CO2-Enriched Water for Gypsum Slurry Fluidity
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Solution Overview
Problem
The existing methods for preparing stucco slurries require excessive water, leading to high energy costs for drying, as more water than stoichiometrically necessary is used to achieve fluidity and low viscosity, which is then removed, resulting in significant energy expenditure.
Innovation Solution
Introducing a measured quantity of carbon dioxide into the process water before mixing with stucco increases slurry fluidity, allowing for a reduction in overall water usage and potentially reducing the amount of foaming agents needed, while using gaseous carbon dioxide avoids by-products from acid-base reactions and leverages abundant, low-cost CO2 from fossil fuel heating systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If more water is used to achieve fluidity and low viscosity of stucco slurry, then processing properties are improved, but energy consumption for drying increases significantly
Solution Approach 1:
The patent introduces carbon dioxide into the process water to change the chemical parameters of the water, specifically lowering its pH. This parameter change allows the stucco slurry to achieve adequate fluidity and low viscosity with reduced water content, thereby resolving the contradiction between processing properties and drying energy consumption
Solution Approach 2:
Carbon dioxide acts as an intermediary substance that modifies the properties of process water. By dissolving CO2 into the water, the patent creates carbonic acid which reduces pH and enhances the fluidity of the stucco slurry, allowing reduced water usage while maintaining processing quality
2Quantity of substance
If stoichiometric amount of water is used for hemihydrate hydration, then water demand is reduced, but fluidity and processability of mixture deteriorate
Solution Approach 1:
The patent changes the chemical parameter (pH) of the process water by introducing carbon dioxide. This parameter change enables the slurry to maintain adequate fluidity and processability with water amounts closer to the stoichiometric requirement, thus reducing overall water demand while preserving workability
3Duration of action of moving object
If CO2 is introduced into slurry after mixing stucco and water, then setting time is increased and durability is improved, but water demand increases
Solution Approach 1:
The patent applies preliminary action by introducing carbon dioxide into the process water before mixing with stucco. This pre-treatment of the water modifies its properties in advance, allowing reduced water demand in the final slurry while still achieving adequate setting time and durability through the chemical modification already present in the water
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 reduces the water demand for stucco slurries, achieving energy savings and minimizing the use of foaming agents, with optimal CO2 concentrations between 1-8 g/L ensuring adequate processing properties and efficient drying.
Implementation Method 1
introducing a measured quantity of carbon dioxide into the process water prior to mixing the process water with the stucco
Implementation Method 2
The addition of CO2 to the slurry allows for larger quantities of water... The increased amount of water is described as favourable because it reduces the risk of spoiling
Data Source
AI summary
The present application concerns a method for the production of a gypsum article, which includes introducing a measured quantity of carbon dioxide into the process water and mixing the stucco with the thus treated water. The CO2-enriched water has the advantage of providing compositions with sufficient processing properties at considerably lower water contents, thus allowing for significant energy savings. The invention also concerns slurries prepared according to this method as well as an apparatus which is adapted to implement this method.