Shear-Thinning Slurry Viscosity Control for Spray-Drying Capacity
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Solution Overview
Problem
The spray-drying process in laundry detergent production is often the rate-determining step, especially for low-built formulations, leading to maximum capacity utilization in existing facilities, necessitating additional or upgraded equipment to increase production capacity.
Innovation Solution
Controlled viscosity adjustment of a shear-thinning slurry by introducing a viscosity increasing agent after mixing, allowing for increased viscosity under specific shear conditions before spray-drying, thereby enhancing process capacity without requiring additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spray-drying process is operated at maximum capacity to meet increasing global laundry detergent powder volume demand, then production output is improved, but the equipment reaches its operational limit requiring additional or upgraded spray-drying equipment
Solution Approach 1:
The invention changes the physical parameters of the slurry by controlling viscosity under specific shear conditions. By adjusting the shear rate and viscosity of the slurry feedstock, the process maximizes the utilization of existing spray-drying equipment capacity without requiring additional equipment investment
Solution Approach 2:
The invention applies dynamic control of shear conditions throughout the process. A shear-thinning slurry is used that exhibits different viscosity characteristics at different shear rates, allowing the slurry to be pumped efficiently at high shear rates while maintaining higher viscosity at low shear rates to improve spray-drying capacity
2Productivity
If a shear-thinning slurry with controlled viscosity is used to increase spray-drying capacity, then productivity is improved, but process control complexity increases
Solution Approach 1:
The viscosity control and shear condition optimization are performed in advance during slurry preparation and pumping stages. By establishing the correct shear-thinning characteristics before the spray-drying step, the actual drying process can operate at maximum capacity without requiring complex real-time control during spraying
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 allows for increased spray-drying capacity without the need for new equipment, optimizing existing facilities and improving production efficiency.
Implementation Method 1
forming an alkaline slurry in a mixer, the slurry having a viscosity of from 0.5 to 50.0 Pas at a temperature of 70° C. and at a shear rate of 50 s−1, wherein the alkaline slurry is shear thinning
Data Source
AI summary
The present invention relates to a process for preparing a spray-dried powder comprising(i) anionic detersive surfactant;(ii) from 0 wt % to 10 wt % zeolite builder;(iii) from 0 wt % to 10 wt % phosphate builder; and(iv) optionally from 0 wt % to 15 wt % silicate salt;wherein the process comprises the steps of:(a) forming an alkaline slurry in a mixer, the slurry having a viscosity of from X to Y s−1 at a temperature of 70° C. and at a shear rate of 50 s−1, wherein the alkaline slurry is shear thinning; and(b) transferring the alkaline slurry from the mixer through at least one pump to a spray pressure nozzle;(c) contacting a viscosity increasing agent to the alkaline slurry after the mixer and before the spray pressure nozzle so as to increase the viscosity of the alkaline slurry to form a viscous alkaline slurry, step (c) being carried out at an average shear rate of from 10 s−1 to 150 s−1;(d) spraying the viscous alkaline slurry through the spray pressure nozzle into a spray-drying tower;(e) spray-drying the viscous alkaline slurry to form a spray-dried powder; and(f) optionally, contacting an alkalinity source with the alkaline slurry and/or the viscosity increasing agent, and/or the viscous alkaline slurry.