle, maintaining continuous reaction conditions. The first slurry is continuously conveyed to the precipitation reaction kettle, and the second slurry is repeatedly introduced back into the carbonization reaction kettle, ensuring uninterrupted reaction processes and high CO2 absorption rates without requiring complex pressurized multi-kettle systems.
3Productivity
If reaction time is extended to improve carbon dioxide absorption, then absorption rate increases, but production efficiency decreases and process time increases
Solution Approach 1:
The system optimizes reaction parameters by controlling the temperature in the carbonization reaction kettle at 70-95°C and pH value at 9-12, enabling rapid and continuous CO2 absorption. The high-intensity stirring and controlled reaction conditions allow the reaction to proceed efficiently within 3-10 minutes, achieving both high absorption rates and short processing times without requiring extended reaction periods.
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
Achieves efficient carbon dioxide absorption and stable silica particle formation under atmospheric pressure, improving reaction efficiency and yield while reducing dissolved silicon content, ensuring continuous production and reliable performance.
Implementation Method 1
the liquid sodium silicate and the carbon dioxide form a first slurry in the first aqueous solution
Implementation Method 2
the second feed pipe is used for introducing first steam
Implementation Method 3
the second slurry is cooled in the cooling reaction kettle to form a third slurry
Implementation Method 4
the third slurry is repeatedly washed and filtered by the hot water in the plate-and-frame filter to form a filter cake
Implementation Method 5
the drying tower dries the fourth slurry to form a silica product
Data Source
AI summary
A high-efficiency short-process production method and production system for carbonized silica is provided. The absorption reaction is completed in a small gas-liquid carbonization reaction kettle at atmospheric pressure, and the absorption is enhanced through high-intensity stirring and gas-liquid interface contact, so that the rapid and continuous reaction of CO2 gas and liquid sodium silicate in the carbonization reaction kettle is realized, and the high-efficiency absorption of carbon dioxide is realized under atmospheric pressure reaction conditions. Carbonization reaction is performed in a small-scale carbonization reaction kettle, and precipitation reaction can be performed in a large-scale precipitation reaction kettle according to the scale. Solid-liquid reaction is performed in the precipitation reaction kettle. By controlling the reaction time, reaction temperature and reaction pH, the fine particles of silicon dioxide generated by the absorption reaction are further aggregated and grown to form silicon dioxide particles with stable structure and reliable performance.