Static Emulsification and Sensitization for Safer Emulsion Explosive Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional emulsion explosive production lines pose significant safety hazards due to mechanical movements, leading to potential explosions, necessitating the development of a safer, full-static production method that replaces dynamic processes with static dispersion and eliminates the loading pump.
Innovation Solution
A method for continuously producing emulsion explosive through static emulsification and sensitization without a loading pump, utilizing a static mixer, orifice plate, or Venturi nozzle, which ensures intrinsic safety by eliminating mechanical stirring and shearing, and using multiple stages of mixing to achieve uniform emulsion formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dynamic emulsification and sensitization methods are used with loading pumps, then continuous production can be achieved, but safety hazards increase due to mechanical movement and potential explosions
Solution Approach 1:
The patent replaces the mechanical loading pump system with a static emulsification and sensitization system. The emulsification process uses static mixers and flow-induced mixing instead of mechanical stirrers, and sensitization is achieved through static contact with sensitizer plates rather than mechanical pumping. This substitution eliminates the mechanical movement that causes safety hazards while maintaining continuous production capability through flow-based processes.
Solution Approach 2:
The patent employs hydraulic principles by using fluid flow itself to achieve mixing and sensitization. The continuous flow of emulsion through the static mixer and contact with sensitizer plates in a controlled fluid environment enables both safety and continuous production. The hydraulic flow system replaces mechanical pumping while maintaining production continuity.
2Reliability
If static emulsification and sensitization methods are used without loading pumps, then safety is improved by eliminating mechanical movement, but production efficiency may be reduced
Solution Approach 1:
The patent maintains continuous production efficiency by ensuring uninterrupted fluid flow through the static emulsification and sensitization system. The continuous flow of oil phase and water phase through the static mixer, followed by continuous contact with sensitizer plates, eliminates idle time associated with batch mechanical mixing while maintaining safety through the absence of mechanical movement.
Solution Approach 2:
The patent prepares the emulsion matrix in advance through static emulsification before sensitization occurs. This preliminary formation of the emulsion structure allows for optimized subsequent sensitization contact, ensuring both safety and efficient production by separating the emulsification and sensitization functions in a continuous flow sequence.
3Manufacturing precision
If multiple stages of mixing are used to achieve uniform emulsion, then emulsion quality is improved, but device complexity increases
Solution Approach 1:
The patent divides the emulsification process into multiple sequential stages within the static mixer, with each stage contributing to progressive emulsion formation. The segmentation of mixing functions across multiple flow paths and contact points achieves uniform emulsion without requiring complex mechanical mixing equipment at each stage, thereby improving emulsion quality while controlling device complexity.
Solution Approach 2:
The patent transitions from mechanical mixing in one dimension to multi-dimensional flow-based mixing. The static mixer creates complex three-dimensional flow patterns, turbulence, and shear zones that achieve thorough mixing without mechanical moving parts. This dimensional approach to mixing improves emulsion uniformity while simplifying the mechanical structure.
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 enhances safety by reducing risk points and material storage, achieving uniform emulsion with improved safety during manufacturing and encapsulation, and eliminates the need for mechanical stirring and explosive pumping, thereby increasing the intrinsic safety level of the production process.
Implementation Method 1
The water phase from the water tank enters the multi-stage coarse emulsion mixers for multiple times after multi-stage diverging at its respective ratios of the explosive, and finally, emulsification is completed through the last stage of coarse emulsion mixers
Implementation Method 2
the static emulsifier and the static sensitization device are made up with at least one of the following: a static mixer, an orifice plate, a jet flow device and a Venturi nozzle
Implementation Method 3
the sensitizer enters an emulsion chamber by means of a sensitizer injector hole located on a primary core, the emulsion is mixed with the sensitizer when going through a primary multi-orifice plate, and then is mixed to uniformity by going through a second multi-orifice plate and a third multi-orifice plate
Data Source
AI summary
A method continuously produces emulsion explosive by emulsification and sensitization in a static state without a loading pump. After the water phase and oil phase enters a static emulsifier for emulsification, the emulsion enters a static sensitization device; the sensitizer enters the static sensitization device through the sensitizer charging inlet and mixes with the emulsion in the static sensitization device. After emulsification and sensitization, the sensitized explosive directly enters an injection pipe for encapsulation. By adopting the static emulsifier and sensitization device, the explosive material storage amount is greatly reduced, and mechanical stirring and shearing for emulsification is avoided. Meanwhile, mechanical mixing for sensitization is omitted and replaced with full-static high-temperature sensitization, and the safety of sensitization is improved. The loading pump is omitted, and the sensitized emulsion directly enters the injection pipe, thus the risk points in the production process and the online explosive material storage amount are reduced.