High-Pressure Granulation of High-Temperature Plastics
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Solution Overview
Problem
Existing methods for granulating plastics with high softening points above 120°C struggle to produce granules that are largely free of vacuoles and convex at every point, as they often require low temperatures and pressures, which are inadequate for such materials.
Innovation Solution
A method involving a process chamber filled with a process fluid at temperatures over 120°C and pressures over 2 bar, where the mixture of process fluid and granules is cooled and then separated under pressure, using a separating device and pressure lock to suppress vacuole formation and recover thermal energy through a heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If low temperature and pressure are used for granulation, then energy consumption is reduced and equipment requirements are simplified, but plastics with high softening points cannot be properly granulated and vacuoles form in the granules
Solution Approach 1:
The patent applies parameter changes by raising both temperature and pressure simultaneously to enable granulation of high softening point plastics. The process uses temperatures above 120°C and pressures above 2 bar, which allows the plastic to remain in a molten state during granulation, preventing vacuole formation while achieving proper granule quality.
Solution Approach 2:
The process chamber serves multiple functions: it acts as both a heating chamber and a pressurization chamber, and also functions as the granulation chamber. This multi-functionality allows simultaneous temperature and pressure control to address the contradiction between processing high softening point plastics and maintaining granule quality.
2Manufacturing precision
If high temperature and pressure are used for granulation, then plastics with high softening points can be granulated without vacuoles, but energy consumption increases and equipment complexity increases
Solution Approach 1:
The process chamber is designed to perform multiple functions simultaneously: heating, pressurizing, and granulation. This eliminates the need for separate heating chambers, pressurization systems, and granulation chambers, thereby reducing overall equipment complexity despite the high temperature and pressure requirements.
Solution Approach 2:
The patent merges the heating system, pressurization system, and granulation mechanism into a single integrated process chamber. The process fluid serves both as a heating medium and a pressurizing medium, while also facilitating the granulation process, thus combining multiple functions into one system.
3Manufacturing precision
If high temperature and pressure are used for granulation, then plastics with high softening points can be granulated without vacuoles, but energy consumption increases
Solution Approach 1:
The patent uses parameter changes by maintaining both high temperature and high pressure simultaneously during granulation. This dual parameter approach enables processing of high softening point plastics above 120°C while preventing vacuole formation, achieving the required granule quality despite increased energy consumption.
Solution Approach 2:
The process fluid serves multiple energy-related functions: it acts as a heating medium, a pressurizing medium, and a cooling medium during separation. This multi-functionality optimizes energy utilization throughout the process, reducing overall energy consumption despite the high temperature and pressure requirements.
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 effectively granulates plastics with high softening points while minimizing vacuole formation and allows for the recovery of thermal energy, producing granules suitable for further processing.
Implementation Method 1
due to the application of a relatively high pressure of > 2 bar, the formation of vacuoles can be practically completely suppressed
Implementation Method 2
the mixture of process fluid, in particular water, and granules is cooled while the pressure is maintained
Implementation Method 3
it is possible to recover the thermal energy inherent in the process fluid in particular by means of a heat exchanger
Data Source
Figure 1~2
AI summary
The invention relates to a method for granulating plastic having a high softening temperature, particularly over 120°C, on a perforated plate for generating strands of fluid plastic and a subsequent process chamber containing a process fluid and having a fragmentation device from which a mixture of process fluid and granulate is extracted while cooling the granulate in a cooling section. The process chamber is filled with a process fluid, particularly water, at a temperature of >120°C and a pressure of >2 bar, and the mixture of process fluid and granulate is fed into a separating device while maintaining the pressure while transiting the cooling section, and the granulate is separated from the process fluid and discharged after being fed through a pressure gate for dropping to the ambient pressure.