Small Form Aluminum Pellets in Batch Chlorohydrate Reactors
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Solution Overview
Problem
Conventional methods for producing aluminum chlorohydrate using large aluminum ingots are labor-intensive, hazardous, and result in high turbidity due to clumping of small form aluminum metal pellets, leading to inefficient batch processing and product quality issues.
Innovation Solution
The use of small form aluminum metal pellets with continuous circulation of aqueous hydrochloric acid through a reactor tank, combined with active or passive hydration and optional iron filtering, to maintain consistent contact between metal surface area and acid, preventing clumping and allowing for continuous batch-to-batch production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large aluminum ingots are used in conventional batch processes, then worker safety is improved by reducing confined space entry risks, but batch preparation time increases and labor intensity increases
Solution Approach 1:
The invention segments the aluminum reactant into small form aluminum metal (SFAM) pellets instead of using large ingots. This segmentation allows the aluminum to be loaded remotely without confined space entry while maintaining safety, and the small pellets react more quickly reducing batch preparation time.
Solution Approach 2:
The system uses remote loading equipment to automatically load SFAM pellets into the reactor, eliminating the need for manual handling by workers in confined spaces. The process serves itself by using mechanized loading rather than human labor for the hazardous task.
2Productivity
If small form aluminum metal pellets are used to increase surface area and reaction rate, then productivity is improved, but clumping occurs causing high turbidity in the product
Solution Approach 1:
The invention implements continuous circulation of aqueous hydrochloric acid through the SFAM pellet bed, ensuring constant movement and contact between the acid and aluminum pellets. This continuous action prevents the pellets from settling and clumping together, maintaining product clarity while achieving high reaction rates.
Solution Approach 2:
The system uses hydraulic circulation to continuously pump and flow the acid solution through the reactor bed. This fluid dynamics approach keeps the SFAM pellets suspended and evenly distributed, preventing clumping and ensuring consistent product quality.
3Device complexity
If SFAM pellets are used without continuous acid circulation, then device complexity is reduced, but gas pressure causes insufficient hydration and crystal formation that clogs the reactor
Solution Approach 1:
The continuous circulation system ensures that acid continuously contacts the SFAM pellets throughout the reaction, maintaining proper hydration and preventing gas pocket formation. This continuous action completes the reaction reliably without clogging.
Solution Approach 2:
The circulation system provides feedback control by monitoring the reaction progress and adjusting acid flow accordingly. This ensures complete reaction while preventing over-pressurization and crystal formation that would clog the reactor.
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 significantly reduces batch preparation time, minimizes hazards, and achieves clearer aluminum chlorohydrate products by maintaining consistent hydration and preventing clumping, enabling continuous production without the need for reactor cleaning between batches.
Implementation Method 1
An industrial process of producing aluminum chlorohydrate (ACH) generally includes reacting aluminum metal with an aqueous acid, such as hydrochloric acid
Implementation Method 2
the reaction between the SFAM and the aqueous acid is driven by mass exothermic conditions and progresses until the solution reaches boiling, when copious amounts of hydrogen gas and steam are rapidly released
Implementation Method 3
The use of small form aluminum metal pellets with continuous circulation of aqueous hydrochloric acid through a reactor tank
Implementation Method 4
combined with active or passive hydration and optional iron filtering, to maintain consistent contact between metal surface area and acid
Data Source
AI summary
A method of producing aluminum chlorohydrate comprises adding small form aluminum metal pellets to a reactant receiving space of a reactor tank to form a pellet bed; adding aqueous hydrochloric acid to the reactant receiving space of the reactor tank; and continuously circulating the aqueous hydrochloric acid through the pellet bed. In some embodiments, the continuously circulating aqueous hydrochloric acid dispels reaction gases from the pellet bed. Methods described herein can, in some cases, further comprise consecutively adding additional small form aluminum metal pellets to the reactant receiving space of the reactor tank as the small form aluminum metal pellets are consumed in the pellet bed.