Scroll Conveyor for Hygroscopic Polymer Wetting
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Solution Overview
Problem
Existing systems for forming aqueous solutions or dilutions of water-soluble or water swellable particulate materials, such as hydrophilic polymers, often result in blockages, lumps, and inefficient mixing due to the hygroscopic nature of these materials, leading to poor solution quality and increased maintenance needs.
Innovation Solution
An apparatus that meters hygroscopic granular powders into an air conveying line, where they are wetted and combined with water to form a homogenous solution, using a scroll conveying line with a means to ensure the material fills the space between the scroll conveyor and the duct, such as a constricting member or a vertical orientation, to prevent agglomeration and blockages, and an air conveying line with antistatic properties to prevent static discharge and dusting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powder is fed by screw action directly into a wetting apparatus, then the powder can be metered and wetted, but the apparatus becomes blocked and the solution quality deteriorates due to agglomeration
Solution Approach 1:
A transition piece is introduced as an intermediary component between the screw feeder outlet and the wetting apparatus inlet. This transition piece prevents direct contact between the screw feeder and the wetting apparatus, eliminating blockages while maintaining efficient powder metering and conveying capabilities.
Solution Approach 2:
The powder conveying system is segmented into distinct functional zones: a screw feeder section for metering, a transition piece section for smooth transfer, and a wetting apparatus section for hydration. This segmentation allows each component to perform its function optimally without interfering with others, preventing blockages.
2Reliability
If compressed air is used to keep the screw feeder outlet clean, then blockages are prevented, but condensation forms on metal surfaces causing sticky agglomerates
Solution Approach 1:
The transition piece serves as an intermediary that eliminates the need for compressed air cleaning. By providing a smooth, blockage-free interface between the screw feeder and wetting apparatus, the transition piece prevents material buildup without requiring air blasting that causes condensation and agglomeration.
3Stability of the object's composition
If the screw feeder is located remotely to remain dry, then powder caking is prevented, but conveying efficiency decreases
Solution Approach 1:
The transition piece acts as an intermediary that allows the screw feeder to be positioned optimally for both dryness and conveying efficiency. It facilitates smooth powder transfer from the screw feeder to the wetting apparatus, maintaining high conveying efficiency while keeping the screw feeder in a dry environment.
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 prevents blockages and agglomeration, ensuring the formation of homogenous aqueous solutions without lumps or fish eyes, while reducing energy consumption and noise, and maintaining efficient powder conveying over longer distances.
Implementation Method 1
an air conveying line through which an air stream conveys the material to a make up unit
Implementation Method 2
The air conveying line will typically comprise a conduit that has an inner surface which has antistatic properties. This may be achieved by constructing the air conveying line from an antistatic material or alternatively by applying an antistatic surface covering to the inner wall of the air conveying conduit. The antistatic inner surface prevents static discharge sparks and also prevents particles of the material being conveyed sticking to the inner surface.
Implementation Method 3
Water spray orifices may be positioned within the upper part of the wetting duct radially outwards of the duct inlet and arranged in such a way so as to direct sprays of water downwardly in the wetting duct in order to wet the particulate material.
Implementation Method 4
Water-soluble or water swellable particulate materials, including polyelectrolyte powder and other similar granular powders of a hygroscopic nature
Implementation Method 5
The particulate material is hydrated or dissolved to form a uniform aqueous dilution or aqueous solution
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Apparatus for forming an aqueous dilution or aqueous solution of a water-soluble or water swellable particulate material in which the material is a water-soluble or water swellable polymer with a weight average particle size of no more than 2000 µm, comprising: a make up unit (18), a scroll conveying line (6) comprising a duct (6A) defined by a wall and a scroll conveyor (6B) within said duct, wherein the scroll conveying line has an inlet (6D) through which material enters and an outlet (6C) through which the material leaves the scroll conveying line, and an air conveying line (3) comprising a duct through which an air stream conveys the material to the make up unit (18) in which the material is hydrated or dissolved to form an aqueous dilution or aqueous solution, in which the air conveying line is provided with an air pressure of at least 20 milli Bar, in which the scroll conveying line (6) is provided with a means for ensuring the material substantially fills the space between the scroll conveyor and the wall of the duct at least at the outlet end of the conveying line, wherein the means is selected from, (a) the scroll conveying line (6) or outlet (6C) is in communication with an element that restricts the flow of material from the outlet, and/or (b) the scroll conveying line (6) is mounted at a gradient or a substantially vertical orientation, such that the outlet (6C) is positioned higher than the inlet (6D).