Continuous Powder Make-Down System with Filter Wiping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Batch processes for dissolving dry powder materials are inefficient and result in incomplete dissolution, leading to undissolved polymers in the solution, which can negatively impact subsequent operations due to their large footprint and slow processing times.
Innovation Solution
A continuous make-down system comprising a liquid supply, material feed, vessel, filter, and agitator, where dry powder is continuously fed and mixed with solvent, agitated to form a solution, and filtered to ensure complete dissolution, with a wiping mechanism to prevent filter blinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch processes are used for dissolving dry powder materials, then complete dissolution can be achieved, but the processing time is long and the footprint is large
Solution Approach 1:
The patent implements a continuous make-down process where dry polymer particles are continuously fed into a dissolution tank, mixed with solvent, and discharged as dissolved solution. This continuous operation eliminates the batch-to-batch idle time and achieves both complete dissolution and reduced processing time, directly resolving the contradiction between dissolution completeness and processing speed
2Productivity
If continuous make-down process is used, then processing time is reduced, but undissolved particles remain in the solution
Solution Approach 1:
The patent introduces a screen as an intermediary component positioned in the discharge line of the dissolution tank. This screen filters out undissolved particles from the continuous flow, ensuring that only fully dissolved solution passes through. This resolves the contradiction by maintaining high processing speed while eliminating undissolved particles through the intermediary filtering mechanism
Solution Approach 2:
The system incorporates a feedback mechanism where the presence of undissolved particles is detected (either visually or through sensors), and the screen acts to remove them, ensuring continuous production of high-quality dissolved solution. This feedback loop maintains dissolution completeness without sacrificing continuous processing efficiency
3Manufacturing precision
If filter is used to remove undissolved particles, then solution quality is improved, but filter blinding occurs reducing flow
Solution Approach 1:
The patent implements a self-cleaning mechanism where a wiper member periodically contacts the screen surface to remove accumulated particles. This self-service approach prevents filter blinding from reducing flow rate, maintaining both high solution quality and sustained productivity without requiring manual intervention or system shutdown
Solution Approach 2:
The wiper member operates periodically to clean the screen surface, removing accumulated particles before they can block the pores. This periodic cleaning action maintains consistent flow rate and solution quality, resolving the contradiction between filtration effectiveness and flow maintenance
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 system achieves efficient and complete dissolution of dry polymers, reducing the likelihood of undissolved particles in the solution and allowing for continuous operation with a smaller footprint compared to batch processes.
Implementation Method 1
dry polymer particles are continuously charged into a dissolution tank, liquid continuously flows into the dissolution tank, and the mixture is continuously stirred until the polymer particles have completely or nearly completely dissolved
Implementation Method 2
the filter preferably has an upstream surface in contact with the inner volume... liquid exiting the vessel through the outlet passes through the filter
Implementation Method 3
The agitator may include a wiping member configured to contact the upstream surface of the filter, e.g., while agitating the inner volume
Data Source
AI summary
A system for continuously making-down a dry powder material is provided. The system may include a liquid supply system, a material feed system, a vessel, a filter, and an agitator. The vessel may receive a continuous supply of liquid from the liquid supply system and a continuous supply of dry powder from the material feed system. The liquid and material may be discharged continuously from the vessel. A filter may sealingly extend across the outlet to filter the solution exiting the vessel. The filter may include an upstream surface in contact with the inner volume of the vessel. The agitator may be disposed within the vessel and may be configured to agitate the contents of the vessel. The agitator may include a wiping member configured to contact the upstream surface of the filter while agitating the contents.