Orthosilicate Solution Production Using Low-Temperature Si-NaOH Reaction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of silicate solutions, particularly sodium silicates, is costly and time-intensive, involving high-temperature furnaces and complex chemical reactions, and their molecular structure and properties are not fully understood, limiting their industrial applications.
Innovation Solution
A method for producing orthosilicate solutions using an exothermic reaction between Si metal and NaOH in a controlled vessel, maintaining the SiO2/Na2O ratio below 1, combined with trichloro-s-triazinetrione to create a disinfecting solution effective against mold and mildew.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional high-temperature furnace methods are used to produce silicate solutions, then the production process is established and reliable, but the production cost increases and the process time extends
Solution Approach 1:
The patent changes the temperature parameter from high-temperature (1300-3500°F) to low-temperature (below 90°C) processing. This parameter change enables the use of simple reaction vessels instead of complex furnaces, dramatically improving productivity while maintaining product quality through controlled stoichiometry and pH
Solution Approach 2:
The patent replaces the mechanical/thermal system of high-temperature furnaces with a chemical reaction system using silicon metal and sodium hydroxide. This substitution eliminates the need for complex furnace equipment and high energy input, reducing both cost and time while improving production efficiency
2Ease of manufacture
If high-temperature furnace processing is used, then silicate solutions can be produced, but the manufacturing cost increases
Solution Approach 1:
The patent uses inexpensive, readily available materials: silicon metal (a byproduct of other industries) and sodium hydroxide. These cheap reactants replace expensive furnace operations and specialized high-temperature equipment, significantly reducing manufacturing costs while maintaining ease of manufacture through simple mixing processes
Solution Approach 2:
The patent introduces water as an intermediary medium to dissolve the reaction products and control the reaction environment. This simple intermediary enables the reaction to proceed at low temperatures without requiring complex furnace systems, reducing manufacturing costs while maintaining ease of manufacture
3Reliability
If complex silicate molecular structures are used, then the solutions have desired industrial properties, but the viscosity control becomes difficult
Solution Approach 1:
The patent uses pH as a feedback parameter to control the silicate molecular structure and viscosity. By monitoring and adjusting pH during the reaction, the process maintains optimal conditions for forming the desired molecular configuration, achieving both reliable industrial performance and precise viscosity control through this feedback mechanism
Solution Approach 2:
The patent changes the SiO2/Na2O ratio parameter to optimize both molecular structure and viscosity. By controlling this compositional parameter along with pH, the process achieves the desired balance between industrial performance and manufacturability, resolving the contradiction between complex structure requirements and viscosity control precision
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 method produces high-quality orthosilicate solutions that can be used to form protective barriers, kill mold and mildew, and enhance the properties of cement and wood, while also being effective in wastewater treatment and biodiesel production.
Implementation Method 1
an exothermic reaction of Si metal and NaOH
Implementation Method 2
combining orthosilicate solution... with the intent of creating a disinfecting solution that can provide a protective barrier
Data Source
AI summary
An aqueous orthosilicate solution comprising m[SiO44−]+nX1+ in an aqueous solution wherein X is an alkali metal cation selected from the group consisting of sodium or potassium; and wherein n is four to five times greater than m. The aqueous orthosilicate solution is made by adding silicon particles of less than about 3 cm and water to a pressure vessel followed by adding a molar excess of alkali caustic to the pressure vessel containing the silicon particles. The temperature in the vessel is maintained not to exceed about 190° F. while an aqueous orthosilicate solution is formed. Upon cooling the formed aqueous orthosilicate solution is recovery. Aluminum or CuO can be added during the initial heating.