Pressure Lock Rotor for Continuous High-Pressure Biomass Extrusion
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Solution Overview
Problem
Existing high-pressure processes for producing biopolymers from biomass, such as levulinic acid from woody residues, face challenges in maintaining specific process parameters like pressure, temperature, and residence time, leading to suboptimal yields due to batch-type or continuous processes that cannot sustain these conditions consistently.
Innovation Solution
A pressure lock system with a rotatable rotor and multiple pressure equalization terminals allows for continuous operation of high-pressure extrusion processes, ensuring material is fed and discharged without clogging or turbulent distribution, maintaining consistent pressure throughout the extruder by alternating connections and pressure compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch or continuous processing modes are used for high-pressure biomass processing, then material can be processed, but optimal process parameters (pressure, temperature, residence time) cannot be maintained consistently, leading to suboptimal yields
Solution Approach 1:
The pressure lock system enables continuous feeding of biomass material into the high-pressure extruder without interrupting the processing operation. The rotor with multiple openings allows material to be continuously introduced while maintaining constant pressure conditions inside the extruder, eliminating the start-stop nature of batch processes and ensuring consistent residence time and temperature profiles throughout the reaction zone.
Solution Approach 2:
The pressure lock acts as an intermediary device between the ambient environment and the high-pressure reaction zone. It provides a transition chamber that allows material to be fed from atmospheric pressure into the high-pressure extruder without causing pressure fluctuations or backflow, thereby maintaining stable process parameters in the reaction zone while enabling continuous operation.
2Ease of operation
If material is introduced from lower pressure area into high pressure chamber, then processing can occur, but pressure level is significantly affected and gas backflow occurs
Solution Approach 1:
The pressure lock rotor is segmented into multiple openings (first opening for material feeding, second opening for pressure equalization, third opening for discharge) that are spatially separated and function independently. This segmentation allows different functions to occur simultaneously at different locations on the rotor, enabling material feeding while maintaining pressure stability through dedicated pressure equalization pathways.
Solution Approach 2:
The pressure equalization opening allows the pressure inside the rotor cavity to be equalized with the extruder pressure before material is introduced through the feeding opening. This preliminary pressure balancing prevents pressure shocks and backflow when material is fed, ensuring smooth transition and maintaining stable pressure conditions in the high-pressure chamber.
3Device complexity
If pressure equalization is not implemented, then device structure is simpler, but clogging and turbulent material distribution occur
Solution Approach 1:
The pressure equalization opening serves as an intermediary pathway that balances pressure between the rotor cavity and the extruder chamber. By providing this intermediate pressure balancing function, the system prevents direct pressure differential effects that would cause turbulent material flow and clogging, ensuring uniform material distribution without requiring complex flow control mechanisms.
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 solution enables continuous high-pressure processing with reduced by-products and increased yield of biopolymers like levulinic acid by maintaining precise process parameters, improving the efficiency and scalability of the extrusion process.
Implementation Method 1
a first pressure equalizing terminal (26) with a pressure equalizing opening (27) offset from the material feeding opening (23) and the material discharge opening (25)... alternatingly connecting the material feeding and discharge openings, ensuring pressure compensation
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5H
AI summary
Pressure lock (10), extruding apparatus (50) for high pressure extrusion, process for producing biopolymers from biomass and use of the extruding apparatus for a process for producing biopolymers from biomass allowing continuous operation of a high pressure process.