Polyferric Chloride Production via Circulating Spray Atomization
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Solution Overview
Problem
The existing production process of polyferric chloride is hindered by the slow dissolution of NO2, leading to low production efficiency in the sodium nitrite catalytic technology.
Innovation Solution
A continuous production device comprising a series of pipelines with integrated mixing, reaction, and concentration stages, utilizing a circulating spray device with a chemical filler plate to enhance gas-liquid contact and a concentration device with screw conveyors for efficient evaporation and heat recovery, along with a drying process to produce polyferric chloride.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sodium nitrite catalytic technology is used for polyferric chloride production, then the production process can proceed, but the dissolution rate of NO2 is slow, leading to low production efficiency
Solution Approach 1:
The reaction pipeline is divided into multiple segments (first mixing pipeline, second reaction pipeline, third reaction pipeline) with multiple atomizing pipes and chemical filler plates distributed throughout. This segmentation increases the total surface area for gas-liquid contact and distributes the dissolution process across multiple stages, significantly enhancing the overall dissolution rate of NO2 while maintaining manageable system complexity
Solution Approach 2:
The invention introduces a three-dimensional reaction structure by adding vertical atomizing pipes that spray liquid upward and chemical filler plates arranged at different heights within the pipeline. This multi-dimensional arrangement maximizes the contact between gas and liquid phases throughout the volume of the pipeline, transforming a potentially two-dimensional surface contact into a three-dimensional volumetric interaction, thereby dramatically improving dissolution efficiency
2Ease of manufacture
If oxygen is used as oxidant instead of chlorate, then production cost is reduced, but the oxidation rate must be maintained close to that of chlorate
Solution Approach 1:
The invention changes the physical parameters of the reaction system by introducing oxygen at multiple points and in multiple forms (bubbling through the reaction mixture, fed through atomizing pipes). This multi-point, multi-form oxygen introduction dramatically increases the dissolved oxygen concentration and availability in the solution, enabling the oxidation rate using cheap oxygen to approach that of expensive chlorate
Solution Approach 2:
Oxygen is introduced in advance at multiple stages (first mixing pipeline, second reaction pipeline, third reaction pipeline) before the oxidation reaction reaches its critical phase. This preliminary saturation of the solution with oxygen ensures that when the oxidation reaction occurs, sufficient oxidant is already available, maintaining high oxidation rates without requiring expensive chlorate
3Productivity
If conventional batch processing is used, then equipment complexity is low, but production efficiency is limited by the slow dissolution of NO2
Solution Approach 1:
The invention merges multiple functions into a single continuous reaction system: mixing of reactants, catalytic oxidation, polymerization, and concentration all occur in sequence within integrated pipelines. The atomizing pipes and chemical filler plates serve dual purposes of enhancing gas-liquid contact and promoting reaction efficiency. This consolidation of functions into a continuous flow system dramatically improves productivity while the modular pipeline design keeps the added complexity manageable
Solution Approach 2:
The invention implements continuous processing where reactants flow continuously through the mixing pipeline, reaction pipelines, and concentration device without batch interruptions. The circulating spray device ensures continuous atomization and gas-liquid contact throughout the reaction process. This continuous operation eliminates idle time between batches and maintains constant reaction conditions, maximizing productivity despite the more complex equipment configuration
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 device accelerates the NO2 absorption and reaction rate, improving catalytic oxidation efficiency and reducing production costs by promoting uniform heating and flow, thereby increasing the overall production efficiency of polyferric chloride.
Implementation Method 1
the atomizer includes an atomizing pipe, the atomizing pipe is arranged horizontally and has an atomizing nozzle arranged upwardly. A horizontally arranged chemical filler plate for promoting gas-liquid contact is arranged below the atomizing pipe
Implementation Method 2
The concentration device includes a steam chamber and a plurality of screw conveyors. Cylinders of the screw conveyors are located inside the steam chamber
Implementation Method 3
each cylinder of each screw conveyor is provided with an interlayer, the interlayer is provided with a thermal conductive oil pipeline
Implementation Method 4
the reaction of catalytic oxidation of ferrous ions by nitrogen oxide is a typical gas-liquid reaction
Implementation Method 5
4FeCl2+2(2−n)HCl+O2→2Fe2(OH)nCl6-n+2(1−n)H2O
Data Source
AI summary
A device for continuous production of polyferric chloride and a method are disclosed. The device includes a first mixing pipeline, a second reaction pipeline, a third reaction pipeline, and a concentration device sequentially connected. The first mixing pipeline, the second reaction pipeline and the third reaction pipeline are each provided with a circulating spray device, and the circulating spray device includes a reflux pump, a reflux pipeline and an atomizer. The atomizer includes an atomizing pipe, and a chemical filler plate for promoting gas-liquid contact is arranged below the atomizing pipe. The reflux pump is used to extract liquid from each reaction tank, and then transport the liquid to the atomizer on the top of the reaction tank. The atomizer is driven by the pressure of the reflux pump or the motor to atomize the liquid.