Modular Explosive Emulsion Facility with Phase Separation
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Solution Overview
Problem
Existing modular installations for manufacturing explosive emulsion precursors are limited by small production capacity, safety risks due to close proximity of oxidizer and fuel phases, complex and costly setup, and difficulties in transportation and assembly.
Innovation Solution
A modular installation with physically separated containers for aqueous and oily phase preparation, optimized for easy transport and assembly, featuring a configuration that allows for maximum production yield and safety, including a third container for emulsion preparation with a shearing device to increase viscosity, and optional equipment like cooling towers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If containers are placed close together to reduce footprint, then space efficiency is improved, but safety is worsened due to proximity of oxidizer and fuel phases
Solution Approach 1:
A non-combustible partition wall is introduced as an intermediary element between the first container (oxidizer) and second container (fuel). This partition acts as a safety barrier that prevents direct contact between hazardous phases while allowing the containers to be positioned close together for space efficiency. The partition wall mediates between the conflicting requirements of compact footprint and safety separation.
2Productivity
If production capacity is increased by adding equipment, then productivity is improved, but device complexity is worsened
Solution Approach 1:
The installation is segmented into modular containers, each dedicated to a specific function (aqueous phase preparation, oily phase preparation, emulsion preparation). This segmentation allows independent optimization of each module and facilitates scalability - production capacity can be increased by adding more modules without complicating the existing ones. Each container can be independently operated, maintained, and scaled.
Solution Approach 2:
The modular container design provides universality - each container can serve multiple purposes (processing, storage, transfer) and can be replicated to increase capacity. The standardized container format allows optional equipment to be added to any container, making the system adaptable to different production requirements without redesigning the entire installation.
3Adaptability or versatility
If containers are assembled on site to optimize configuration, then adaptability is improved, but loss of time is worsened due to assembly requirements
Solution Approach 1:
Equipment is pre-installed within standardized containers at the factory before transport to the site. This preliminary action eliminates the need for complex on-site assembly - containers are simply positioned and connected via pre-fabricated interfaces. The containers arrive ready-to-operate, significantly reducing installation time while maintaining configuration flexibility through the modular design.
Solution Approach 2:
The system incorporates dynamic elements such as movable partitions within containers and adjustable positioning of containers on the support structure. These dynamic features allow the installation to be adapted to different site conditions after assembly, providing configurability without requiring disassembly or complex installation procedures.
4Device complexity
If large containers are used to reduce number of components, then device complexity is improved, but ease of manufacture is worsened due to transport difficulties
Solution Approach 1:
Smaller functional units are nested within standardized container structures. Each container acts as a housing that contains processing equipment, tanks, and auxiliary systems in a compact, transportable format. This nesting approach maintains functional integration while conforming to standard transport dimensions, avoiding the need for custom large-scale container fabrication.
Solution Approach 2:
The container dimensions are optimized to match standard transport parameters (ISO container sizes) rather than being designed solely for functional capacity. This parameter change allows the same container design to be manufactured and transported using conventional infrastructure, while still providing sufficient volume for the required equipment through efficient space utilization and vertical arrangement.
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
Enables efficient, safe, and scalable production of explosive emulsion precursors with enhanced safety by separating hazardous phases, facilitating easy transport and assembly, and achieving high production capacity.
Implementation Method 1
the water is heated to a temperature of at least 65° C. (degrees Celsius)... the oily phase is heated to approximately 40-90°C, preferably 50-70°C
Implementation Method 2
dissolution tanks for the preparation of the aqueous phase as well as a boiler separated by a partition. The other container includes the oil phase and invert emulsion preparation tanks as well as a separate electrical installation.
Implementation Method 3
the viscosity of the premix is increased using a shearing device to obtain an emulsion of higher viscosity
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present invention relates to a modular installation (1) enabling the implementation of a process for manufacturing an explosive emulsion precursor comprising at least a first container (100) dedicated to the preparation of an aqueous phase comprising a first dissolution tank (110), comprising a first parallelepiped tank (110) with at least 5 walls arranged parallel and applied against respectively at least 5 walls of said first container, said first means of heating said first tank (110) comprising a first tubular heat exchanger (120), said first tubular heat exchanger being made up of a network of heat transfer fluid pipes arranged longitudinally and transversely, continuously, at different height levels, capable of heating the liquid contained in said first parallelepiped tank.