Inline Mixing Device with Pulsed Powder Dosing Control
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Solution Overview
Problem
Existing inline mixing processes face challenges in achieving uniform distribution and dissolution of powdery substances in liquids, leading to inhomogeneities, agglomeration, and increased energy consumption due to discontinuous supply methods, which can result in microbiological growth and product fouling.
Innovation Solution
A method controlling the introduction of powdery substances into liquids using a continuous inline mixing process with discontinuous pulsed dosing, where the duration of dosing pulses and intervals are adjusted based on real-time power consumption to maintain a constant dry matter concentration and optimize energy use, ensuring even distribution and dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If discontinuous supply of powdery substance is used, then uniform distribution is improved, but energy consumption increases due to increased stirring power
Solution Approach 1:
The patent applies periodic action by implementing discontinuous pulsed dosing of the powdery substance instead of continuous supply. The dosing occurs in periodic pulses with specific duration and interval ratios, creating periodic mixing demands that reduce overall energy consumption while maintaining uniform distribution through controlled intermittent feeding.
Solution Approach 2:
The patent implements dynamics by making the dosing parameters (pulse duration and interval) adjustable and adaptable. The system dynamically adjusts the dosing regime based on mixing requirements, allowing optimization between uniform distribution and energy consumption by varying the pulse characteristics according to process conditions.
2Manufacturing precision
If discontinuous supply of powdery substance is used, then uniform distribution is improved, but risk of agglomeration and microbiological growth increases
Solution Approach 1:
The periodic pulsed dosing creates regular intervals where the mixing system can fully incorporate and distribute the powdery substance before the next pulse. This periodic action prevents agglomeration by ensuring complete mixing between doses and reduces microbiological growth risks by avoiding prolonged stagnant periods where powder might settle.
Solution Approach 2:
The patent employs feedback control by monitoring mixing effectiveness and adjusting subsequent dosing pulses accordingly. The system uses information from previous dosing cycles to optimize pulse timing and duration, ensuring that uniform distribution is achieved while preventing conditions that lead to agglomeration or contamination.
3Manufacturing precision
If continuous stirring and mixing is applied, then homogenization is improved, but energy consumption increases
Solution Approach 1:
The patent replaces continuous stirring with periodic mixing action that occurs in response to pulsed dosing. The mixer operates intensively during and immediately after each dosing pulse to achieve homogenization, then rests during the interval between pulses. This periodic action maintains homogenization quality while dramatically reducing overall energy consumption compared to continuous operation.
Solution Approach 2:
The patent ensures continuity of useful action by designing the pulsed dosing and mixing sequence so that mixing activity is concentrated during the most critical periods when powder is being introduced and immediately afterward. This concentrates the useful mixing action when it is most needed for homogenization, while minimizing energy-wasting continuous operation during periods when uniform distribution is already achieved.
Data Source
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AI summary
The invention relates to a method for controlling the introduction of a pulverulent material (P) into a liquid (F) consisting of at least one component for an inline mixing method according to the preamble of claim 1 or the preamble of sub-claim 2 and to a mixing device for carrying out the method, said method and mixing device ensuring that the disadvantages of the prior art which have become known are prevented. This is achieved by a first method in that, among others, • the pulverulent material (P) is supplied in a discontinuous manner in pulses by means of a chronological sequence of metering pulses (i), each of which is characterized by a mass flow of the pulverulent material (ṁP), a duration of the metering pulse (Δt1), and a time interval between adjacent metering pulses (Δt2), • a time-dependent power consumption (l(t)) is ascertained which is proportional to a stirring and/or shearing and homogenizing power required for a temporarily available mixing product (M*), and • at the end of the time interval between adjacent metering pulses (Δt2) and in the event of a deviation of the time-dependent power consumption (l(t)) from the reference power consumption (lo) by more than a specified tolerance, either upwards or downwards, the duration of the metering pulse (Δt1) for the following metering pulse (i) is shortened in the first case and lengthened in the second case while maintaining the ratio (V = Δt1/Δt2).