Mixing Tank Liquid Level Control for Uniform Neutralization
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Solution Overview
Problem
Existing mixing processes for producing mixed solutions, such as those used in the production of polyacrylic acid-based water-absorbent resins, suffer from quality variations due to uneven stirring and temperature fluctuations, leading to inconsistent neutralization and ultimately affecting the quality of the final product.
Innovation Solution
A mixing apparatus and method that controls the supply and transportation of materials to maintain a consistent liquid level within a predetermined range, using a stirring device with specific blade configurations and controlled discharge and return mechanisms to ensure uniform mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If materials are continuously supplied and circulated in a neutralization system, then productivity is improved, but manufacturing precision deteriorates due to stirring unevenness and temperature variation
Solution Approach 1:
The mixing tank is divided into multiple zones with different stirring intensities. A first stirring device with high stirring capability is positioned at the material supply end to ensure thorough mixing of incoming materials, while a second stirring device with lower stirring capability is positioned at the discharge end. This segmentation allows continuous circulation for productivity while maintaining uniform neutralization through localized intensive mixing where materials are introduced.
2Manufacturing precision
If stirring intensity is increased to improve mixing uniformity, then manufacturing precision is improved, but device complexity and energy consumption increase
Solution Approach 1:
Different stirring intensities are applied to different locations within the mixing tank based on local requirements. The first stirring device at the material supply end operates at high intensity to handle the incoming materials that require thorough mixing, while the second stirring device at the discharge end operates at lower intensity since the materials have already been pre-mixed. This local differentiation achieves uniform neutralization without requiring the entire system to operate at high complexity and energy consumption levels.
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 apparatus effectively suppresses quality variations in the mixed solution by ensuring uniform stirring and temperature control, resulting in a more homogeneous product with reduced precipitate formation and improved consistency.
Implementation Method 1
The stirring device stirs a mixed solution of the two or more kinds of materials inside the mixing tank
Implementation Method 2
by adjusting the temperature of the mixed solution by the heat exchanger 6, the temperature of the mixed solution in the circulation loop can be maintained within a desired range
Implementation Method 3
The transportation line is connected to the mixing tank and transports the mixed solution inside the mixing tank to an outside of the mixing tank
Implementation Method 4
This produces a mixed solution containing an acrylate produced by a neutralization reaction between acrylic acid and a basic substance
Data Source
AI summary
A mixing apparatus includes a material supply line, a mixing tank, a stirring device, and a transportation line. The material supply line supplies two or more kinds of materials including a liquid. The mixing tank accommodates the two or more kinds of materials that have been supplied. The stirring device stirs a mixed solution of the two or more kinds of materials inside the mixing tank. The transportation line transports the mixed solution inside the mixing tank to an outside of the mixing tank. The mixing apparatus maintains a liquid level height of the mixed solution inside the mixing tank at a level falling within a predetermined range by controlling at least one of a supply amount of the two or more kinds of materials to be supplied into the mixing tank and a transportation amount of the mixed solution to be transported to the outside of the mixing tank.