Plant-Based Sheet Slurry Moisture Control for Easier Drying
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Solution Overview
Problem
The production of plant-based sheets is hindered by the difficulty in mixing plant-based materials with sheet-forming agents due to varying properties between batches, leading to energy-intensive and time-consuming drying processes, and machinery wear from abrasive powders.
Innovation Solution
A method involving determining the moisture content of plant-based powder materials, adjusting the water content to a predestined target range (55-85% by weight) using detectors and flow rate controllers, and employing a controlled drying process to form a uniform slurry, reducing handling time and machinery wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plant-based materials are mixed with sheet-forming agents to produce slurry, then sheets can be formed, but the mixing process becomes very difficult and time-consuming due to changing properties between batches
Solution Approach 1:
The moisture content of plant-based materials is determined before mixing, and the required water amount is pre-calculated based on this measurement. This preliminary action allows the mixing process to proceed smoothly without adjustments during mixing, resolving the contradiction by preparing the correct water amount in advance rather than dealing with variable properties during the mixing process itself
2Productivity
If slurry is dried to form plant-based sheets, then sheets are produced, but the drying process becomes very energy consuming and time-consuming
Solution Approach 1:
The moisture content is determined and water amount is pre-calculated before mixing, ensuring the slurry has the optimal water content from the start. This preliminary action reduces the drying burden, allowing faster and more energy-efficient drying while maintaining sheet quality
Solution Approach 2:
The water content of the slurry is precisely controlled by calculating the required water amount based on measured moisture content. This parameter optimization ensures the slurry is neither too wet (requiring excessive drying energy) nor too dry (slowing down sheet formation), resolving the contradiction between drying speed and energy consumption
3Ease of manufacture
If plant-based materials are handled in powder form, then processing is possible, but great wear of machinery occurs due to the abrasive nature of powder particles
Solution Approach 1:
The moisture content is measured and water is added before mixing, transforming the abrasive powder into a cohesive slurry. This preliminary action of moisture adjustment reduces the abrasive nature of the material during subsequent handling and processing, protecting machinery while maintaining processing capability
4Productivity
If water content in slurry is not controlled, then mixing is simpler, but the slurry requires prolonged handling and drying time
Solution Approach 1:
The moisture content is determined and water amount is pre-calculated before mixing. This preliminary measurement and calculation, while adding a step to the process, actually simplifies subsequent handling by ensuring optimal slurry consistency from the start, reducing prolonged handling issues without requiring complex real-time adjustments
Solution Approach 2:
The moisture content measurement provides feedback that is used to calculate the precise water amount needed. This feedback mechanism ensures the slurry achieves the correct water content, optimizing handling speed and drying efficiency while maintaining manageable process complexity through a straightforward measure-calculate-add approach
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 method ensures uniform slurry formation and easy drying, minimizing defects and machinery wear while optimizing energy consumption.
Implementation Method 1
a plant material moisture detector, in particular a microwave detector, is present
Implementation Method 2
a plant material moisture detector, in particular an infrared detector, is present
Implementation Method 3
drying the slurry to form the plant-based sheet
Data Source
AI summary
The invention relates to a method for producing a plant-based material sheet comprising: —providing a plant-based powder material and a cellulose-based sheet-forming agent, —determining a moisture content of the plant-based material, —mixing the plant-based powder material, the cellulose-based sheet-forming agent and an amount of water to form a slurry, —drying the slurry to form the plant-based sheet, —wherein the amount of water added for slurry formation is calculated based on the determined moisture content of the plant-based powder material. Such a method allows the adjustment of the amount of water added for slurry formation based on the determined moisture content of the plant-based powder material.