Melt Extrusion of Alkali Metal Bicarbonate Paste
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Solution Overview
Problem
Current methods for producing alkali metal bicarbonate particles are costly and time-consuming, requiring multiple steps such as crystallization, grinding, and sieving, which are not suitable for producing specific shapes or adjusting properties like bulk density, porosity, and CO2 release temperatures effectively.
Innovation Solution
A process involving the preparation of a paste-like composition by mixing alkali metal salts with functionalizing agents and melting them during extrusion, allowing for control over shape, size, porosity, and bulk density, and achieving enhanced CO2 release properties and dissolution times through melt-extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray-drying method is used to produce alkali metal bicarbonate particles, then bulk density can be controlled, but multiple additional steps (crystallization, grinding, sieving) are required to achieve desired particle shape and properties
Solution Approach 1:
The invention combines multiple unit operations (crystallization, shaping, drying) into a single extrusion step. The paste composition is extruded through a die to form particles with desired shape directly, eliminating the need for separate crystallization, grinding, and sieving steps that were required in conventional spray-drying methods.
Solution Approach 2:
The invention prepares a paste composition with specific rheological properties before extrusion, incorporating binding agents and control agents in advance. This preliminary formulation allows the particles to maintain desired shape and properties during extrusion and drying, eliminating the need for subsequent processing steps.
2Adaptability or versatility
If conventional crystallization and drying processes are used, then alkali metal bicarbonate particles can be produced, but dissolution time and CO2 release temperature cannot be effectively adjusted
Solution Approach 1:
The invention changes physical and chemical parameters of the paste composition, including viscosity, composition ratios, and extrusion temperature, to control particle properties. By adjusting these parameters during extrusion, the dissolution time and CO2 release temperature can be effectively tailored without compromising production efficiency.
Solution Approach 2:
The invention introduces binding agents and control agents as intermediary substances that mediate between the alkali metal bicarbonate and the final particle properties. These intermediaries allow precise control over dissolution behavior and CO2 release characteristics while maintaining high production rates.
3Shape
If multiple processing steps are employed to modify particle shape, then specific shapes can be achieved, but the process becomes expensive and time-consuming
Solution Approach 1:
The invention merges particle formation, shaping, and drying into a single integrated extrusion process. The paste is extruded through a shaped die that directly forms the desired particle geometry, and the particles are then dried in one continuous operation, eliminating multiple separate processing steps.
Solution Approach 2:
The invention utilizes phase transition of the binding agent during extrusion and drying to fix the particle shape. The paste transitions from a plastic state during extrusion to a solidified shape after drying, allowing complex geometries to be formed without subsequent machining or shaping operations.
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 process enables the production of alkali metal bicarbonate formulations with improved dissolution times and CO2 release properties, allowing for the adjustment of chemical reactivity and specific particle shapes, suitable for various industrial applications.
Implementation Method 1
melting a functionalizing agent to a temperature above the melting point of the functionalizing agent to obtain a melted functionalizing agent
Implementation Method 2
by (melt-)extrusion of a paste-like composition obtained by admixing the alkali metal salt with a functionalizing agent
Data Source
AI summary
The present invention relates to a process for preparing a formulation comprising an alkali metal salt selected from the group consisting of alkali metal bicarbonate salts, alkali metal carbonate salts, alkali metal sesquicarbonate salts and combinations thereof, wherein said process comprises the step of extruding a paste-like composition comprising a functionalizing agent and the metal salt. The invention furthermore relates to a formulation obtainable from said process and to the use of this formulation in various applications such as in plastic foaming or in food and feed leavening compositions.