Continuous Dispersion Separation for Monomodal Particle Size Control
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Solution Overview
Problem
Current methods for producing dispersions with defined particle sizes are inefficient and costly, as they often result in bimodal particle size distributions, requiring repeated processing and large, over-dimensioned plants to achieve a monomodal distribution, and filtration methods are not effective for small particle sizes.
Innovation Solution
A continuous method that separates mixed dispersions into coarse and fine fractions using a separating device, where the fine fraction is recirculated and not reprocessed, allowing only the coarse fraction to be crushed and returned, thereby reducing plant size and energy consumption, and utilizing particle filters to maintain desired particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch processing with repeated crushing is used to achieve monomodal particle size distribution, then the desired particle size quality is improved, but process efficiency deteriorates and energy consumption increases
Solution Approach 1:
The patent replaces the conventional mechanical batch processing system with a continuous processing system that uses hydrodynamic forces and controlled separation mechanisms to achieve particle size classification, eliminating the need for repeated mechanical crushing cycles and significantly improving process efficiency
Solution Approach 2:
The invention implements continuous processing where the dispersion flows continuously through the system with single-pass particle size control, replacing the discontinuous batch processing that required multiple repeated cycles, thereby maintaining constant productive action and improving overall efficiency
2Manufacturing precision
If conventional batch processing with repeated crushing is used to achieve monomodal particle size distribution, then the desired particle size quality is improved, but plant size increases
Solution Approach 1:
The patent replaces the large-volume mechanical batch processing equipment with a compact continuous processing system that achieves the same particle size control in a single pass, significantly reducing the required plant volume and equipment footprint
Solution Approach 2:
The invention segments the particle size control function into a dedicated continuous separation stage, allowing the system to be more compact and efficiently organized compared to the integrated repeated crushing approach that requires larger equipment volumes
3Manufacturing precision
If filtration is used to remove coarse particles, then particle size quality is improved, but costs increase and filtration is ineffective for small particles
Solution Approach 1:
The patent replaces the filtration-based particle removal approach with a continuous separation system that uses hydrodynamic forces to classify and separate particles by size, eliminating the need for expensive filtration equipment and reducing operational costs while maintaining effectiveness for both large and small particles
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 enables the production of dispersions with a specific particle size distribution efficiently, reducing costs and plant size, while ensuring the quality of pigment-based inks and dyes by maintaining a monomodal distribution of fine particles, thus preventing nozzle clogging and ensuring consistent product quality.
Implementation Method 1
a separating device for continuous separation of a mixed dispersion into a coarse fraction dispersion and a fine fraction dispersion
Implementation Method 2
at least one particle filter, in order to ensure that particles of the dispersed phase, which exceed a specific maximum particle size, are not introduced into the separating device
Data Source
AI summary
A method for producing dispersions with a defined particle size includes following steps: A) Preparation of a mixed dispersion in a predispersion process, B) introduction of the mixed dispersion into at least one continuously operating separating device, C) separation of the mixed dispersion in the separating device into coarse particles of a coarse-part dispersion and into fine particles of a fine-part dispersion, D) discharging the fine particle dispersion from the separating device into at least one storage tank, E) discharging the coarse particle dispersion from the separating device into at least one disperser, F) grinding the coarse particles of the coarse particle dispersion in the disperser into a dispersed particle mixture and returning the dispersed particle mixture to the mixing tank in the predispersion process, and G) mixing the dispersed particle mixture returned to the predispersion process with the mixing dispersion produced in the predispersion process in the mixing tank.