Metal Hydroxide Particle Growth Control by Reaction Solution Circulation
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Solution Overview
Problem
Conventional batch-type and CSTR-type co-precipitation processes face challenges in controlling particle distribution and BET of multi-component metal hydroxides, leading to non-uniform particle sizes, reduced productivity, and increased process costs due to reactor saturation and discharge of intermediate reactants.
Innovation Solution
A novel preparation device with a combination of batch-type co-precipitation and reaction solution circulation, utilizing a raw material feeder, reactor, storage tank, and operation controller to control particle growth and distribution by circulating the reaction solution between the reactor and storage tank until target particle size is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If CSTR-based continuous co-precipitation method is used, then mixture density is excellent and energy density is high, but particle size and composition become non-uniform due to different residence times
Solution Approach 1:
The continuous CSTR process is segmented into multiple stages with different residence times. The method divides the precipitation process into initial nucleation stage, intermediate growth stage, and final maturation stage, allowing control over particle formation at each stage while maintaining continuous operation benefits
Solution Approach 2:
The method performs preliminary classification of particles by size before final discharge. A classification mechanism is introduced that separates newly formed small particles from grown larger particles, allowing selective discharge and maintaining uniform particle size distribution in the final product
2Manufacturing precision
If batch-type method is used to control particle size uniformly, then productivity decreases due to reactor saturation and discharge of intermediate reactants
Solution Approach 1:
The invention maintains continuous operation by introducing a particle classification and selective discharge mechanism. This allows the reactor to continuously receive raw materials and discharge products without saturation, eliminating the need to stop for intermediate reactant discharge while maintaining uniform particle size control
Solution Approach 2:
A feedback control system is implemented that monitors particle size distribution in real-time and adjusts discharge rates and raw material feed rates accordingly. This ensures particle size uniformity is maintained while optimizing productivity by preventing reactor saturation
3Manufacturing precision
If reaction time is excessively long to grow particles, then degree of completeness of secondary particles increases but amount of fines detached increases
Solution Approach 1:
The method performs preliminary classification to separate fines from secondary particles before the detachment issue occurs. By classifying particles during the growth process and removing fines early, the system prevents subsequent detachment losses while maintaining particle completeness
Solution Approach 2:
The system implements periodic classification and discharge cycles that interrupt continuous operation at optimal intervals. This allows complete particle growth to occur during reaction phases while periodically removing fines before they can detach from secondary particles
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 device enables precise control of particle distribution and BET, minimizing productivity losses and reducing the need for intermediate reactant discharge, resulting in high-quality multi-component metal hydroxides with uniform particle sizes and increased productivity.
Implementation Method 1
a reactor for reacting the raw materials fed from the raw material feeder to prepare a reaction solution and grow particles of the multi-component metal hydroxide contained in the reaction solution
Data Source
AI summary
Disclosed is a device for preparing multi-component metal hydroxide including a raw material feeder configured to feed raw materials including a metal raw material, a pH adjuster and a complexing agent, a reactor configured to react the raw materials fed from the raw material feeder to prepare a reaction solution and grow particles of multi-component metal hydroxide contained in the reaction solution, a storage tank configured to store the reaction solution transferred from the reactor, a first duct configured to transfer the raw materials from the raw material feeder to the reactor, a second duct configured to transfer the reaction solution from the reactor to the storage tank, a third duct configured to transfer the reaction solution from the storage tank to the reactor, and an operation controller configured to control operations of the reactor and the storage tank to circulate the reaction solution between the reactor and the storage tank until the particles of multi-component metal hydroxide grow to a target particle size.