System and method for the continuous treatment of solids at non-atmospheric pressure
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Solution Overview
Problem
Existing methods for processing solid materials at non-atmospheric pressures often require high-pressure delivery mechanisms, leading to shear forces that alter the material characteristics, and are typically conducted in batch processes rather than continuously.
Innovation Solution
A system and method for continuous processing of solid materials at non-atmospheric pressures, where the material is delivered to a process vessel under the same pressure conditions without disrupting the vessel's operation, using a material delivery apparatus with pressure-controlled chambers to isolate and equalize pressure, allowing for continuous treatment without significant shear stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high pressure delivery mechanisms are used to process solid materials at non-atmospheric pressure, then the material can be delivered to the process vessel, but shear forces are generated that alter the material characteristics
Solution Approach 1:
The delivery system is segmented into multiple chambers (first chamber at atmospheric pressure, second chamber at non-atmospheric pressure) separated by a valve. This allows pressure equalization in stages, preventing shear forces from acting on the solid material during pressure transition while still enabling delivery to the process vessel.
Solution Approach 2:
The second chamber acts as an intermediary pressure equalization zone between the atmospheric pressure source and the non-atmospheric pressure process vessel. Solid material is transferred through this intermediate chamber, allowing pressure adjustment without direct exposure to high shear forces that would occur in a single-stage pressure delivery system.
2Reliability
If batch processing is used to treat solids at non-atmospheric pressure, then pressure control can be maintained, but continuous processing is not achieved
Solution Approach 1:
The system enables continuous processing by implementing a cyclic operation where the valve alternates between connecting the first chamber to the second chamber for pressure equalization and connecting the second chamber to the process vessel for material discharge. This continuous cycling maintains pressure control while achieving uninterrupted material flow through the system.
Solution Approach 2:
The valve operates periodically, switching between two states: (1) allowing pressure equalization from the atmospheric pressure first chamber to the non-atmospheric pressure second chamber, and (2) allowing material discharge from the second chamber to the process vessel. This periodic valve action reconciles the need for pressure control with continuous material processing.
3Stress or pressure
If pressure is adjusted within the delivery chamber, then non-atmospheric pressure delivery is achieved, but the process vessel operating pressure is disrupted
Solution Approach 1:
The pressure adjustment function is segmented to occur exclusively in the second chamber, which is isolated from the process vessel during pressure equalization. The valve prevents pressure changes in the second chamber from propagating to the process vessel, allowing delivery pressure adjustment without disrupting process vessel operating pressure.
Solution Approach 2:
The second chamber serves as a pressure buffer that isolates the process vessel from pressure fluctuations. Pressure is adjusted in the second chamber, which acts as an intermediary between the pressure source and the process vessel, preventing direct pressure disruption to the vessel while still enabling non-atmospheric pressure delivery when needed.
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
Enables continuous processing of solid materials at non-atmospheric pressures without altering their characteristics, allowing for precise control of the final product's properties and preventing shear-induced modifications, such as starch granule rupture or degradation.
Implementation Method 1
adjusting a pressure within the chamber of the material delivery apparatus to a non-atmospheric pressure that is substantially equal to a non-atmospheric pressure in a process vessel downstream of the material delivery apparatus
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
Systems and processes may be used for continuously processing a solid material such as a solid starch-bearing material at a non-atmospheric pressure. In some examples, the material is delivered to a process vessel at substantially the same non-atmospheric pressure condition as the process vessel so as to avoid shearing the material. In some examples, the solid material is continuously fed into a process vessel, continuously processed in the process vessel, and continuously discharged from the process vessel.