Lance-Based Flushing Medium Distribution in Polymer Recycling
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Solution Overview
Problem
Plastics recycling applications face issues with residual moisture, density fluctuations, and volatile substances affecting extruder performance and product quality, with existing solutions failing to completely remove impurities, leading to reduced productivity and uneven melting.
Innovation Solution
A method and device utilizing plate-shaped lances with upward and downward surfaces to introduce a flushing medium into the processing container, allowing for efficient and complete removal of impurities by ensuring the medium flows evenly throughout the material, with the medium being introduced below the material level and distributed between mixing tools to enhance cleaning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gas is introduced via bottom or side walls, then impurities are removed, but the flushing medium does not distribute evenly throughout the material
Solution Approach 1:
The gas introduction system is segmented into multiple nozzles distributed across the mixing tool surfaces, allowing the flushing medium to be introduced at multiple locations simultaneously. This segmentation enables uniform distribution throughout the material while maintaining a simple overall structure.
Solution Approach 2:
The gas introduction is extended from a single-point or single-plane introduction (bottom or side wall) to a multi-dimensional distribution system where nozzles are arranged on both upper and lower surfaces of mixing tools. This dimensional expansion ensures comprehensive coverage and uniform distribution of the flushing medium throughout the material volume.
2Object-affected harmful factors
If compressed air is introduced via spray nozzles, then impurities are removed, but the device structure becomes more complex
Solution Approach 1:
The mixing tools serve multiple functions: they perform the primary mixing operation and simultaneously act as gas distribution manifolds. The nozzles are integrated into the mixing tool structure, allowing the same component to fulfill both mixing and flushing medium introduction functions, thereby avoiding additional complex gas introduction hardware.
Solution Approach 2:
The gas introduction system is merged with the existing mixing tool structure. Instead of being a separate complex system, the nozzles are integrated directly into the mixing tools, combining the flushing medium introduction function with the mixing function in a single unified structure.
3Device complexity
If mixing tools are used to introduce flushing medium, then dosing is simplified, but the flushing medium cannot reach internal areas of the receptacle
Solution Approach 1:
The gas introduction capability is segmented across multiple mixing tools positioned at different locations and heights within the receptacle. Each mixing tool introduces flushing medium to its local area, and the combination of multiple segmented introduction points achieves comprehensive coverage of the entire receptacle volume, including internal areas.
Solution Approach 2:
The mixing tools are positioned to take advantage of the dynamic movement and circulation of material within the receptacle. As material moves and circulates, the flushing medium introduced at various points by the mixing tools is distributed throughout the entire volume, including internal areas that would be difficult to reach with static introduction points.
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 solution effectively removes impurities, improves processing quality, and reduces energy consumption by ensuring thorough cleaning with minimal flushing medium usage, addressing the limitations of previous technologies in handling high-moisture plastics and internal moisture issues.
Implementation Method 1
The impurities can adhere to the outside of the surfaces of the material to be processed, as is the case in particular with washing water, surface coatings, etc., and then evaporate there
Implementation Method 2
The impurities to be removed can therefore also be sublimating solids or dust
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for preparing and cleaning a polymer material, wherein the fragmented and non-melted polymer material is moved and heated in a container (1) by at least one mixing and/or comminuting tool (12, 21), and wherein in order to remove undesired interfering substances that impair the preparation or further processing of the material, a rinsing medium is introduced into the container (1) in an area below the level of the material in the container (1) during operation or below the material level of the mixing vortex that forms, wherein the rinsing medium is conducted at least through a partial area of the material to form a forced flow and wherein the rinsing medium then enriched or saturated with interfering substances is subsequently discharged from the container (1) in an area above the level of the material in the container (1) during operation or above the material level of the mixing vortex. The invention is characterized in that the rinsing medium is introduced into the container (1) by means of at least one feeding means (50), which is arranged on at least one lance (70) that protrudes from a side wall (2) of the container (1) into the interior of the container (1).