Spray-Drying Process Pressure Drop Reduction via Viscosity Modification
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Solution Overview
Problem
The existing spray-drying process for laundry detergent base powder faces a dichotomy due to the need to minimize the distance between low and high pressure pumps to avoid pressure drop, which increases costs and complexity, while maintaining efficient operation.
Innovation Solution
Introducing a stream of viscosity-increasing detergent ingredients, such as alkyl benzene sulphonic acid, between the low and high pressure pumps, carefully controlling its flow rate and point of addition to minimize pressure drop, allowing the pumps to be placed further apart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the distance between low pressure pump and high pressure pump is increased, then the cost and complexity of high pressure pipe work is reduced, but the pressure drop between the two pumps increases
Solution Approach 1:
The invention changes the physical-chemical parameters of the slurry by adding viscosity-increasing detergent ingredients (such as alkyl benzene sulphonic acid) to modify the fluid properties. This allows the system to maintain acceptable pressure drop characteristics over longer pipe lengths by altering the slurry's viscosity and flow behavior, thereby resolving the contradiction between pipe length and pressure drop.
2Reliability
If the low pressure pump is positioned close to the mixer, then consistent feed to the pump is ensured, but the distance to the high pressure pump increases resulting in significant pressure drop
Solution Approach 1:
By adding viscosity-increasing detergent ingredients to the slurry in the connecting pipe, the invention modifies the fluid parameters to reduce pressure drop. This allows the low pressure pump to remain close to the mixer for reliable feeding while the modified slurry properties enable longer piping to the high pressure pump without excessive pressure loss.
3Productivity
If the high pressure pump is positioned close to the spray nozzle, then efficient operation is maintained, but the length of high pressure capable pipe work increases due to cost and complexity constraints
Solution Approach 1:
The invention modifies the slurry parameters by adding viscosity-increasing ingredients, which reduces pressure drop along the pipe. This enables the high pressure pump to be positioned closer to the spray nozzle for efficient operation while reducing the required length and complexity of high pressure pipe work, as the modified slurry can travel further with acceptable pressure loss.
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 reduces the pressure drop between the pumps, enabling longer pipe lengths between them while maintaining efficient operation, thereby optimizing the spray-drying process.
Implementation Method 1
introducing a stream of detergent ingredient, especially viscosity increasing detergent ingredients such as alkyl benzene sulphonic acid
Implementation Method 2
spraying the mixture through the spray nozzle into a spray-drying tower
Implementation Method 3
spray-drying the mixture to form a spray-dried powder
Data Source
AI summary
A process for preparing a spray-dried detergent powder having: (i) detersive surfactant; and (ii) other detergent ingredients; wherein the process includes the steps of: (a) forming an aqueous detergent slurry in a mixer; (b) transferring the aqueous detergent slurry from the mixer to a pipe leading through a first pump and then through a second pump to a spray nozzle; (c) contacting a detergent ingredient to the aqueous detergent slurry in the pipe after the first pump and before the second pump to form a mixture; (d) spraying the mixture through the spray nozzle into a spray-drying tower; and (e) spray-drying the mixture to form a spray-dried powder, wherein the pressure drop between (i) the pressure in the pipe at the outlet of the first pump to (ii) the pressure in the pipe at the inlet to the second pump is less than 8×105 Pa.