Falling Liquid Column for Blending Process Materials
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Solution Overview
Problem
Conventional bulk delivery systems for process materials in industries like pharmaceuticals and semiconductors face inefficiencies in blending due to limited wetted surface area and forced convective mixing, leading to batch inconsistencies and high costs from multiple solid feeders required for each tank.
Innovation Solution
A process material contacting system utilizing a falling liquid column to increase the wetted surface area and enhance mixing efficiency, allowing a single solid feeder to serve multiple tanks, with remote blending and closed-loop control to reduce variability and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If conventional blending tanks with limited surface area are used, then equipment complexity is reduced, but wetted surface area for liquid contact is insufficient leading to poor mixing efficiency
Solution Approach 1:
The patent transforms the blending process from a static horizontal tank configuration to a vertical falling liquid column configuration. This dimensional change creates a continuously renewing wetted surface area along the height of the column, dramatically increasing the effective contact area between liquid and solid particles without requiring a proportionally larger horizontal footprint or complex multi-tank systems.
Solution Approach 2:
The invention introduces dynamic motion to the liquid phase by creating a falling column rather than a static pool. The liquid continuously flows downward, constantly renewing the wetted surface area and creating forced convection that enhances mixing efficiency. This dynamic approach replaces the static, limited surface area of conventional tanks with a continuously regenerating contact surface.
2Manufacturing precision
If multiple solid feeders are used for each tank to ensure batch consistency, then manufacturing precision is improved, but device complexity and system cost increase
Solution Approach 1:
The falling liquid column blender serves multiple functions: it acts as both the mixing chamber and the distribution point for multiple solid feeders. The design allows one blender to receive material from multiple feeders simultaneously or sequentially, eliminating the need for dedicated feeders for each tank. This multi-functional approach maintains batch consistency while reducing overall system complexity.
Solution Approach 2:
The invention merges the functions of multiple blending tanks and their associated feeders into a single falling liquid column system. By combining multiple material streams into one dynamic mixing environment, the system achieves the same or better batch consistency with fewer individual components, thereby reducing device complexity and cost.
3Productivity
If static blending tanks are used, then equipment simplicity is maintained, but forced convective mixing efficiency is insufficient leading to batch variability
Solution Approach 1:
The invention replaces static blending tanks with a dynamic falling liquid column system. The continuous downward flow of liquid creates forced convection that actively entrains and mixes solid particles, dramatically improving mixing efficiency. The dynamic nature of the falling column ensures consistent mixing action throughout the process, eliminating the batch variability associated with static systems.
Solution Approach 2:
The patent replaces traditional mechanical mixing systems (impellers, agitators) with a gravity-driven falling liquid column system. The natural gravitational flow of the liquid creates sufficient forced convection for effective mixing without requiring complex mechanical mixing devices. This substitution maintains equipment simplicity while achieving superior mixing efficiency through fluid dynamics rather than mechanical agitation.
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 improved mixing efficiency, reduces batch-to-batch variability, and lowers overall system costs by enabling a single solid feeder to serve multiple tanks, while maintaining product character and consistency.
Implementation Method 1
increase forced convective mixing efficiency of the liquid mixture
Implementation Method 2
uses a falling liquid column to provide continuously changing contact surface between the liquid and added process material
Data Source
AI summary
An improved method and apparatus for blending process materials. Preferred embodiments of the present invention are directed to a process material contacting system to increase wetted surface area for liquid contact as well as increase forced convective mixing efficiency of the liquid mixture. Use of a novel process material contacting apparatus allows one solid feeding element to serve multiple process material tanks, thus reducing overall system costs and decreasing set-up time/process variability while increasing operational efficiency. According to a preferred embodiment of the present invention, rather than adding a process material to a volume of liquid held in a blending tank, the added process material is remotely blended with the liquid outside the process material tank.