Granulation Nuclei Control for Narrow Particle Size Distribution
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Solution Overview
Problem
Existing granulation processes produce granules with broad particle size distributions, leading to increased costs due to the need for additional classification equipment and high dust formation, which complicates the process and increases energy consumption.
Innovation Solution
Introducing a second feed stream of granulation nuclei with a narrow particle size distribution into the granulation zone, characterized by a standard deviation of less than 15% of the mean particle size, which reduces the need for classification equipment and minimizes dust formation by stabilizing the granulation process and improving fluidization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional granulation process is used, then granules can be produced, but the particle size distribution is broad requiring additional classification equipment and increasing process complexity
Solution Approach 1:
The patent introduces granulation nuclei with a pre-defined narrow particle size distribution into the granulation zone before the main granulation process begins. These pre-formed nuclei serve as seeds that control the subsequent growth of granules, ensuring that the final product maintains a narrow particle size distribution without requiring complex classification equipment.
Solution Approach 2:
The patent changes the parameter of particle size distribution by introducing nuclei with a specific standard deviation (less than 15% of mean particle size) into the granulation zone. This parameter control ensures that the granules grown from these nuclei inherit the narrow size distribution, eliminating the need for extensive classification equipment.
2Productivity
If granulation nuclei are formed by solidification of liquid composition droplets, then granules can be produced, but dust is formed and removed from the granulation zone
Solution Approach 1:
The patent performs the solidification action in advance by forming granulation nuclei with a narrow particle size distribution before introducing them into the granulation zone. This preliminary formation ensures that the nuclei are stable and do not undergo further solidification or fragmentation during the granulation process, thereby preventing dust formation while maintaining high productivity.
3Ease of operation
If fluidizing air flow is increased to keep granulation nuclei in the fluidized bed, then granulation can proceed, but dust is removed from the granulation zone
Solution Approach 1:
The patent changes the parameter of particle size distribution by using nuclei with a narrow size distribution (standard deviation less than 15% of mean particle size). This parameter control allows the use of lower fluidizing air flows while still maintaining effective granulation, as the uniform size distribution prevents excessive turbulence that would otherwise generate and remove dust.
4Manufacturing precision
If crushing is applied to reduce oversized particles, then particle size can be controlled, but dust is formed
Solution Approach 1:
The patent performs the size control action in advance by introducing nuclei with a pre-defined narrow particle size distribution into the granulation zone. This preliminary action eliminates the need for subsequent crushing operations, as the granules grow to the desired size directly from the controlled nuclei, thereby preventing dust formation while maintaining precise particle size control.
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 results in granules with a narrow particle size distribution, reducing the need for classification equipment, lowering production costs, and enhancing process stability, while also reducing dust formation and energy consumption.
Implementation Method 1
the formation of granulation nuclei by solidification of droplets of the liquid composition that is fed to the granulation zone
Implementation Method 2
the air flow required to fluidize the growing particles present in the granulation zone
Data Source
AI summary
The present invention relates to a process for the preparation of granules comprising the steps of: providing a granulation zone comprising particles, the particles being kept in motion; providing a first feed stream comprising a liquid composition into the granulation zone, the liquid composition being applied onto or over the moving particles in the granulation zone; withdrawing a product stream comprising granules from the granulation zone, the granules being the result of layered growth of the moving particles in the granulation zone; wherein a second feed stream comprising granulation nuclei is fed into the granulation zone, wherein the granulation nuclei have a particle size distribution characterized by a standard deviation of the particle size that is less than 15% of the mean particle size, and wherein the second feed stream comprises between 0.05 wt % and 50 wt % of the product stream.