Forced-Air Belt Dryer Control for Water Absorbent Polymer Beads

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Solution Overview

Problem

Existing processes for preparing water-absorbing polymer beads lack high process stability, particularly in controlling the water content during drying, which affects the mechanical stability and subsequent comminution, leading to inconsistent product quality.

Innovation Solution

A continuous process that involves polymerization, drying on a forced-air belt dryer, comminution, classification, and postcrosslinking, where the water content of the polymer gel is continuously determined and used as a controlled variable to adjust the dryer settings, ensuring precise control and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the water content of the polymer gel is not continuously controlled during drying, then the process is simpler to operate, but the mechanical stability and product quality become inconsistent

Engineering Contradiction:

Improvewater content consistencyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements continuous feedback control by measuring the water content of the polymer gel during drying and using this information to adjust drying parameters in real-time, ensuring consistent water content and mechanical stability while maintaining manageable system complexity through automated control loops

Inventive Principle:

Principle #23Feedback

2Stability of the object's composition

If the water content varies during drying, then the drying process is faster and more flexible, but the mechanical stability and comminution quality deteriorate

Engineering Contradiction:

Improvemechanical stabilityVSAvoiddrying speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent applies dynamic control by continuously adjusting drying parameters based on real-time water content measurements, allowing the drying process to adapt its speed and intensity to maintain optimal mechanical stability while maximizing productivity through optimized drying curves

Inventive Principle:

Principle #15Dynamics

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 enhances the absorbency under load and centrifuge retention capacity of the water-absorbing polymer beads by maintaining a consistent water content, improving product quality and stability throughout the production process.

Implementation Method 1

drying of the polymer gel on a forced-air belt dryer

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

forced-air belt dryer

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

water-absorbing polymers are used to produce diapers, tampons, sanitary napkins and other hygiene articles, but also as water-retaining agents in market gardening

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS9327270B2Method for the continuous production of water absorbent polymer particles

Publication Date: 2016.05.03 BASF SE

AI summary

A process for continuously preparing water-absorbing polymer beads, comprising the drying of a polymer gel on a forced-air belt dryer, the water content of the polymer gel being used to control the forced-air belt dryer during or after the drying.