Sequential Granulation of Glass Powders Without Drying
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Solution Overview
Problem
Conventional wet granulation processes for glass raw materials require a separate drying step, leading to increased energy consumption and complex handling processes, including the risk of granule breakage and high energy costs.
Innovation Solution
A process that divides powdery materials into two portions, with a binding liquid added to the first portion in a granulator to form 'wet' granules, and then the second portion is added to achieve 'dry' granules without the need for a separate drying step, optimizing water content and handling stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet granulation is used to improve handling and melting properties, then granule stability and melting kinetics are improved, but a separate drying step is required which increases energy consumption and process complexity
Solution Approach 1:
The invention combines the granulation and drying operations into a single continuous process within the granulator. The granulator performs both functions by controlling liquid addition and residence time, eliminating the need for a separate drying step and reducing overall energy consumption while maintaining granule stability
Solution Approach 2:
The process maintains continuous operation where granulation and drying occur simultaneously in the granulator without interruption. The continuous flow of material through the granulator allows moisture control to occur during the granulation process itself, eliminating idle time and additional energy-intensive drying cycles
2Strength
If wet granulation is used to improve handling properties, then granule strength is improved, but the process requires separate granulator and dryer equipment increasing device complexity
Solution Approach 1:
The invention merges the granulator and dryer into a single piece of equipment. The granulator is designed to perform both granulation and drying functions by controlling liquid binder addition and maintaining appropriate residence time, thereby reducing the number of equipment units and simplifying the overall process configuration
Solution Approach 2:
The granulator is designed as a multi-functional device that can perform both granulation and drying operations. By adjusting operational parameters such as liquid addition rate and residence time, the same equipment accomplishes multiple process objectives, reducing the need for specialized equipment for each function
3Ease of manufacture
If wet granulation is used to improve granule formation, then agglomeration is facilitated, but handling of wet granules becomes difficult due to sticking
Solution Approach 1:
The process continuously moves material through the granulator, preventing wet granules from sticking and accumulating. The continuous motion and tumbling action within the granulator keeps granules loose and free-flowing throughout the process, eliminating handling difficulties associated with sticky wet granules
Solution Approach 2:
The granulator performs preliminary drying action during the granulation process itself. By controlling the environment and residence time within the granulator, initial moisture reduction occurs before granules leave the equipment, preventing sticking during subsequent handling operations
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 approach eliminates the need for a drying step, reducing energy consumption and handling complexities while maintaining granule stability and minimizing residual fine particles, allowing for efficient production of glass granules with improved melting kinetics and homogeneity.
Implementation Method 1
a binding liquid which is conventionally water to which an additive such as caustic soda is often added. This binding liquid is essential to allow the formation of the granule, it acts as a lubricant and facilitates the agglomeration of the mixture
Data Source
AI summary
The present invention relates to a method for manufacturing granules via the wet method using powder materials, in particular raw materials for the production of glass. The inventive method includes the following consecutive steps: (i) the powder materials to be granulated are divided into at least two portions, a first portion and a second portion; (ii) a binding liquid is added to the first portion of powder materials; (iii) the first mixture obtained is agglomerated in the granulator such as to obtain granules (a); (iv) the second portion of powder materials is added to the granulator; and (v) the novel mixture obtained is agglomerated in the granulator such as to obtain granules (b). Said sequential granulation method produces granules with a humidity level that guarantees the stability of said granules and the ease of handling said granules by dispensing with the drying step.