Concave Spinning Disc Reactor for Nanoparticle Control
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Solution Overview
Problem
Spinning disc reactors (SDRs) face limitations in controlling reaction time and scaling up production of nanoparticles, leading to challenges in achieving uniform particle size distribution and widespread adoption.
Innovation Solution
The apparatus features a plurality of concave plates with concentric grooves and optional side wall portions, allowing for controlled residence time of reactants and enhanced mixing through rotating plates with opposing directions, and flexible inlet line configurations for precise introduction of feedstock materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat spinning plate is used in traditional SDRs, then the device complexity is low and ease of manufacture is high, but the control over residence time and reaction conditions is limited, preventing effective scaling up
Solution Approach 1:
The patent applies curvature by replacing the flat spinning plate with a concave reaction surface. This concave geometry creates a well-defined reaction volume that traps reactants longer, increasing residence time and allowing better control over reaction conditions. The curved surface also promotes better mixing through centrifugal forces while maintaining a relatively simple overall structure that can be manufactured.
Solution Approach 2:
The patent introduces a vertical dimension by creating a concave reaction surface that extends away from the rotation plane. This adds depth to the traditionally two-dimensional flat plate, creating a three-dimensional reaction volume that enhances residence time control and mixing while maintaining rotational symmetry for ease of manufacture.
2Manufacturing precision
If the rotational speed and temperature are varied to control the reaction, then the ease of operation is improved, but the control remains limited and cannot achieve the required precision for uniform particle size distribution
Solution Approach 1:
The patent changes the geometric parameters of the reaction surface by introducing a concave shape with specific curvature radius. This geometric parameter change fundamentally alters the flow dynamics and residence time distribution, enabling precise control over reaction conditions and particle size distribution without requiring complex variations in rotational speed or temperature.
3Manufacturing precision
If traditional co-precipitation methods are used, then the device complexity is low, but the control over reaction time is poor leading to non-uniform particle size distribution
Solution Approach 1:
The concave reaction surface creates a well-defined reaction volume that confines reactants during the co-precipitation process. This curvature ensures uniform exposure to reaction conditions and consistent residence time across all reactant particles, leading to uniform particle size distribution while maintaining a relatively simple reactor structure.
4Productivity
If SDRs are scaled up to increase production quantity, then the productivity is improved, but the control over reaction conditions deteriorates, preventing widespread adoption
Solution Approach 1:
The concave reaction surface design maintains effective control over reaction conditions even when scaled up. The curved geometry creates a self-contained reaction volume that preserves residence time control and mixing efficiency regardless of the overall reactor size, enabling scalable production while maintaining particle size uniformity.
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 setup enables more precise control over reaction conditions, improved mixing, and increased control over particle size distribution, facilitating the production of monodisperse nanoparticles with enhanced scalability.
Implementation Method 1
a plurality of concave first plates (101) mounted for rotation about the same rotation axis (102)... a collection unit (110) arranged to collect a reaction product formed from reaction of the liquid feedstock materials as a liquid colloid ejected from an outer edge of each plate (101)
Implementation Method 2
each concave reaction surface (103) comprises a plurality of concentric grooves... Applying grooves or ridges to the reaction surface can enhance mixing and reaction of the feedstock materials
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to an apparatus and methods for producing liquid colloids such as suspensions of nanoparticles, in which liquid feedstock materials are reacted on a reaction surface of a rotatable plate. The apparatus has a first plate (101) mounted for rotation about a rotation axis (102), the first plate (101) providing a reaction surface (103) having a concave portion; first (106) and second (107) inlet lines arranged to introduce respective first and second liquid feedstock materials to the reaction surface (103); and a collection unit (110) arranged to collect a reaction product formed from reaction of the liquid feedstock materials as a liquid colloid ejected from an outer edge of the plate (101).