Helical Reaction Channel for Continuous Immiscible Liquid Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for treating immiscible molten liquids with different densities, such as molten metals and oxide melts or molten salts, face challenges in achieving continuous separation and maintaining temperature stability, leading to inefficiencies in impurity removal and process complexity.
Innovation Solution
A continuous treatment apparatus featuring open-ended helical reaction channels within a vertical housing, allowing for countercurrent flow of liquids with different densities, where the higher-density liquid flows downwards and the lower-density liquid flows upwards, enhancing contact time and interaction for effective impurity transfer without movable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch processing with interrupted slag addition is used, then separation of molten silicon and slag can be achieved, but productivity is reduced and temperature stability deteriorates
Solution Approach 1:
The patent implements continuous slag treatment by eliminating batch interruptions. Slag is continuously added to the molten silicon bath through a supply system, and the treated silicon is continuously tapped through a tap hole. This continuous operation maintains productivity while achieving effective separation through the density difference between slag and silicon, resolving the contradiction between continuous processing and separation efficiency.
Solution Approach 2:
The treatment apparatus is divided into functional zones: a slag addition zone at the top, a reaction zone in the middle where slag and silicon interact, and a tapping zone at the bottom for removing treated silicon. This spatial segmentation allows continuous slag addition and simultaneous continuous tapping without mixing the input and output streams, enabling both continuous operation and effective separation.
2Reliability
If complicated apparatus design with multiple components is used, then slag treatment function is improved, but device complexity increases and temperature control becomes difficult
Solution Approach 1:
The reaction chamber serves multiple functions: it is the container for molten silicon, the zone for slag addition, the reaction zone for impurity removal, and the chamber from which treated silicon is tapped. This multi-functionality eliminates the need for separate components for each operation, simplifying the overall apparatus structure while maintaining effective slag treatment through the density-driven separation mechanism.
Solution Approach 2:
The apparatus utilizes the natural density difference between slag and molten silicon to achieve separation without requiring complex mechanical separation devices. The heavier slag sinks to the bottom while the lighter treated silicon rises and can be tapped off, allowing the system to separate phases automatically based on physical properties rather than requiring active separation mechanisms.
3Manufacturing precision
If slag addition is stopped during tapping, then complete slag removal is achieved, but loss of time increases and productivity decreases
Solution Approach 1:
The apparatus is designed so that the tap hole is positioned at the bottom of the reaction chamber, allowing treated silicon to be removed from the lowest point where slag would naturally accumulate. This preliminary positioning of the tap hole ensures that silicon can be tapped continuously without stopping slag addition, as the tap location naturally favors silicon removal while slag remains in the upper zones for continued treatment.
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 apparatus enables a true continuous process for treating molten metals and salts, ensuring efficient separation and refining by maintaining optimal interaction between the liquids, reducing the risk of solidification, and simplifying temperature control.
Implementation Method 1
two immiscible molten liquids having different densities
Implementation Method 2
the higher-density liquid flows downwards and the lower-density liquid flows upwards
Implementation Method 3
ensuring efficient separation and refining by maintaining optimal interaction between the liquids
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an apparatus for continuous treatment of two immiscible molten liquids having different densities. The apparatus comprises at least one open-ended helical reaction channel (3) arranged inside a substantially vertical housing (1), means for the continuous supply of the liquid with the higher density to the upper open end of said at least one reaction channel (3) and means for continuous supply of the liquid with the lower density to the lower open end of said at least one helical reaction channel (3), means for continuous removal of the liquid with the higher density at the lower open end of said helical reaction channel and means for removal of the liquid with the lower density from the upper open end of said helical reaction channel (3). The invention further relates to a method for continuous treatment of two immiscible molten liquids having different densities using the apparatus of the present invention.