Granulated Bleached Catalysts with Binder Solution
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Solution Overview
Problem
Existing bleach activator granules have low activity and are difficult to produce, leading to equipment contamination and complex cleaning processes due to dust containing heavy metals, with existing production methods requiring large amounts of binders and additional equipment like fluidized bed systems.
Innovation Solution
A process for producing bleach catalyst granules with a carrier material containing over 70% carbonate and silicate, combined with a bleach catalyst and organic polymer binder, which are mixed and granulated to create granules with improved performance and storage stability, reducing equipment contamination and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional production methods are used with large amounts of binders and melts, then granules can be produced, but the granules have low activity and require complex cooling and drying stages
Solution Approach 1:
The invention changes the physical state parameter of the binder from melt form to solution form, eliminating the need for cooling stages. The binder is applied as an aqueous solution containing 5-20% binder content, which is then dried to form granules without requiring complex cooling and drying equipment
Solution Approach 2:
The invention extracts and eliminates the harmful cooling and drying stages from the production process. By using a solution-based binder application method, the process removes the need for fluidized bed systems and complex thermal processing equipment
2Ease of manufacture
If conventional production methods are used, then granules can be produced, but equipment is contaminated with heavy metal dust requiring complex cleaning and costly disposal
Solution Approach 1:
The invention introduces an intermediary binder solution that coats the catalyst particles, preventing heavy metal dust from becoming airborne and contaminating equipment. The binder acts as a binding matrix that holds catalyst particles together, eliminating dust generation during handling and transport
Solution Approach 2:
The invention converts the potentially harmful heavy metal dust into a beneficial bound state within the granule structure. The catalyst particles are embedded in the binder matrix, transforming from a contamination risk into a stable, non-dusting product that is easier to handle and store
3Quantity of substance
If large amounts of binders are used in production, then granules can be formed, but the process requires additional equipment like fluidized bed systems
Solution Approach 1:
The invention optimizes the binder concentration parameter to 5-20% in aqueous solution, which is sufficient for granule formation without requiring excessive binder amounts. This moderate concentration allows for effective granulation using simple mixing equipment rather than complex fluidized bed systems
Solution Approach 2:
The invention replaces complex mechanical fluidized bed systems with a simpler wet granulation approach using aqueous binder solutions. The granulation is achieved through controlled mixing and drying processes that do not require sophisticated equipment
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 resulting granules exhibit increased bleaching effectiveness, improved processability, and enhanced storage stability, with reduced contamination and production complexity, making them suitable for use in machine dishwashing detergents.
Implementation Method 1
the carrier material containing more than 70 % by weight carbonate(s) and silicate(s)
Implementation Method 2
0.1 to 6% by weight of a binder from the group of organic polymers
Implementation Method 3
bleach catalysts in particular having proven to be particularly effective
Data Source
AI summary
Granulated bleached catalysts comprising, based on the total weight of the granulated material, a) from 0.1 to 30% by weight of a bleached catalyst, b) from 10 to 99% by weight of a support material, c) from 0.1 to 5% by weight of a binder selected from the group consisting of organic polymers have improved producability, processability and increased bleach-activating action.