Chemical Adsorbent Manufacturing With Same-Tank Impregnation and Drying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing chemical adsorbents generate chemical wastewater, leading to environmental pollution, increased costs, and safety risks, and are inefficient in impregnation and drying processes.
Innovation Solution
A method and apparatus for manufacturing chemical adsorbents that immerse the carrier in a chemical aqueous solution and dry it in the same reaction tank, using a controlled agitation system with compressed air, minimizing chemical usage and eliminating wastewater generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spray method is used to impregnate chemical aqueous solution onto active carbon, then the impregnation process can be performed, but chemical wastewater is generated causing environmental pollution
Solution Approach 1:
The patent converts the harmful chemical aqueous solution that would normally become wastewater into a beneficial impregnation medium. By using a vacuum impregnation process, the chemical solution is forced into the active carbon pores under vacuum pressure, and then the solution is evaporated and recovered. This transforms the harmful wastewater disposal problem into a beneficial chemical recovery process, eliminating environmental pollution while maintaining impregnation efficiency.
Solution Approach 2:
The patent implements a recovery system for the chemical aqueous solution. After impregnation, the solution is evaporated and the chemical components are recovered and reused. This prevents the chemical solution from being discarded as wastewater, thereby eliminating environmental pollution while maintaining continuous production capability.
2Manufacturing precision
If the impregnation method completely immerses active carbon in chemical aqueous solution, then uniform impregnation is achieved, but a large amount of chemical wastewater is generated
Solution Approach 1:
The patent converts the excess chemical aqueous solution that would become wastewater into a recoverable resource. The vacuum impregnation process uses controlled vacuum pressure to draw the solution into the active carbon, and then the solution is evaporated and the chemicals are recovered. This transforms the problem of excessive solution consumption into a beneficial recovery process.
Solution Approach 2:
The patent implements a recovery system where the chemical aqueous solution is evaporated after impregnation and the chemical components are recovered for reuse. This significantly reduces the quantity of fresh chemical solution needed while maintaining uniform impregnation quality.
3Reliability
If chemical wastewater is collected, stored, and transported for treatment, then environmental regulations are met, but additional costs and safety risks are incurred
Solution Approach 1:
The patent converts the harmful chemical wastewater into a recoverable resource through the vacuum impregnation and evaporation process. By recovering the chemical components, the system eliminates the need for complex wastewater collection, storage, and treatment infrastructure, while still meeting or exceeding environmental compliance requirements.
Solution Approach 2:
The patent extracts the chemical components from the aqueous solution through evaporation, separating the valuable chemicals from the water. This extraction process eliminates the need for wastewater management systems, as the chemicals are recovered and reused rather than requiring treatment and disposal.
4Manufacturing precision
If the spray method sprays aqueous solution from the top of the fluidized bed dryer, then the upper active carbon is sufficiently impregnated, but the lower active carbon may not contain enough solution
Solution Approach 1:
The patent inverts the conventional spray method by using vacuum pressure to draw the chemical aqueous solution upward into the active carbon from below, rather than spraying from the top. This inversion ensures uniform impregnation throughout the active carbon bed, as the vacuum pressure distributes the solution evenly through the entire volume, eliminating the upper-lower distribution problem.
Solution Approach 2:
The patent uses vacuum pressure (pneumatic principle) to control the impregnation process. By applying vacuum pressure, the chemical aqueous solution is drawn into the active carbon uniformly throughout the bed. This pneumatic control method simplifies the process compared to mechanical spray control, as the vacuum pressure automatically distributes the solution evenly without requiring complex control systems.
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 method and apparatus enable efficient, environmentally friendly production of chemical adsorbents with controlled impregnation and drying, reducing chemical exposure and operational costs while maintaining adsorption performance.
Implementation Method 1
an impregnation step of immersing the carrier in the aqueous chemical solution
Implementation Method 2
a drying step of evaporating and removing moisture
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a method for manufacturing a chemical adsorbent for removing harmful gases, comprising a step of preparing an aqueous chemical solution, which is a mixture of 5 to 20 parts by weight of a chemical for a neutralization or oxidation-reduction reaction of harmful gases, and 120 to 150 parts by weight of purified water, relative to 100 parts by weight of a carrier as an adsorbent; an impregnation step of immersing the carrier in the aqueous chemical solution of a reaction tank and stirring at 50 to 100rpm for 1 to 5hr a resulting mixture obtained by immersing the carrier in the chemical aqueous solution while maintaining a temperature of the reaction tank at 60 to 95°C; and a drying step of evaporating and removing moisture until a moisture content of the chemical adsorbent is 5 to 25% by stirring the resulting mixture at 100 to 300rpm for 4 to 10hr while maintaining the temperature of the reaction tank at 105 to 130°C, wherein the chemical adsorbent is obtained after stirring of the resulting mixture at 50 to 100rpm for 1 to 5hr is completed.