Spherical Tungstic Acid via Elevated Temperature Acidification
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Solution Overview
Problem
Current processes for producing tungstic acid are complex, expensive, and result in low bulk density, irregularly shaped particles, making it difficult to handle and process into tungsten metal powder, while existing methods fail to produce spheroidally agglomerated tungstic acid with high bulk density.
Innovation Solution
Reacting tungstate solutions with mineral acids at elevated temperatures to produce tungstic acid with a spherical morphology and high bulk density, using a process that involves acidifying an aqueous alkaline tungstate solution with sulfuric or hydrochloric acid at temperatures between 50 to 103°C, preferably 70 to 100°C, in a continuous stirred tank or cascade of tanks, with controlled stirring and flow rates to achieve optimal pH and precipitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional precipitation processes are used to produce tungstic acid, then high purity product is obtained, but the process becomes complex and expensive with multiple steps
Solution Approach 1:
The invention extracts and eliminates unnecessary intermediate steps from the conventional process. Instead of using multiple precipitation and purification steps, the patent directly reacts tungstate solutions with mineral acids to produce tungstic acid in one operation, removing the complexity of solvent extraction and multiple crystallization steps while maintaining adequate purity
Solution Approach 2:
The invention changes the reaction parameters by using mineral acids (sulfuric or hydrochloric) instead of conventional acidification methods, and by controlling temperature at 50-103°C. This parameter change simplifies the process while producing tungstic acid with desirable spherical morphology and high bulk density, eliminating the need for complex purification sequences
2Manufacturing precision
If conventional acidification of APT dispersion is used, then tungstic acid is obtained, but the particles have irregular flocculent morphology and low bulk density
Solution Approach 1:
The invention changes the reaction conditions by conducting the acidification at elevated temperatures (50-103°C) rather than at lower temperatures. This temperature parameter change fundamentally alters the particle formation mechanism, producing spherical agglomerates instead of irregular flocculent structures, while maintaining product purity
Solution Approach 2:
The invention achieves spherical particle morphology through controlled acidification conditions. The spherical shape is obtained by optimizing the reaction parameters (temperature, acid type, concentration) that promote spherical agglomeration during precipitation, transforming the conventional irregular particle shape into a spherical form with high bulk density
3Ease of operation
If low bulk density tungstic acid is produced, then handling and processing becomes more difficult, but conventional methods cannot produce spheroidally agglomerated acid
Solution Approach 1:
The invention changes the temperature parameter to 50-103°C and uses mineral acids to produce spheroidally agglomerated tungstic acid with high bulk density (≥1.5 g/cm³). This parameter change simultaneously achieves both spherical morphology for easy handling and high density, eliminating the need for complex post-processing steps
Solution Approach 2:
The invention produces spheroidally agglomerated particles through optimized acidification conditions, creating spherical morphology that inherently improves handling and flow characteristics. The spherical shape reduces particle interlocking and improves bulk density, making the material easier to handle without requiring additional processing steps
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 process yields tungstic acid with excellent filtration and flow properties, high bulk density, and spherical morphology, significantly improving the cost-effectiveness of reducing it to tungsten metal powder, with bulk densities above 1.5 g/cm3 and controlled alkali content, suitable for various quality tungsten metal powders.
Implementation Method 1
reacting tungstate solutions with mineral acids at elevated temperature to produce tungstic acid
Implementation Method 2
acidifying an aqueous alkaline tungstate solution with sulfuric or hydrochloric acid at temperatures between 50 to 103°C
Implementation Method 3
reacting tungstate solutions with mineral acids at elevated temperatures
Data Source
AI summary
Process for the production of a powdered spherical tungstic acid by acidification of an aqueous alkaline tungstate solution with mineral acid at elevated temperature, preferably in a continuous stirred tank or a cascade of at least 2 continuous stirred tanks, and tungstic acid obtainable in this way, which is characterized by a high bulk density and spherical morphology.