Laminar Flow Spray Drying for Detergent Mixing Control
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Solution Overview
Problem
In the spray-drying process for laundry detergent production, incompatible detergent ingredients often mix excessively during the prolonged residence time in crutcher mixers, leading to chemical variability and performance issues due to product segregation, necessitating a method to minimize their contact until late in the process.
Innovation Solution
Introducing incompatible detergent ingredients into the aqueous slurry in laminar flow conditions, controlling flow rates to maintain laminar flow and minimize turbulence, thereby reducing axial mixing and ensuring minimal contact until the spray nozzle, where they are mixed and spray-dried together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If detergent ingredients are mixed together in a crutcher mixer to form an aqueous detergent slurry, then the manufacturing process can proceed efficiently, but incompatible detergent ingredients undergo excessive mixing and prolonged contact time leading to chemical variability and performance issues
Solution Approach 1:
The mixing process is segmented into two distinct stages: (1) initial mixing of compatible ingredients in the crutcher mixer to form the aqueous detergent slurry, and (2) separate introduction of incompatible detergent ingredients through a side stream injection system. This segmentation prevents excessive contact time between incompatible ingredients while maintaining manufacturing efficiency.
Solution Approach 2:
The incompatible detergent ingredients are prepared separately in advance and held in a separate line before being introduced into the main slurry stream at a controlled point. This preliminary action allows the main slurry to be formed efficiently while the incompatible ingredients are ready for controlled introduction, minimizing their contact time.
2Stability of the object's composition
If incompatible detergent ingredients are introduced at a later stage in the spray-drying process, then mixing and contact time between incompatible ingredients is minimized, but further mixing control is needed to prevent axial mixing in the pipe
Solution Approach 1:
The flow regime parameter is changed from turbulent to laminar flow in the section of pipe where incompatible ingredients are introduced. By controlling the Reynolds number to be less than 2300, axial mixing is minimized while still allowing the ingredients to be transported to the spray nozzle. This parameter change provides precise mixing control.
Solution Approach 2:
A separate side stream line acts as an intermediary channel for introducing incompatible detergent ingredients into the main slurry stream. This intermediary system allows controlled injection at a specific location while maintaining laminar flow conditions, preventing excessive mixing before the spray nozzle.
3Productivity
If turbulent flow is used in the pipe, then mixing occurs more rapidly, but excessive axial mixing and turbulence prevent minimal contact between incompatible detergent ingredients
Solution Approach 1:
The flow regime parameter (Reynolds number) is changed from turbulent (Re > 4000) to laminar (Re < 2300) in the pipe section where incompatible ingredients are introduced. This parameter change reduces axial mixing and turbulence while maintaining adequate mixing speed through the controlled laminar flow environment.
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 minimizes the mixing of incompatible detergent ingredients, preventing chemical variability and ensuring consistent performance by maintaining laminar flow and controlled mixing, resulting in a stable and consistent spray-dried powder.
Implementation Method 1
The Inventors carefully ensure that the detergent ingredient is contacted to an aqueous detergent slurry that is in laminar flow, and then carefully control the flow rates of both the aqueous detergent slurry and the detergent ingredient to ensure that the resultant mixture is also in laminar flow. In this manner, turbulence of the fluid in the pipe is avoided and the degree of axial mixing that may occur is substantially minimized.
Data Source
AI summary
The present invention relates to a process for preparing a spray-dried powder comprising: (i) detersive surfactant; and (ii) other detergent ingredients; wherein the process comprises the steps of: (a) forming an aqueous detergent slurry in a mixer; (b) transferring the aqueous detergent slurry from the mixer in a pipe leading through at least one pump to a spray nozzle; (c) contacting a detergent ingredient to the aqueous detergent slurry in the pipe after the mixer and before the spray nozzle to form a mixture; (d) spraying the mixture through the spray nozzle into a spray-drying tower; and (e) spray-drying the mixture to form a spray-dried powder, wherein in step (c) the aqueous detergent slurry and the resultant mixture are in laminar flow, and wherein in step (c) the ratio of (i) the flow rate of the aqueous detergent slurry in kgmin-1 to (ii) the flow rate of the detergent ingredient in kgmin-1 is in the range of from 1 to 70.