Cascading Purification for Crystal Impurity Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for purifying materials, such as crystallization, face challenges in efficiently separating impurities from desired materials, especially on a large scale, and often require additional purification steps due to incomplete solvent removal and residual impurities on the surface of crystals.
Innovation Solution
A cascading dissolving solution and washing process is employed, where a material is combined with progressively stronger dissolving solutions and rinsed with cleaner solutions, allowing for the separation of impurities and subsequent recycling of dissolving chemicals and water to maintain solution properties, ultimately resulting in a highly purified material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If crystallization is used to purify material, then the material can be separated from impurities, but the crystals become coated with impurities and additional purification steps are needed
Solution Approach 1:
The patent divides the purification process into multiple sequential washing stages, where each stage uses progressively weaker washing solutions. This segmentation allows thorough removal of impurities from crystal surfaces while maintaining crystal integrity, eliminating the need for additional purification steps after crystallization.
Solution Approach 2:
The patent changes the concentration parameter of washing solutions across different stages, using stronger solutions initially to remove heavy impurity coatings, then progressively weaker solutions to achieve final purification. This parameter variation enables effective impurity removal without requiring multiple distinct purification methods.
2Manufacturing precision
If solvent is not entirely removed from crystals, then impurities remain on crystal surface, but complete solvent removal increases processing complexity
Solution Approach 1:
The patent implements continuous washing operations where washing solutions are continuously circulated through multiple stages, ensuring complete removal of solvent and impurities from crystal surfaces. This continuous action achieves thorough purification without requiring complex batch processing or additional drying equipment.
Solution Approach 2:
The patent uses washing solutions as intermediary substances that facilitate the removal of impurities and residual solvent from crystal surfaces. These intermediary liquids transfer impurities from the crystals to the washing solution, which is then separated and discarded, simplifying the overall purification process.
3Manufacturing precision
If multiple purification steps are added to increase purity, then product quality improves, but processing time and cost increase
Solution Approach 1:
The patent combines multiple purification functions into a single integrated washing cascade system. By merging impurity removal, solvent elimination, and surface cleaning into one continuous multi-stage process, the patent achieves high purity results without proportionally increasing processing time or requiring separate purification operations.
Solution Approach 2:
The washing solutions in the cascade system progressively clean crystals as they move through stages, with each stage automatically performing purification on the output from the previous stage. This self-service arrangement eliminates the need for external intervention or additional processing steps, reducing overall processing time while maintaining high purity.
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 method effectively increases the purity of materials by selectively dissolving impurities, allowing for the generation of a highly valued product while reducing waste and costs through recycling, and controlling exothermic reactions.
Implementation Method 1
The dissolving solution can react with or dissolve impurities in the material
Implementation Method 2
The dissolving solution can react with or dissolve impurities in the material
Implementation Method 3
The material can then be rinsed with a rinsing solution to remove dissolving solution and impurities
Data Source
AI summary
The present invention provides a method of purifying a material using a cascading dissolution and washing process. The dissolution and washing processes can contain single or multiple stages. Water and dissolving chemicals are recycled through the process towards the beginning of the process.