Hopper Mixing Chamber for Uniform Heat Distribution
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Solution Overview
Problem
Existing hopper systems for the heat treatment of plastic granules face challenges in achieving uniform heat distribution and moisture control, leading to inefficiencies and potential material degradation.
Innovation Solution
The new hopper configuration incorporates an annular mixing chamber around the lower conical portion to mix and heat the process fluid before distribution, eliminating the vertical inlet duct and using diffuser supports to distribute the fluid, thereby enhancing heat recovery and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a vertical inlet duct is used to introduce process fluid into the hopper, then the fluid can be delivered to the material, but heat losses occur and temperature uniformity is poor
Solution Approach 1:
The patent removes the vertical inlet duct from the hopper interior and relocates it to the exterior. The diffuser is positioned at the bottom of the hopper with inlet openings that face upward, allowing process fluid to be introduced horizontally into the material bed rather than vertically from above. This extraction of the inlet duct from the traditional position eliminates the associated heat losses and improves temperature uniformity throughout the material.
Solution Approach 2:
The patent changes the dimensionality of fluid introduction from vertical (top-down) to horizontal (side-entry at bottom level). The diffuser is oriented with its axis horizontal and perpendicular to the hopper axis, with inlet openings facing upward. This dimensional change allows fluid to enter the material bed laterally rather than vertically, improving heat distribution and reducing thermal losses.
2Temperature
If process fluid is introduced at high flow rate to ensure adequate heating, then the heating effect is enhanced, but energy consumption increases
Solution Approach 1:
The patent employs a diffuser with multiple inlet openings distributed across its surface, allowing process fluid to be introduced at multiple localized points simultaneously. This distributed local introduction pattern ensures comprehensive coverage of the material bed, improving heating efficiency and reducing the total flow rate required compared to a single-point injection system.
Solution Approach 2:
The diffuser is pre-configured with multiple inlet openings positioned to optimize fluid distribution before the heating process begins. This preliminary arrangement of inlet openings ensures that when process fluid is introduced, it immediately achieves uniform distribution and effective heating, eliminating the need for high flow rates to compensate for poor distribution.
3Productivity
If the hopper is designed with a conical lower portion to facilitate material discharge, then material flow is improved, but heat distribution becomes non-uniform
Solution Approach 1:
The patent maintains the asymmetric conical shape of the lower hopper portion for effective material discharge while compensating for the heat distribution issue through the strategically positioned diffuser. The diffuser is located at the bottom of the conical section with inlet openings facing upward, creating a symmetric pattern of fluid introduction that counteracts the asymmetric geometry's thermal disadvantages and achieves uniform heat distribution throughout the material.
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 configuration reduces heat losses, improves temperature uniformity, and enhances the efficiency of the heat treatment process, allowing for the effective processing of polymers sensitive to thermal degradation while minimizing energy consumption.
Implementation Method 1
the process fluid is conveyed by process fluid generators, typically air or air/nitrogen mixtures, known in jargon as the 'dryer.' Once the fluid is introduced into the container where the plastic material is stored, it passes through the plastic mass, heating it and removing the moisture.
Implementation Method 2
an annular mixing chamber around the lower conical portion to mix and heat the process fluid before distribution
Implementation Method 3
a diffuser installed which consists of a hollow body on the wall of which there are holes that connect the interior of the diffuser with the interior of the hopper
Data Source
AI summary
A hopper for the heat treatment of a material contained therein includes a casing with an upper portion, into which the material to be treated is introduced, and a bottom part or lower portion, from which the material is discharged; a diffuser of a process fluid located inside the hopper; a system for introducing the process fluid inside the diffuser; a mixing chamber arranged to enclose at least the lower portion of the hopper externally; a system for introducing the process fluid inside the mixing chamber; and a system that fluidically connects the interior of the mixing chamber with the interior of the diffuser.