On-Site PCC Reactor for Paper Mill Filler Production

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Solution Overview

Problem

The traditional method of producing Precipitated Calcium Carbonate (PCC) for use as a filler in paper production involves separate facilities, leading to high transportation costs, the need for retention agents, and increased water consumption. Additionally, the production process can result in uneven size distribution of PCC crystals and the formation of deposits.

Innovation Solution

A method and reactor design that allows for the direct production of PCC within the paper mill, where carbon dioxide and lime milk are injected into a liquid flow in a reactor equipped with a mixer, creating a suitable size distribution of calcium carbonate crystals and preventing deposits. The reactor can be easily integrated into existing paper mill equipment without significant interruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PCC is produced in separate facilities and transported to paper mills, then production capacity is sufficient, but transportation costs increase and retention agents are required

Engineering Contradiction:

ImprovePCC production capacityVSAvoidtransportation costs

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent merges the PCC production facility with the paper mill by integrating the reactor system directly into the paper production line. This allows PCC to be produced on-site and immediately incorporated into the fiber suspension, eliminating the need for separate facilities and transportation infrastructure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The paper mill produces its own PCC requirements through the integrated reactor system, serving its own filler needs without external supply. The system uses readily available materials (lime milk and carbon dioxide) that are already present or easily generated within the paper mill environment.

Inventive Principle:

Principle #25Self-service

2Productivity

If PCC is produced in separate facilities, then production scale is adequate, but the need for retention agents increases

Engineering Contradiction:

ImprovePCC production capacityVSAvoidretention agent requirement

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The PCC crystals are produced and incorporated into the fiber suspension before the papermaking process begins. This preliminary incorporation ensures proper adhesion without requiring additional retention agents during subsequent processing stages.

Inventive Principle:

Principle #10Preliminary action

3Quantity of substance

If PCC is produced using traditional methods, then calcium carbonate is obtained, but uneven crystal size distribution and deposits form

Engineering Contradiction:

Improvecalcium carbonate productionVSAvoidcrystal size distribution uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The reactor system uses dynamic mixing conditions with adjustable impeller speeds and flow rates to control crystal growth. By optimizing the mixing dynamics, the system achieves uniform crystal size distribution and prevents deposit formation on reactor walls.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system controls crystal formation by adjusting key parameters including pH level, temperature, mixing speed, and residence time. These parameter optimizations ensure consistent crystal size distribution and prevent unwanted deposits.

Inventive Principle:

Principle #35Parameter changes

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

This approach reduces transportation costs, minimizes the need for retention agents, and improves the adherence of PCC crystals to fibers, while also preventing the formation of oversized crystals and deposits, thus enhancing the efficiency and cost-effectiveness of PCC production in paper mills.

Implementation Method 1

carbon dioxide and lime milk are injected into a liquid flow in a reactor equipped with a mixer, creating a suitable size distribution of calcium carbonate crystals

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

carbon dioxide and lime milk are injected into a liquid flow in a reactor equipped with a mixer

Methodology Applied

Scientific EffectMixing: Stirring

Implementation Method 3

the resulting calcium carbonate precipitates from the solution into crystals

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Data Source

PatentUS20250066215A1Method and reactor for producing produce calcium carbonate

Publication Date: 2025.02.27 WETEND TECH

AI summary

A method and a reactor to crystalize calcium carbonate and to form crystals in a liquid flow (F) with the concentration of 2.5% to 5% inside or on the surfaces of a fiber dispersion containing solid matter. The method includes feeding carbon dioxide (CO2) and lime milk (LM) (Ca(OH)2) into the liquid flow and reacting the CO2 with the Ca(OH)2 wherein the carbon dioxide (CO2) and/or lime milk (LM) is injected with a mixer crosswise into the liquid flow (F) and the injection is performed with a feed tube (2) to cause a dwell time of the crystallizing reaction of 0.5 to 10 seconds before a nozzle (20) of the reactor (1), after which the liquid flow (F) is mixed with the liquid or fiber suspension in container (4)