Turbidimeter-Based Solid Concentration Monitoring in Trichlorosilane Production

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Solution Overview

Problem

Conventional trichlorosilane production methods lack effective means for quickly detecting abnormalities in chemical reactors, which can lead to inefficiencies and reduced recovery rates of tetrachlorosilane.

Innovation Solution

A method involving the measurement of solid substance concentration in after-crystallization residues using a turbidimeter, allowing for prompt detection of abnormalities in chemical reactors and improving tetrachlorosilane recovery rates by monitoring the concentration of solid substances in the residue before concentrating it.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional trichlorosilane production methods are used without solid substance concentration monitoring, then the production process continues uninterrupted, but abnormalities in chemical reactors cannot be quickly detected

Engineering Contradiction:

Improvedetection capabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical monitoring systems with optical measurement (turbidimetry). By measuring the turbidity of liquid samples to detect solid substance concentration changes, the system achieves reliable abnormality detection using simple optical principles rather than complex mechanical sensors or continuous analytical instrumentation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs disposable sampling and measurement approach where liquid samples are taken, measured for turbidity, and then discarded. This avoids the need for expensive, complex continuous monitoring equipment while achieving the same detection goal through simple, inexpensive turbidimeter measurements on transient samples.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Speed

If solid substance concentration is measured continuously in the residue, then abnormalities can be detected quickly, but the measurement process becomes more complex and time-consuming

Engineering Contradiction:

Improveabnormality detection speedVSAvoidmeasurement time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The patent performs measurements on residue samples after crystallization has already occurred, rather than attempting continuous real-time monitoring during the reaction process. This preliminary measurement approach allows quick detection of abnormalities that have already manifested in the residue, avoiding the need for complex real-time monitoring while still providing timely detection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent measures solid substance concentration in liquid residue samples as a proxy for detecting reactor abnormalities, rather than directly monitoring the reactor process itself. This copying approach allows indirect but rapid detection of process issues through simple turbidity measurements on extracted samples.

Inventive Principle:

Principle #26Copying

3Productivity

If solid substance concentration management is implemented, then tetrachlorosilane recovery rate is improved, but the process requires additional measurement and control steps

Engineering Contradiction:

Improvetetrachlorosilane recovery rateVSAvoidprocess control complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements feedback control by measuring solid substance concentration in the residue and using this information to adjust the crystallization and separation process parameters. This feedback mechanism optimizes tetrachlorosilane recovery by ensuring proper separation of solids from the liquid phase containing dissolved tetrachlorosilane, while keeping the control system simple through single-parameter turbidity-based feedback.

Inventive Principle:

Principle #23Feedback

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

Enables rapid detection of reactor abnormalities and enhances tetrachlorosilane recovery by accurately measuring and managing solid substance concentrations, thereby improving overall production efficiency.

Implementation Method 1

a concentration measuring step of measuring a concentration of a solid substance which is contained in an after-crystallization residue

Methodology Applied

Scientific EffectTurbidity measurement: Absorption (EM radiation)

Implementation Method 2

a crystallizing step of crystallizing part of aluminum chloride, contained in the residue, by cooling the residue

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentEP3530621B1Method for controlling concentration of solid content and method for producing trichlorosilane

Publication Date: 2021.12.01 TOKUYAMA CORP

Figure 1

AI summary

Realized is a solid substance concentration managing method which allows quick detection of an abnormality in a chemical reactor. The invention is an invention of a solid substance concentration managing method of managing a concentration of a solid substance which is contained in a residue that is discharged in a reaction product gas processing step included in a trichlorosilane producing method, the solid substance concentration managing method including a concentration measuring step of measuring the concentration of the solid substance which is contained in an after-crystallization residue that is obtained by crystallizing part of aluminum chloride.