Pellet Crystallization Control with Buffer Diversion
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Solution Overview
Problem
The production of granules from plastic materials, particularly thermoplastic polyesters, is hindered by crystallization disruptions, leading to sticking issues and process interruptions, resulting in waste and discontinuous production.
Innovation Solution
A method and device that utilize a control device to monitor crystallization and divert granules to a buffer during disruptions, allowing for temporary storage and re-crystallization when the issue resolves, with temperature adjustments to prevent sticking, ensuring continuous and reliable production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If granules are separated from cooling fluid quickly and fed to crystallization unit, then production efficiency is improved, but crystallization disruptions cause sticking and process interruption
Solution Approach 1:
The patent applies preliminary action by cooling granules in a cooling fluid before separation, preparing them in advance for crystallization. This pre-cooling step ensures granules are ready for immediate crystallization when fed to the crystallization unit, maintaining continuous production flow and preventing sticking issues during the crystallization process.
2Loss of substance
If crystallization is interrupted due to disruption, then granules must be disposed of at great expense, but continuous production becomes difficult or impossible
Solution Approach 1:
The patent implements continuity of useful action by maintaining the cooling process continuously. Granules are cooled in the cooling fluid and then quickly separated and fed to the crystallization unit without interruption. This continuous flow prevents granule accumulation and sticking, ensuring that even if crystallization faces disruptions, the production process can continue smoothly without significant waste.
3Reliability
If granules are stored in buffer during crystallization disruption, then sticking is prevented, but additional equipment and control complexity are required
Solution Approach 1:
The patent uses a buffer as an intermediary component between the separation device and crystallization unit. When crystallization disruption occurs, granules are diverted to the buffer for temporary storage, preventing sticking. The buffer acts as a mediator that allows the system to handle disruptions without stopping production, and granules are fed back to crystallization when conditions improve. This adds minimal complexity while significantly improving reliability.
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 enables safe and reliable production of granules by preventing sticking and minimizing waste, allowing the process to continue seamlessly even during crystallization failures, ensuring efficient handling and processing.
Implementation Method 1
Cooling the granules in a cooling fluid
Implementation Method 2
Crystallization of the granules
Data Source
AI summary
The invention relates to a method and a device for producing and treating plastic pellets. According to said method, a melt of the plastic material is granulated to give pellets, the pellets are cooled in a cooling fluid, the pellets are separated from the cooling fluid and the pellets are crystallized. The device according to the invention is characterized by comprising a control unit which monitors the crystallization step and controls the method in such a manner that in case of a disturbance of crystallization the pellets are supplied to an intermediate storage after separation of the pellets from the cooling fluid and as soon as the disturbance is removed, the pellets temporarily stored in the intermediate storage are supplied to crystallization and are crystallized.