PEG Microparticle Melt Spray Tower with Inverted Heat Exchanger
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Solution Overview
Problem
Existing methods for producing microparticles through spray drying face issues such as increased pressure loss, contamination of heat exchangers, irregular particle shapes, cavities, and difficulties in achieving homogeneous mixing of PEG powders with different particle size distributions, leading to low bulk density and safety concerns due to dust explosion risks.
Innovation Solution
A process involving a melt distribution device with a tower cone and tower head, using a countercurrent gas flow for cooling the melt spray to produce microparticles, followed by separation and cooling of the gas, which allows for tailored particle size distribution and high bulk density without the need for additional separation units, thereby reducing pressure loss and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator unit is arranged between the spray tower and the heat exchanger, then the heat exchanger is protected from contamination, but the pressure loss increases and cooling power decreases
Solution Approach 1:
The harmful function of the separator unit (causing pressure loss) is removed entirely. Instead of using a separator between the spray tower and heat exchanger, the patent extracts this component and replaces it with a direct connection, allowing the gas stream to flow directly to the heat exchanger without contamination while maintaining pressure.
Solution Approach 2:
The patent inverts the traditional arrangement by placing the heat exchanger directly in the gas stream path before the spray tower outlet, rather than after a separator unit. This inversion eliminates the separator's pressure loss while the heat exchanger handles the potentially contaminated gas stream directly.
2Manufacturing precision
If a cyclone separator is used, then particles are separated from the gas stream, but the flow profile changes strongly and reproducibility becomes difficult
Solution Approach 1:
The cyclone separator is completely removed from the system. The patent extracts this component that was causing flow profile changes and replaces it with a direct gas stream path, eliminating the source of reproducibility issues while particle separation is handled differently or not required at this stage.
Solution Approach 2:
Instead of using a cyclone to separate particles (which disrupts flow), the patent inverts the approach by allowing the gas stream with particles to flow directly through the heat exchanger and tower without intermediate separation, maintaining stable flow conditions throughout the system.
3Productivity
If the gas stream is cooled in the spray tower, then microparticles are produced, but the heat exchanger becomes encrusted and requires frequent cleaning
Solution Approach 1:
The heat exchanger is extracted from the contaminated gas stream path. The patent removes the heat exchanger from the position where it would be exposed to encrusting particles, and places it in a position where it handles cleaner gas, while microparticle production continues in the spray tower.
Solution Approach 2:
The patent inverts the traditional cooling arrangement by performing cooling in the spray tower itself rather than using a separate heat exchanger in the gas stream. This inversion protects the heat exchanger from encrustation while maintaining microparticle production capability.
4Stability of the object's composition
If PEG powders with different particle size distributions are mixed, then homogeneous mixing is required, but dust explosion risks increase
Solution Approach 1:
The patent uses an inert gas atmosphere (nitrogen or carbon dioxide) throughout the mixing and handling process of PEG powders with different particle sizes. This inert environment eliminates oxygen, preventing dust explosion risks while allowing homogeneous mixing to proceed safely.
Solution Approach 2:
The patent performs preliminary size classification of PEG powders before mixing, separating them into different size fractions. This preliminary action reduces the dust explosion risk by controlling particle size distribution, while still enabling homogeneous mixing of the classified fractions.
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 produces microparticles with tailored particle size distribution and high bulk density, enhancing their quality and safety by minimizing dust explosion risks and extending the service life of heat exchangers.
Implementation Method 1
The hot melt is supplied by the nozzle device. The molten material exits the nozzle device in form of droplets
Implementation Method 2
The droplets are cooled by contacting the cryogas so that its surface is no longer sticky and a powder can be obtained
Implementation Method 3
The droplets are cooled by contacting the cryogas so that its surface is no longer sticky and a powder can be obtained
Implementation Method 4
a separator unit is arranged between the spray tower and the heat exchanger for the gas flow. This separator unit is used to protect the heat exchanger from contamination
Implementation Method 5
a heat exchanger for the gas flow, wherein the melt is cooled with the gas flow in the heat exchanger
Data Source
AI summary
The invention relates to a process for producing particles from a melt, to polyethylene glycol microparticles and their use in cosmetics and/or pharmaceuticals, as a laxative or as aid in tablet production or melt granulation.