Spherical Rubber Chemicals Overhead Granulation
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Solution Overview
Problem
Existing rubber chemical granulation methods result in powdery or semispherical shapes that lead to dust pollution, low heat transfer efficiency, high equipment costs, and quality issues due to fine powder crystals and hardening, causing environmental and material losses.
Innovation Solution
A method for producing spherical rubber chemicals with an average diameter of 0.2mm to 10mm, using an overhead granulation process with a distribution plate and controlled cooling liquid, such as water or aqueous ammonia, to form spherical granules with improved heat transfer and reduced dust generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary belt condensation granulating process is used, then continuous granulation is achieved, but heat transfer efficiency decreases significantly
Solution Approach 1:
The patent introduces a water-cooled rod as an intermediary cooling medium between the molten rubber material and the environment. The molten material contacts the cold surface of the water-cooled rod, enabling efficient heat transfer through the rod wall to the cooling water, thus solving the heat transfer efficiency problem while maintaining continuous granulation capability
Solution Approach 2:
The patent employs hydraulic cooling system using water flowing through the hollow rod to remove heat from the molten rubber material. The cooling water circulates through the rod, absorbing heat efficiently and enabling continuous production without the energy loss associated with air cooling or less efficient thermal contact methods
2Productivity
If rotary belt granulation is used, then granules are formed, but semispherical shape with sharp arris is produced causing dust pollution
Solution Approach 1:
The patent uses a water-cooled rod with a circular cross-section, causing the molten rubber material to form spherical droplets as they contact and cool on the curved surface. This spherical shape eliminates the sharp edges and flat surfaces of semispherical granules, preventing dust formation during handling and transportation while maintaining continuous granulation production
Solution Approach 2:
Instead of forming granules on a moving belt and then scraping them off (which creates dust), the patent inverts the approach by forming complete spheres directly in a cooling bath, eliminating the scraping operation and associated dust pollution entirely
3Temperature
If steel belt cooling is used, then heat removal is achieved, but facility bulk increases due to prolonged steel belt length
Solution Approach 1:
The patent replaces the long steel belt cooling system with a compact hydraulic cooling system using water flowing through a hollow rod. This enables efficient heat removal in a much shorter distance and smaller space, dramatically reducing facility bulk while maintaining effective cooling capability
Solution Approach 2:
The water-cooled rod acts as a compact heat exchange intermediary, concentrating the cooling function into a small, manageable component rather than requiring a long steel belt. This intermediary approach achieves the same temperature control in a fraction of the space
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
The spherical granules increase production efficiency, prevent dust pollution, and enhance product quality by reducing fine powder issues, improving melting point consistency and surface smoothness for better mixing and handling.
Implementation Method 1
the cooling medium removes heat from the molten liquid via the steel belt, and heat is transferred from the molten liquid to the steel belt and then to the cooling medium
Implementation Method 2
the molten liquid material is distributed evenly on a steel belt moving at a uniform speed below a special distributing device depending on the viscosity range of the molten material. Meanwhile, under forced cooling of a continuously spraying device provided under the steel belt, the material is cooled and solidified during the movement and transportation procedure
Data Source
Figure 1
Figure 2~3C
AI summary
The present invention provides spherical rubber chemicals and the method for preparing the same. The spherical rubber chemicals of the present invention include spherical antioxidants, spherical vulcanization agents, spherical processing aids, spherical reinforcing agents, or spherical adhesive agents. With the spherical rubber chemicals of the present invention, the shortcomings of powdery or semi-spherical rubber chemicals are overcome, including eliminating the dust pollution during granulation procedure and avoiding the raw material loss and the environmental pollution, while solving the quality problem of lower melting point of product caused by the presence of fine powder crystal. Furthermore, the resultant rubber chemicals has an improved smoothness of surface, which is helpful to improve the flowing and mixing behaviors of the rubber chemicals in mixing or open milling process with rubbers.