Spray-Drying Process Vacuum Cooling for Detergent Temperature Control
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Solution Overview
Problem
The challenge in producing low-density, highly soluble spray-dried laundry detergent powders is the difficulty in controlling the temperature profile during the spray-drying process, particularly when zeolite and phosphate materials are removed, leading to overheating.
Innovation Solution
Operating the spray-drying tower under vacuum conditions to introduce ambient air and control the temperature of the spray-dried powder, ensuring it remains below 150°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zeolite and phosphate materials are removed from the aqueous slurry to improve environmental profile and solubility, then the detergent powder becomes more environmentally sustainable and highly soluble, but the temperature control of the spray-dried powder becomes difficult and overheating occurs
Solution Approach 1:
The patent introduces a vacuum system as an intermediary mechanism to control the temperature of spray-dried powder. By creating negative pressure in the spray-drying zone, ambient air is drawn in to provide cooling, preventing overheating that occurs when zeolite and phosphate are removed from the formulation.
Solution Approach 2:
The patent changes the pressure parameter of the spray-drying zone from atmospheric to negative pressure (vacuum conditions). This parameter change enables ambient air to be sucked into the tower, providing a cooling effect that maintains temperature control while using environmentally sustainable, highly soluble detergent ingredients.
2Ease of manufacture
If zeolite and phosphate materials are removed from the aqueous slurry to improve dissolution profile at cooler washing temperatures, then the detergent powder dissolves better at 30°C or 20°C, but the temperature profile during spray-drying becomes difficult to control
Solution Approach 1:
The vacuum system acts as an intermediary cooling mechanism that enables the production of highly soluble detergent powders without zeolite or phosphate. The controlled introduction of ambient air through vacuum conditions prevents temperature profile失控 that would otherwise occur with these environmentally friendly, highly soluble ingredients.
3Ease of operation
If the spray-drying tower operates at atmospheric pressure to simplify the process, then the process is easier to operate, but the spray-dried powder overheats and temperature control is poor
Solution Approach 1:
The patent changes the pressure parameter from atmospheric to negative pressure to achieve temperature control. This parameter modification introduces a cooling effect through vacuum-driven ambient air intake, preventing overheating while maintaining operational feasibility through automated vacuum control systems.
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 effectively manages the temperature control of the spray-dried powder, enhancing the dissolution profile and environmental sustainability of the detergent powder.
Implementation Method 1
by ensuring that the spray-drying zone is under a vacuum, i.e. such that the pressure in the spray-drying zone is negative. This ensures that ambient air is sucked into the spray-drying tower, which in turn provides a much need cooling effect on the spray-dried powder formed therein
Implementation Method 2
spraying the aqueous slurry into a spray-drying tower that has hot air flowing through that then evaporates the water from the slurry droplets
Data Source
AI summary
A spray-drying process to prepare a spray-dried powder having: (a) anionic detersive surfactant; (b) from 0 wt % to 10 wt % zeolite builder; (c) from 0 wt % to 10 wt % phosphate builder; (d) optionally from 0 wt % to 10 wt % silicate salt; (e) optionally carbonate salt; (f) optionally polymeric material; and (g) optionally from 0 wt % to 10 wt % water, wherein, the process has the steps of: (i) spraying an aqueous slurry comprising: from (a) anionic detersive surfactant; (b) from 0 wt % to 20 wt % zeolite builder; (c) from 0 wt % to 20 wt % phosphate builder; (d) optionally from 0 wt % to 20 wt % silicate salt; (e) optionally carbonate salt; (f) optionally polymeric material; and (g) water, into a spray-drying zone, wherein the spray-drying zone is under negative pressure and wherein the air inlet air temperature into the spray-drying zone is greater than 150° C.; and (ii) drying the aqueous slurry to form a spray-dried powder.