Chemical Milling Bath Regeneration by Aluminosilicate Precipitation
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Solution Overview
Problem
The chemical milling of aluminum semi-finished products faces challenges with the high cost and environmental impact of spent bath disposal due to high aluminum concentrations, which require frequent restoration and disposal, leading to inefficiencies and increased operational costs.
Innovation Solution
A regeneration process is introduced that precipitates aluminosilicates by adding a source of silicon to the spent solution, forming zeolites, which reduces aluminum concentration and allows the bath to be reused, thereby minimizing disposal and restoring sodium hydroxide levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If chemical milling solutions are used repeatedly, then operational cost is reduced, but solution effectiveness deteriorates due to contaminant buildup
Solution Approach 1:
The patent changes the chemical parameters of the milling solution by adjusting pH levels, adding specific chemicals, and controlling temperature to restore effectiveness. The system monitors solution chemistry and makes real-time parameter adjustments to maintain etching capability while extending solution life.
Solution Approach 2:
The patent recovers valuable components from spent milling solution through filtration, chemical treatment, and concentration processes. Contaminants are removed and useful chemicals are recovered and reused, reducing waste disposal costs and operational expenses while maintaining solution effectiveness.
2Duration of action of stationary object
If filtration systems are added to remove contaminants, then solution life is extended, but system complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated filtration and treatment units that perform particle removal, chemical regeneration, and fluid circulation in a single compact system. This merging reduces the number of separate components and simplifies system operation while effectively extending solution life.
Solution Approach 2:
The system incorporates automatic filtration and regeneration capabilities that operate without continuous manual intervention. Sensors monitor solution quality and trigger filtration cycles automatically, reducing operational complexity while maintaining extended solution life through consistent contaminant removal.
3Manufacturing precision
If solution volume is increased to maintain concentration, then etching precision is maintained, but material waste increases
Solution Approach 1:
Instead of increasing volume to maintain concentration, the system changes other parameters such as temperature, pH, and additive concentrations to preserve etching precision. This allows maintaining effective etching performance with reduced solution volume, thereby reducing material waste.
Solution Approach 2:
The system recovers and concentrates useful chemicals from large volumes of spent solution, extracting valuable etchants and reagents for reuse. This recovery process reduces the need to dispose of large volumes of solution while maintaining etching precision through controlled replenishment of active ingredients.
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 effectively reduces aluminum concentration, enabling the reuse of the milling bath and produces valuable zeolites, thus reducing disposal costs and environmental impact while maintaining process efficiency.
Implementation Method 1
a centrifugal separation system which receives the chemical milling solution and separates suspended particles from the chemical milling solution
Implementation Method 2
an ion exchange system which receives the chemical milling solution and removes ionic contaminants from the chemical milling solution by ion exchange
Implementation Method 3
an evaporation system which receives the chemical milling solution and concentrates the chemical milling solution by evaporation of solvent
Data Source
Figure 1
AI summary
A process for regenerating chemical milling solutions, comprising the steps of introducing a reagent containing silicon into a solution in such a way as to establish a molar ratio of Si/ Al equal to 1 in the solution, and letting the silicon and aluminum in solution react, up until the formation of a phase containing aluminosilicates.